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The potential of graphite/polyimide is assessed on a graphite/polyimide honeycomb sandwich panels and stiffened panel concepts to develop lightweight panels for use at elevated temperatures. The capability is attained to correctly predict panel buckling behavior and panel strength at elevated temperatures.
Cu-to-Cu thermal compression bonding (TCB) has emerged as a promising solution for ultrafine pitch packaging in 3D integrated circuit technologies. Despite the progress made by conventional Cu-to-Cu TCB methods in achieving good mechanical strength of the Cu bonds, the bonding processes generally require high temperature and high pressure, which may degrade the performance and reliability of the device. Therefore, it is imperative to investigate the processing parameters to understand the bonding mechanism and achieve effective TCB at a low temperature and low pressure. Here, we developed an in situ TCB technique inside a scanning electron microscope. The in situ TCB method enables a real-time observation of bonding development, which provides critical insights into how the texture and microstructure of Cu bumps may influence the creep and surface diffusion during the bonding process. This work features a strategy to advance our understanding of the bonding mechanisms and provides insight into tailoring the microstructure of Cu for bonding at a low temperature and low pressure.
Results of a compression test of a beaded panel intended for a proposed hypersonic aircraft are presented. The panel was tested to failure at room temperature to determine its buckling characteristics, in particular, to study the buckling caused by pure compression. The boundary conditions of the panel simulated as nearly as possible a wing mounted condition. Strain, out-of-plane deflection, and load data were measured, and elastic buckling strength as well as mode shapes of the panel were determined. Application of the moire technique is described.
Fatigue life, damage-initiation and propagation, and residual strength data are presently examined to ascertain the response of notched AS4/PEEK specimens to fully reversed tension/compression loading. Stiffness measurements made during the low-level fatigue history show that compression stiffness and tension stiffness degrade throughout the fatigue life. Damage to specimens fatigued at higher cyclic stresses developed primarily in the direction perpendicular to the loading. As in the case of specimens fatigued at lower stress levels, residual compressive stress decreased with damage development.
The flow field characteristics are simulated numerically in an oblique shock wave/laminar boundary layer interaction for three different bleed configurations. The numerical solution for the flow field is obtained for the strong conservation-law form of the two-dimensional compressible Navier-Stokes equations using an implicit scheme. The computations model the flow in the interaction region and inside the bleed slot for an impinging oblique shock of sufficient strength to cause boundary layer separation on a flat plate boundary layer. The computed results are presented for a normal bleed slot at three different locations, upstream, across and downstream of the shock impingement point. The detailed flow characteristics in the interaction zone and inside the bleed slot are compared for the three cases. The resulting surface pressure and shear stress distributions are also compared for the three bleed cases and for the shock wave boundary layer interaction without bleed.
Compressive creep properties of an NiAl/AlN(p) composite produced by a reaction milling process were investigated at 1400 and 1500 K and at slow strain rates, to investigate the relative strength of this composite at high temperatures, and to determine if the consolidation technique affects the 1400 K creep properties. Results indicate that the stress exponent of the NiAl/AlN(p) composite was similar to that for unreinforced NiAl. However, the activation energy for the composite was found to be more than twice that measured in the unreinforced matrix. Oxidation did not affect the composite at 1400 K, but a significant attack was observed in a sample subjected to fast deformation at 1500 K.
The irrelevance of most composite failure criteria to conventional fiber-polymer composites is claimed to have remained undetected primarily because the experiments that can either validate or disprove them are difficult to perform. Uniaxial tests are considered inherently incapable of validating or refuting any composite failure theory because so much of the total load is carried by the fibers aligned in the direction of the load. The Ten-Percent Rule, a simple rule-of-mixtures analysis method, is said to work well only because of this phenomenon. It is stated that failure criteria can be verified for fibrous composites only by biaxial tests, with orthogonal in-plane stresses of the same as well as different signs, because these particular states of combined stress reveal substantial differences between the predictions of laminate strength made by various theories. Three scientifically plausible failure models for fibrous composites are compared, and it is shown that only the in-plane shear test (orthogonal tension and compression) is capable of distinguishing between them. This is because most theories are 'calibrated' against the measured uniaxial tension and compression tests and any cross-plied laminate tests dominated by those same states of stress must inevitably 'confirm' the theory.
