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NASA NTRS1988

Fibre-matrix bond strength studies of glass, ceramic, and metal matrix composites

An indentation test technique for compressively loading the ends of individual fibers to produce debonding has been applied to metal, glass, and glass-ceramic matrix composites; bond strength values at debond initiation are calculated using a finite-element model. Results are correlated with composite longitudinal and interlaminar shear behavior for carbon and Nicalon fiber-reinforced glasses and glass-ceramics including the effects of matrix modifications, processing conditions, and high-temperature oxidation embrittlement. The data indicate that significant bonding to improve off-axis and shear properties can be tolerated before the longitudinal behavior becomes brittle. Residual stress and other mechanical bonding effects are important, but improved analyses and multiaxial interfacial failure criteria are needed to adequately interpret bond strength data in terms of composite performance.

Grande, D. H.↗

NASA NTRS1975

Critical aspect ratio for tungsten fibers in copper-nickel matrix composites

Stress-rupture and tensile tests were conducted at 816 C (1500 F) to determine the effect of matrix composition on the minimum fiber length to diameter ratio (critical aspect ratio) below which fibers in a tungsten fiber/copper-nickel alloy matrix composite could not be stressed to their ultimate load carrying capability. This study was intended to simulate some of the conditions that might be encountered with materials combinations used in high-temperature composites. The critical aspect ratio for stress-rupture was found to be greater than for short-time tension, and it increased as the time to rupture increased. The increase was relatively slight, and calculated fiber lengths for long service appear to be well within practical size limits for effective reinforcement and ease of fabrication of potential gas turbine components.

Jech, R. W.↗

NASA NTRS1974

Stress-rupture strength and microstructural stability of tungsten-hafnium-carbon-wire reinforced superalloy composites

Tungsten-hafnium-carbon - superalloy composites were found to be potentially useful for turbine blade applications on the basis of stress-rupture strength. The 100- and 1000-hr rupture strengths calculated for 70 vol. % fiber composites based on test data at 1090C (2000F) were 420 and 280 MN/m2 (61,000 and 41,000 psi, respectively). The investigation indicated that, with better quality fibers, composites having 100- and 1000-hr rupture strengths of 570 and 370 MN/m2 (82,000 and 54,000 psi, respectively), may be obtained. Metallographic studies indicated sufficient fiber-matrix compatibility for 1000 hr or more at 1090C (2000F).

Petrasek, D. W.↗

NASA NTRS2017

Meteorite Material Model for Structural Properties

To assess the threat posed by an asteroid entering Earth's atmosphere, one must predict if, when, and how it fragments during entry. A comprehensive understanding of the asteroid material properties is needed to achieve this objective. At present, the meteorite material found on earth are the only objects from an entering asteroid that can be used as representative material and be tested inside a laboratory setting. Due to complex petrology, it is technically challenging and expensive to obtain reliable material properties by means of laboratory test for a family of meteorites. In order to circumvent this challenge, meteorite unit models are developed to determine the effective material properties including Youngs modulus, compressive and tensile strengths and Poissons ratio, that in turn would help deduce the properties of asteroids. The meteorite unit is a representative volume that accounts for diverse minerals, porosity, cracks and matrix composition. The Youngs Modulus and Poissons Ratio in the meteorite units are calculated by performing several hundreds of Monte-Carlo simulations by randomly distributing the various phases inside these units. Once these values are obtained, cracks are introduced in these meteorite units. The size, orientation and distribution of cracks are derived by extensive CT-scans and visual scans of various meteorites from the same family. Subsequently, simulations are performed to attain stress-strain relations, strength and effective modulus values in the presence of these cracks. The meteorite unit models are presented for H, L and LL ordinary chondrites, as well as for terrestrial basalt. In the case of the latter, data from the simulations is compared with experimental data to validate the methodology. These material models will be subsequently used in fragmentation modeling of full scale asteroids.

Meteorite↗

DOE OSTI2022

Selected results from full-core hydrogen redistribution asymptotic analysis in YH-moderated heat-pipe cooled microreactor

Yttrium hydride is the main candidate for moderation of high temperature nuclear microreactors . This is due to its high thermal stability and relatively high hydrogen retention at temperatures exceeding 870 C. One of the main issues associated with the use of yttrium hydride is that, when exposed to temperature, stress, or concentration gradients, the hydrogen contained in the metallic matrix tends to redistribute and leak from the moderating elements, potentially leading to reactivity losses and power swings. This paper is focused on presenting selected results from the asymptotic hydrogen redistribution analysis performed on the Simplified Microreactor Benchmark Assessment (SiMBA) problem, a microreactor core conceptual design developed at INL. The analysis is based on full core analysis, relies uniquely on Bison to perform hydrogen redistribution calculations, and discusses the physical causes of the reactivity feedback. It was found that the feedback is negative, but it is one order of magnitude lower than the one found for the empire reactor unit-cell. This is due to the lower axial temperature gradient together with the effect of the reflector.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2020

