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NASA NTRS1999

Elastic Moduli of Pyrolytic Boron Nitride Measured Using 3-Point Bending and Ultrasonic Testing

Three-point bending and ultrasonic testing were performed on a flat plate of PBN. In the bending experiment, the deformation mechanism was believed to be shear between the pyrolytic layers, which yielded a shear modulus, c (sub 44), of 2.60 plus or minus .31 GPa. Calculations based on the longitudinal and shear wave velocity measurements yielded values of 0.341 plus or minus 0.006 for Poisson's ratio, 10.34 plus or minus .30 GPa for the elastic modulus (c (sub 33)), and 3.85 plus or minus 0.02 GPa for the shear modulus (c (sub 44)). Since free basal dislocations have been reported to affect the value of c (sub 44) found using ultrasonic methods, the value from the bending experiment was assumed to be the more accurate value.

Kaforey, M. L.↗

NASA NTRS1986

Analysis of Delamination Growth from Matrix Cracks in Laminates Subjected to Bending Loads

A major source of delamination damage in laminated composite materials is from low-velocity impact. In thin composite laminates under point loads, matrix cracks develop first in the plies, and delaminations then grow from these cracks at the ply interfaces. The purpose of this study was to quantify the combined effects of bending and transverse shear loads on delamination initiation from matrix cracks. Graphite-epoxy laminates with 90 deg. plies on the outside were used to provide a two-dimensional simulation of the damage due to low-velocity impact. Three plate bending problems were considered: a 4-point bending, 3-point bending, and an end-clamped center-loaded plate. Under bending, a matrix crack will form on the tension side of the laminate, through the outer 90 deg. plies and parallel to the fibers. Delaminations will then grow in the interface between the cracked 90 deg. ply and the next adjacent ply. Laminate plate theory was used to derive simple equations relating the total strain energy release rate, G, associated with the delamination growth from a 90 deg. ply crack to the applied bending load and laminate stiffness properties. Three different lay-ups were tested and results compared. Test results verified that the delamination always formed at the interface between the cracked 90 deg. ply and the next adjacent ply. Calculated values for total G sub c from the analysis showed good agreement for all configurations. The analysis was able to predict the delamination onset load for the cases considered. The result indicated that the opening mode component (Mode I) for delamination growth from a matrix crack may be much larger than the component due to interlaminar shear (Mode II).

Murri, G. B.↗

NASA NTRS1988

Analysis of delamination growth from matrix cracks in laminates subjected to bending loads

A major source of delamination damage in laminated composite materials is from low-velocity impact. In thin composite laminates under point loads, matrix cracks develop first in the plies, and delaminations then grow from these cracks at the ply interfaces. The purpose of this study was to quantify the combined effects of bending and transverse shear loads on delamination initiation from matrix cracks. Graphite-epoxy laminates with 90 deg plies on the outside were used to provide a two-dimensional simulation of the damage due to low-velocity impact. Three plate bending problems were considered: a 4-point bending, 3-point bending, and an end-clamped center-loaded plate. Under bending, a matrix crack will form on the tension side of the laminate, through the outer 90 deg plies and parallel to the fibers. Delaminations will then grow in the interface between the cracked 90 deg ply and the next adjacent ply. Laminate plate theory was used to derive simple equations relating the total strain energy release rate, G, associated with the delamination growth from a 90 deg ply crack to the applied bending load and laminate stiffness properties. Three different lay-ups were tested and results compared. Test results verified that the delamination always formed at the interface between the cracked 90 deg ply and the next adjacent ply. Calculated values for total G sub c from the analysis showed good agreement for all configurations. The analysis was able to predict the delamination onset load for the cases considered. The result indicated that the opening mode component (Mode I) for delamination growth from a matrix crack may be much larger than the component due to interlaminar shear (Mode II).

Murri, Gretchen Bostaph↗

NASA NTRSDate not supplied

Microscale Constitutive Model Sensitivity on Multiscale Modeling of Fiber Reinforced Composites

Fiber reinforced composites are desirable in applications where low weight and high strength are needed, but are susceptible to microscale variability during manufacturing, making failure predictions difficult. The impact microscale variability has on macroscale mechanical response is difficult to predict due to the computational efficiency needed to simulate many, large, high fidelity, microscale models. In this study, a multiscale approach was taken to model 3-point bend, 4-point bend, and tensile experiments of a unidirectional composite from only having microstructure scans of these samples and constituent properties from literature. These scans were sampled with different sized windows, and statistically equivalent microstructures were generated, then simulated for stiffness, strength, and fracture toughness using an efficient micromechanical. Mesoscale models were created where element sizes equaled microstructure size, and properties were assigned through sampling of microscale simulation results. First, this study showed the effect of using Weibull scaling on constituent matrix strength on macroscale response. Then, a comparison was made between different element sizes and experiments. Finally, model dimensions were fixed, and the effect of randomly distributed local properties alone was examined. Results showed that the scatter of strength and stiffness in the experiments could be predicted well using images of the microscale fiber morphologies and that using stochastic properties produced a 3% coefficient of variation of strength for all experiments.