The available computational simulation capability is used to demonstrate the structural viability of composite fan blades of innovative Exo-Skeletal Engine (ESE) developed at NASA Glenn Research Center for a subsonic mission. Full structural analysis and progressive damage evaluation of ESE composite fan blade is conducted through the NASA in-house computational simulation software system EST/BEST. The results of structural assessment indicate that longitudinal stresses acting on the blade are in compression. At a design speed of 2000 rpm, pressure and suction surface outer most ply stresses in longitudinal, transverse and shear direction are much lower than the corresponding composite ply strengths. Damage is initiated at 4870 rpm and blade fracture takes place at rotor speed of 7735 rpm. Damage volume is 51 percent. The progressive damage, buckling, stress and strength results indicate that the design at hand is very sound because of the factor of safety, damage tolerance, and buckling load of 6811 rpm.
The results of a numerical study to assess the effect of skin buckling on the internal load distribution in a stiffened fuselage panel, with and without longitudinal cracks, are presented. In addition, the impact of changes in the internal loads on the fatigue life and residual strength of a fuselage panel is assessed. A generic narrow-body fuselage panel is considered. The entire panel is modeled using shell elements and considerable detail is included to represent the geometric-nonlinear response of the buckled skin, cross section deformation of the stiffening components, and details of the skin-string attachment with discrete fasteners. Results are presented for a fixed internal pressure and various combinations of axial tension or compression loads. Results illustrating the effect of skin buckling on the stress distribution in the skin and stringer, and fastener loads are presented. Results are presented for the pristine structure, and for cases where damage is introduced in the form of a longitudinal crack adjacent to the stringer, or failed fastener elements. The results indicate that axial compression loads and skin buckling can have a significant effect on the circumferential stress in the skin, and fastener loads, which will influence damage initiation, and a comparable effect on stress intensity factors for cases with cracks. The effects on stress intensity factors will influence damage propagation rates and the residual strength of the panel.
This report describes the preliminary results of an investigation on component reliability analysis and reliability-based design optimization of thin-walled circular composite cylinders with average diameter and average length of 15 inches. Structural reliability is based on axial buckling strength of the cylinder. Both Monte Carlo simulation and First Order Reliability Method are considered for reliability analysis with the latter incorporated into the reliability-based structural optimization problem. To improve the efficiency of reliability sensitivity analysis and design optimization solution, the buckling strength of the cylinder is estimated using a second-order response surface model. The sensitivity of the reliability index with respect to the mean and standard deviation of each random variable is calculated and compared. The reliability index is found to be extremely sensitive to the applied load and elastic modulus of the material in the fiber direction. The cylinder diameter was found to have the third highest impact on the reliability index. Also the uncertainty in the applied load, captured by examining different values for its coefficient of variation, is found to have a large influence on cylinder reliability. The optimization problem for minimum weight is solved subject to a design constraint on element reliability index. The methodology, solution procedure and optimization results are included in this report.
To investigate borides effect on the hot deformation behavior and microstructure evolution of powder metallurgy high borated stainless steel, hot compression tests at the temperatures of 950– 1150 °C and the strain rates of 0.01– 10 s{sup −1} were performed. Flow stress curves indicated that borides increased the material's stress level at low temperature but the strength was sacrificed at temperatures above 1100 °C. A hyperbolic-sine equation was used to characterize the dependence of the flow stress on the deformation temperature and strain rate. The hot deformation activation energy and stress exponent were determined to be 355 kJ/mol and 3.2, respectively. The main factors leading to activation energy and stress exponent of studied steel lower than those of commercial 304 stainless steel were discussed. Processing maps at the strains of 0.1, 0.3, 0.5, and 0.7 showed that flow instability mainly concentrated at 950– 1150 °C and strain rate higher than 0.6 s{sup −1}. Results of microstructure illustrated that dynamic recrystallization was fully completed at both high temperature-low strain rate and low temperature-high strain rate. In the instability region cracks were generated in addition to cavities. Interestingly, borides maintained a preferential orientation resulting from particle rotation during compression. - Highlights: •The decrement of activation energy was affected by boride and boron solution. •The decrease of stress exponent was influenced by composition and Cottrell atmosphere. •Boride represented a preferential orientation caused by particle rotation.
Hydrodynamic instability experiments allow access to material properties at extreme conditions, where strain rates exceed 105 s -1 and pressures reach 100 GPa. Current hydrodynamic instability experimental methods require in-flight radiography to image the instability growth at high pressure and high strain rate, limiting the facilities where these experiments can be performed. An alternate approach, recovering the sample after loading, allows measurement of the instability growth with profilometry. Tantalum samples were manufactured with different 2D and 3D initial perturbation patterns and dynamically compressed by a blast wave generated by laser ablation. The samples were recovered from peak pressures between 30 and 120 GPa and strain rates on the order of 107 s -1 , providing a record of the growth of the perturbations due to hydrodynamic instability. These records are useful validation points for hydrocode simulations using models of material strength at high strain rate. Recovered tantalum samples were analyzed, providing an estimate of the strength of the material at high pressure and strain rate.