Impact of control blade insertion on the deformation behavior of SiC-SiC channel boxes in BWRs

This article describes the analysis of distortion of a silicon carbide fiber-reinforced, silicon carbide matrix (SiC-SiC) composite channel box under in-reactor conditions of a boiling water reactor (BWR). The BWR core has significant gradients in the fast neutron flux across the channel box due to the presence of water rods within the fuel assemblies, and these gradients increase further with the insertion of control blades. As a result of the temperature and neutron flux dependent irradiation-induced swelling of SiC, the SiC-SiC composite channel box can undergo distortion. In this work, we evaluate the SiC-SiC channel box distortion for three different control blade positions. This analysis is based on the neutron flux and temperature distributions in the BWR core calculated using the neutronics code MPACT and thermal-hydraulics code CTF. This calculation is coupled through temperature feedback. Subsequently, we have performed structural analysis based on the calculated neutron flux and temperature distributions to determine the deformation and stress development in the channel box. The structural analysis was performed using the fuel performance modeling code BISON and the commercial finite element analysis software Abaqus. The results indicate that large gradients in fast neutron flux (up to 35–40% across a single axial level) will develop across the channel box. Due to these gradients, the channel box will undergo time-dependent bending for all the control blade positions in the assembly. The time-dependent bowing behavior is dominated by the transient swelling of SiC-SiC material under non-uniform neutron flux, and changes with variation in the control blade position. The bending will cause temporary interference between the channel box and control blade, and the interference is expected to be most severe for the fully inserted control blade position. The developed stresses due to differential swelling in the channel box exceed the proportional limit stress of the material, which may cause matrix microcracking in the channel box. However, the stresses remain below the tensile strength of the material, and therefore, development of a full, through-thickness crack in the channel box is not expected. Finally, further work is recommended to explore and evaluate the mitigation strategies.

42 ENGINEERING↗

NASA NTRS1995

Real time acousto-ultrasonic NDE technique for monitoring damage in ceramic composites under dynamic loads

Research effort was directed towards developing a near real-time, acousto-ultrasonic (AU), nondestructive evaluation (NDE) tool to study the failure mechanisms of ceramic composites. Progression of damage is monitored in real-time by observing the changes in the received AU signal during the actual test. During the real-time AU test, the AU signals are generated and received by the AU transducers attached to the specimen while it is being subjected to increasing quasi-static loads or cyclic loads (10 Hz, R = 1.0). The received AU signals for 64 successive pulses were gated in the time domain (T = 40.96 micro sec) and then averaged every second over ten load cycles and stored in a computer file during fatigue tests. These averaged gated signals are representative of the damage state of the specimen at that point of its fatigue life. This is also the first major attempt in the development and application of real-time AU for continuously monitoring damage accumulation during fatigue without interrupting the test. The present work has verified the capability of the AU technique to assess the damage state in silicon carbide/calcium aluminosilicate (SiC/CAS) and silicon carbide/ magnesium aluminosilicate (SiC/MAS) ceramic composites. Continuous monitoring of damage initiation and progression under quasi-static ramp loading in tension to failure of unidirectional and cross-ply SiC/CAS and quasi-isotropic SiC/MAS ceramic composite specimens at room temperature was accomplished using near real-time AU parameters. The AU technique was shown to be able to detect the stress levels for the onset and saturation of matrix cracks, respectively. The critical cracking stress level is used as a design stress for brittle matrix composites operating at elevated temperatures. The AU technique has found that the critical cracking stress level is 10-15% below the level presently obtained for design purposes from analytical models. An acousto-ultrasonic stress-strain response (AUSSR) model for unidirectional and cross-ply ceramic composites was formulated. The AUSSR model predicts the strain response to increasing stress levels using real-time AU data and classical laminated plate theory. The Weibull parameters of the AUSSR model are used to calculate the design stress for thermo-structural applications. Real-time AU together with the AUSSR model was used to study the failure mechanisms of SiC/CAS ceramic composites under static and fatigue loading. An S-N curve was generated for a cross-ply SiC/CAS ceramic composite material. The AU results are corroborated and complemented by other NDE techniques, namely, in-situ optical microscope video recordings and edge replication.

Tiwari, Anil↗

NASA NTRS1973

Theoretical calculation of the compressibility of porous media.