A major thrust of the Ultra-Efficient Engine Technology (UEET) Program at the NASA Glenn Research Center is to develop advanced hot-section engine components using SiC/SiC ceramic matrix composites (CMC's) with thermostructural capability to 2400 F (1315 C). In previous studies, UEET determined that the higher the ultimate tensile strength (UTS) of the as-fabricated CMC, the greater its structural performance at 2400 F. Thus efforts have been ongoing within UEET to understand and develop fiber architecture approaches that can improve the UTS of SiC/SiC CMC's. Under UEET, SiC/SiC test panels and demonstration engine components are currently produced by the multi-ply layup of two-dimensional fabric pieces. The fabric is typically formed of multifilament tows containing high-performance Sylramic (Dow Corning) SiC fiber that is woven into two-dimensional five-harness satin fabric with 20 ends per inch in the 0 degree and 90 degree directions. In some cases, fabric pieces containing woven Sylramic fiber tows are thermally treated at NASA to form Sylramic-iBN fibers that contain a very thin in-situ-grown boron nitride layer on their surfaces. The final SiC/SiC panels and components are fabricated at the CMC vendor by compressing the fabric pieces in tools and then depositing a thin BN interphase coating on the fibers by chemical vapor deposition. The last step at the vendor is to infiltrate the BN-coated fiber architecture with SiC and silicon matrix constituents to form a dense product. Because the as-produced Sylramic fiber tows are sized with a thin polymer coating to facilitate handling and weaving, the individual fibers within the tows and fabric are in close contact with each other. This contact is further increased during fabric compression. One important recent finding is that increasing Sylramic fiber tow width in a fabric increases the UTS of the final SiC/SiC CMC. This effect is presumably related to minimizing fiber/fiber contact, which can be detrimental to CMC strength because of the boron-rich chemistry and roughness of the Sylramic fiber surface. Tows can be spread by mechanically agitating the Sylramic fabric prior to CMC fabrication or by simply thermally treating the Sylramic fabric as in the formation of the Sylramic-iBN fibers. However, CMC's with the treated Sylramic-iBN fabric are even stronger than CMC's with mechanically spread Sylramic tows. The extra strength capability is presumably related to the in situ BN on the fiber surface, which adds compliance to the fiber surfaces and is more resistant to oxygen impurities introduced during the chemical vapor deposition BN process. As shown, another important finding is that the use of fabric with tows having less than the standard of 20 ends per inch provides advantages in terms of reduced ply height and increased ply and CMC strength. The reduced ply height provides more control of part thickness by allowing more plies for a given thickness and by reducing interlaminar residual stresses between plies. The increased ply strength is presumably related to a reduced number of interlaced 90 tows, which, in turn, reduces the crimp angle on the high-modulus fibers in the 0 degree tows. Also, as shown, although fabric with fewer ends per inch reduced the maximum fiber fraction in an eight-ply CMC panel; CMC UTS actually increased because of increased ply strength. Thus, using fabric with fewer ends per inch has several advantages, including providing a significantly higher strength per fiber fraction in the CMC. Consequently, ongoing UEET efforts will attempt to use architectural approaches for components that minimize fiber-fiber contacts and fiber bending within the final composite microstructure.
Additive manufactured Ti-5Al-5V-5Mo-3Cr (Ti-5553) is being considered as an AM repair material for engineering applications because of its superior strength properties compared to other titanium alloys. Here, we describe the failure mechanisms observed through computed tomography, electron backscatter diffraction (EBSD), and scanning electron microscopy (SEM) of spall damage as a result of tensile failure in as-built and annealed Ti-5553. We also investigate the phase stability in native powder, as-built and annealed Ti-5553 through diamond anvil cell (DAC) and ramp compression experiments. We then explore the effect of tensile loading on a sample containing an interface between a Ti-6Al-V4 (Ti-64) baseplate and additively manufactured Ti-5553 layer. Post-mortem materials characterization showed spallation occurred in regions of initial porosity and the interface provides a nucleation site for spall damage below the spall strength of Ti-5553. Preliminary peridynamics modeling of the dynamic experiments is described. Finally, we discuss further development of Stochastic Parallel PARticle Kinteic Simulator (SPPARKS) Monte Carlo (MC) capabilities to include the integration of alpha (α)-phase and microstructural simulations for this multiphase titanium alloy.