The normalized bulk compressibility of a porous medium is expressed directly in terms of pore strains. The derived expression holds over all porosity and allows for direct substitution of both different pore geometries and pore-pore interactions into the strain term. Pores are assumed to be open. The parent (matrix forming) material is assumed to be homogeneous and isotropic. Pore fluids may be admitted. A simple pore-pore interaction term is introduced. Upper-bound stiffness equations (i.e., equations ignoring pore-pore interactions) are derived for media with oblate spheroidal pores. Effective stress is introduced into the general equation for the normalized bulk compressibility.

Warren, N.↗

DOE OSTI2020

Deformation accommodating periodic computational domain for a uniform velocity gradient

Many multiscale methods for granular materials use periodic computational domains to consider particle scale interactions and then calculate the stress to drive the continuum scale calculations. For problems involving large material deformations, the computation domain often needs to be reinitialized because of the distortion, causing the loss of the history information of the system. This work introduces an algorithm to accommodate a large deformation of the material while maintaining the computational domain cuboid to avoid the domain reinitialization during the computation. The algorithm uses a rotating frame of reference, in which the velocity gradient can be represented by an upper triangular matrix. The deformation caused by the upper triangular matrix is treated by the image system implied in the periodicity to maintain the computational domain cuboid. The effect from the rotation of the reference frame is considered using the inertial forces. Finally, simulations of simple and pure shear motions are carried out to illustrate the algorithm.

42 ENGINEERING↗

DOE OSTI2019

Implicit renormalization approach to the problem of Cooper instability

In the vast majority of cases, superconducting transition takes place at exponentially low temperature T c out of the Fermi liquid regime. We discuss the problem of determining T c from known system properties at temperatures T >> T c , and stress that this cannot be done reliably by following the standard protocol of solving for the largest eigenvalue of the original gap-function equation. However, within the implicit renormalization approach, the gap-function equation can be used to formulate an alternative eigenvalue problem, where solving leads to an accurate prediction for both T c and the gap function immediately below T c . Furthermore, with diagrammatic Monte Carlo techniques, this eigenvalue problem can be solved without invoking the matrix inversion or even explicitly calculating the four-point vertex function.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

NASA NTRS1984

Delamination growth analysis in quasi-isotropic laminates under loads simulating low-velocity impact

A geometrically nonlinear finite-element analysis has been developed to calculate the strain energy released by delaminating plates during impact loading. Only the first mode of deformation, which is equivalent to static deflection, was treated. Both the impact loading and delamination in the plate were assumed to be axisymmetric. The strain energy release rate in peeling, GI, and shear sliding, GII, modes were calculated using the fracture mechanics crack closure technique. Energy release rates for various delamination sizes and locations and for various plate configurations and materials were compared. The analysis indicated that shear sliding was the primary mode of delamination growth. The analysis also indicated that the midplane (maximum transverse shear stress plane) delamination was more critical and would grow first before any other delamination of the same size near the midplane region. The delamination growth rate was higher (neutrally stable) for a low toughness (brittle) matrix and slower (stable) for high toughness matrix. The energy release rate in the peeling mode, GI, for a near-surface delamination can be as high as 0.5GII, and can contribute significantly to the delamination growth.

Shivakumar, K. N.↗

NASA NTRSDate not supplied

Hierarchical Multiscale Process Modeling of A Textile Composite Y-Joint for the Aurora D8 Aircraft

Woven polymer matrix composites (PMCs) are widely used in aerospace applications for their favorable specific properties. However, the behavior of the inter- and intra-tow matrix during manufacturing of woven PMCs is difficult to isolate experimentally due to geometric and processing complexities. Classical closed-form homogenization approaches allow for composite thermos-chemo-mechanical properties to be characterized at any fiber volume fraction. In this work, virtual curing is applied to the inter- and intra-tow matrix materials of a plain weave repeating unit cell (RUC). Thermo-chemo-mechanical property evolution within the tows is calculated using the Concentric Cylinder Model (CCM) and the Rule of Mixtures (ROM). Curing is implemented through user-written subroutines within the commercial finite element method software Abaqus. Virtual curing results are compared with those from a linear-elastic thermal cool down simulation in Abaqus. Results indicate that tow property evolution during curing has a non-negligible effect on the final stress state.

curing↗

DOE OSTI2024

Utilizing integrated neutron diffraction and elastoplastic self-consistent crystal plasticity model to quantitatively assess the strengthening mechanism in Al–12.5Ce and Al–12.5Ce–0.4Mg alloys