In this study, the synthesis of CeO 2 and titanium dioxide (TiO 2 ) doped CeO 2 (TDC) monoliths are investigated, and their fracture strength is assessed using an equibiaxial flexure testing technique at room temperature. Pellets were synthesized using conventional powder processing and sintering methods to produce the desired characteristics. The TiO 2 dopant concentration was optimized at 0.1 wt % TiO 2 to obtain dense, solid-solution pellets with an enhanced grain microstructure. A ball-on-ring fixture was used to obtain the TRS and Weibull parameters of over 30 pellets for CeO 2 and 0.1 wt % TDC to compare fracture behavior. The TRS of CeO 2 pellets ranged from 88 to 160 MPa and the TRS of 0.1 wt % TDC pellets ranged from 102 to 171 MPa, both being consistent with published values. Weibull parameters, such as characteristic strength and Weibull modulus, were extracted as 129 MPa and 8.5 for CeO 2 and 150 MPa and 9.3 for 0.1 wt % TDC, respectively. Although Hertzian contact damage was observed on compressive surfaces, failure initiation occurred on the tensile surfaces of both types of samples. Fracture surface analysis for CeO 2 indicated a predominantly intergranular fracture while 0.1 wt % TDC had a predominantly transgranular fracture mode. Finally, the TRS of 0.1 wt % TDC resulted in increased Weibull parameters when compared to CeO 2 , indicating sample chemistry and microstructure impact mechanical behavior for these samples.
Plastic-bonded granular materials (PBM) are widely used in industrial sectors, including building construction, abrasive applications, and defense applications such as plastic-bonded explosives. The mechanical behavior of PBM is highly nonlinear, irreversible, rate dependent, and temperature sensitive governed by various micromechanical attributions such as grain crushing and binder damage. This paper presents a thermodynamically consistent, microstructure-informed constitutive model to capture these characteristic behaviors of PBM. Key features of the model include a breakage internal variable to upscale the grain-scale information to the continuum level and to predict grain size evolution under mechanical loading. In addition, a damage internal state variable is introduced to account for the damage, deterioration, and debonding of the binder matrix upon loading. Temperature is taken as a fundamental external state variable to handle non-isothermal loading paths. The proposed model is able to capture with good accuracy several important aspects of the mechanical properties of PBM, such as pressure-dependent elasticity, pressure-dependent yield strength, brittle-to-ductile transition, temperature dependency, and rate dependency in the post-yielding regime. Furthermore, the model is validated against multiple published datasets obtained from confined and unconfined compression tests, covering various PBM compositions, confining pressures, temperatures, and strain rates.
This paper presents results of numerical simulation of interaction between a Boeing 747-400 aircraft and the protective shell of a nuclear power plant. The shell is presented as a complex multilayered cellular structure consisting of layers of concrete and fiber concrete bonded with steel trusses. Numerical simulation was performed three-dimensionally using the original algorithm and software taking into account algorithms for building grids of complex geometric objects and parallel computations. Dynamics of the stress-strain state and fracture of the structure were studied. Destruction is described using a two-stage model that allows taking into account anisotropy of elastic and strength properties of concrete and fiber concrete. It is shown that wave processes initiate destruction of the cellular shell structure; cells start to destruct in an unloading wave originating after the compression wave arrival at free cell surfaces.
Observations of the magnetic field near Venus suggest that elements of three different models (direct interaction, tangential discontinuity, magnetic barrier) are present. A bow shock is found to occur at an altitude of about 0.3 Venus radii at the subsolar point. The compression of the decelerated solar wind plasma behind the bow shock causes interplanetary field lines to 'pile up'. The magnetic field inside the bow shock increases from approximately twice the IMF strength at the bow shock to values in the range of approximately 40-100 gammas at altitudes between about 200 and 1,200 km. The maximum value of the piled up field, which is correlated with the dynamic pressure of the solar wind outside the bow shock, is found at lower altitudes for larger field strengths. Just Venus-ward of the maximum field, the pressure of the cold plasma increases to a level balancing the pressure of the external magnetic field. Hence, to a first approximation, the ionosphere has a diamagnetic response excluding the magnetosheath field. However, strong magnetic fields are found at times throughout the ionosphere.