An integrated in-situ neutron diffraction and elastic plastic self-consistent crystal plasticity (EPSC-CP) modeling scheme is performed on a binary Al–12Ce alloy and a ternary Al–12Ce–0.4Mg alloys. Using this scheme, the constitutive parameters, i.e. elastic constants and slip system parameters of individual phases can be calibrated which can be used in microstructure-based CP models to predict materials performance. From this study, it is shown that the elastic constants of Al 11 Ce 3 intermetallics calculated from density function theory calculation in the literature are rather accurate. When applied to the EPSC-CP model, the lattice strains of both the binary and ternary alloys are correctly predicted as compared with experiments, and large lattice strain differences between Al (100) plane and Al 11 Ce 3 (010) plane are demonstrated. The slip system parameters calibrated by the scheme shows that the addition of 0.4 wt% Mg in the alloy has little influence on the critical resolved shear stress of initial dislocation glide in the Al matrix which caused plastic yield in the material. This can be explained by the very dilute Mg solute content in the Al solid solution, causing large spacing of Al–Mg lattice misfit sites and little impact on resistance of dislocation glide at initial yield. The 0.4 wt% Mg addition, on the other hand, has a large influence on the hardening term in the slip system parameters, indicating those Al–Mg misfit sites do help dislocation accumulation during the deformation. The impact of dilute Mg addition on the Al slip system parameters is also reflected in the flow behavior of the ternary alloy: little impact on the yield stress, but a large impact on working hardening and tensile strength of the materials which is consistent with the literature.

36 MATERIALS SCIENCE↗

NASA NTRS1984

Delamination growth analysis in quasi-isotropic laminates under loads simulating low-velocity impact

A geometrically nonlinear finite-element analysis was developed to calculate the strain energy released by delamination plates during impact loading. Only the first mode of deformation, which is equivalent to static deflection, was treated. Both the impact loading and delamination in the plate were assumed to be axisymmetric. The strain energy release rate in peeling, G sub I, and shear sliding, G sub II, modes were calculated using the fracture mechanics crack closure technique. Energy release rates for various delamination sizes and locations and for various plate configurations and materials were compared. The analysis indicated that shear sliding (G sub II) was the primary mode of delamination growth. The analysis also indicated that the midplane (maximum transverse shear stress plane) delamination was more critical and would grow before any other delamination of the same size near the midplane region. The delamination growth rate was higher (neutrally stable) for a low toughness (brittle) matrix and slower (stable) for high toughness matrix. The energy release rate in the peeling mode, G sub I, for a near-surface delamination can be as high as 0.5G sub II and can contribute significantly to the delamination growth.

Shivakumar, K. N.↗

NASA NTRS1990

Damage states in laminated composite three-point bend specimens: An experimental-analytical correlation study

Damage states in laminated composites were studied by considering the model problem of a laminated beam subjected to three-point bending. A combination of experimental and theoretical research techniques was used to correlate the experimental results with the analytical stress distributions. The analytical solution procedure was based on the stress formulation approach of the mathematical theory of elasticity. The solution procedure is capable of calculating the ply-level stresses and beam displacements for any laminated beam of finite length using the generalized plane deformation or plane stress state assumption. Prior to conducting the experimental phase, the results from preliminary analyses were examined. Significant effects in the ply-level stress distributions were seen depending on the fiber orientation, aspect ratio, and whether or not a grouped or interspersed stacking sequence was used. The experimental investigation was conducted to determine the different damage modes in laminated three-point bend specimens. The test matrix consisted of three-point bend specimens of 0 deg unidirectional, cross-ply, and quasi-isotropic stacking sequences. The dependence of the damage initiation loads and ultimate failure loads were studied, and their relation to damage susceptibility and damage tolerance of the mean configuration was discussed. Damage modes were identified by visual inspection of the damaged specimens using an optical microscope. The four fundamental damage mechanisms identified were delaminations, matrix cracking, fiber breakage, and crushing. The correlation study between the experimental results and the analytical results were performed for the midspan deflection, indentation, damage modes, and damage susceptibility.

Starbuck, J. Michael↗

NASA NTRS2002

Incorporation of Mean Stress Effects into the Micromechanical Analysis of the High Strain Rate Response of Polymer Matrix Composites

The results presented here are part of an ongoing research program, to develop strain rate dependent deformation and failure models for the analysis of polymer matrix composites subject to high strain rate impact loads. A micromechanics approach is employed in this work, in which state variable constitutive equations originally developed for metals have been modified to model the deformation of the polymer matrix, and a strength of materials based micromechanics method is used to predict the effective response of the composite. In the analysis of the inelastic deformation of the polymer matrix, the definitions of the effective stress and effective inelastic strain have been modified in order to account for the effect of hydrostatic stresses, which are significant in polymers. Two representative polymers, a toughened epoxy and a brittle epoxy, are characterized through the use of data from tensile and shear tests across a variety of strain rates. Results computed by using the developed constitutive equations correlate well with data generated via experiments. The procedure used to incorporate the constitutive equations within a micromechanics method is presented, and sample calculations of the deformation response of a composite for various fiber orientations and strain rates are discussed.

Goldberg, Robert K.↗

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↗