statistical microstructure↗

NASA NTRS2001

Transverse Tension Fatigue Life Characterization Through Flexure Testing of Composite Materials

The transverse tension fatigue life of S2/8552 glass-epoxy and IM7/8552 carbon-epoxy was characterized using flexure tests of 90-degree laminates loaded in 3-point and 4-point bending. The influence of specimen polishing and specimen configuration on transverse tension fatigue life was examined using the glass-epoxy laminates. Results showed that 90-degree bend specimens with polished machined edges and polished tension-side surfaces, where bending failures where observed, had lower fatigue lives than unpolished specimens when cyclically loaded at equal stress levels. The influence of specimen thickness and the utility of a Weibull scaling law was examined using the carbon-epoxy laminates. The influence of test frequency on fatigue results was also documented for the 4-point bending configuration. A Weibull scaling law was used to predict the 4-point bending fatigue lives from the 3-point bending curve fit and vice-versa. Scaling was performed based on maximum cyclic stress level as well as fatigue life. The scaling laws based on stress level shifted the curve fit S-N characterizations in the desired direction, however, the magnitude of the shift was not adequate to accurately predict the fatigue lives. Furthermore, the scaling law based on fatigue life shifted the curve fit S-N characterizations in the opposite direction from measured values. Therefore, these scaling laws were not adequate for obtaining accurate predictions of the transverse tension fatigue lives.

OBrien, T. Kevin↗

NASA NTRS2004

Exploratory Investigation of Failure Mechanisms in Transition Regions between Solid Laminates and X-cor(registered tm) Truss Sandwich

Small sub-component specimens consisting of solid laminates at the ends that transition to X-cor(R) truss sandwich in the center, were tested in a combination of three point bending, uni-axial tension, and combined tension and bending. The failure process in the transition region was documented for each loading using digital video and high-resolution cameras. For the 3-point bending tests, most of the deformation occurred in the solid laminate regions on either end of the specimen. Some pin debonding from the skin of the X-cor(R) truss sandwich was observed in the transition region and was accompanied by audible "pings" throughout the loading. Tension loaded specimens failed in the sandwich skin in the middle of the gage length, accompanied by separation of the sandwich core from the back skin and by delamination between the top skin and bottom skin at the transition region. The pinging associated with pin debonding occurred as the load was increased. However, the frequency of the pinging exceeded any visual observations of pin debonding in the video of the transition region. For specimens tested in combined tension and bending, the greatest amount of pinging occurred during initial application of the axial load. High-resolution images in the transition region indicated that the pinging corresponded to pins debonding and buckling due to the through-thickness Poisson contraction of the specimen. This buckling continued to a much smaller extent as the transverse load was applied.

OBrien, T. Kevin↗

NASA NTRS2021

Modular Composite Damage Detection System (MCDDS)

The 2020 CIF funded Modular Composite Damage Detection System (MCDDS) aims to advance the technology of damage detection in composites in the areas of thin, flexible damage detection panel construction, encapsulation techniques in composite matrixes, innovative integration and interfacing techniques with flexible embedded sensory panels, repair methods of composite materials, and improved packaging of the MCDDS. Custom thin, flexible polyimide printed circuit boards (PCBs) were designed and procured for fabrication of test specimens. A custom interface PCB was designed and fabricated to monitor the newly developed damage detection test specimens. Test specimens were fabricated using the novel flexible circuitry that were either fully or partially encapsulated. The fully encapsulated specimens were used to demonstrate embedded damage detection concepts and the partially encapsulated specimens were used to demonstrate surface-mounted (laminate) damage detection concepts. The new composite damage detection test specimens were tested and evaluated to determine if the novel damage detection sensory panels could withstand low-cycle threshold fatigue loading per a modified version of American Society for Testing and Materials (ASTM) D 7264 for up to 50 cycles without void formation. The data for multiple sensory panels indicates that the newly fabricated sensory panels are robust and do indeed withstand three-point bend flexural loading for more than 50 cycles. Additionally, testing was performed to determine if damage could be detected in damage detection test specimens subjected to failure using a 3-point bend test per a modified version of ASTM D 7264. Again, multiple sensory panels (both fully and partially encapsulated) showed the ability to detect damage to specimens subjected to failure per a modified version of ASTM D 7264. Additionally, a novel concept for tracking and monitoring of cracking (and potentially delamination) in composites was designed and developed that utilizes painted-on conductors.

Christopher Forney↗

NASA NTRS2022

Design Optimization of Energized Composite Using Simulation and Experimental Methods

As electric vehicles (EVs) are evolving, innovative technologies like “energized composite” that can store energy in the car's body helps extend its range per charge. The composite's unique ability to function as both structural body panel and charge storage medium stems from its unique pattern design between “electrochemical areas (EcA)” and “epoxy area (EpA)”. Herein, a design optimization study is presented to obtain a balanced ratio between EcA versus EpA to maximize the charge storage ability of the composite while maintaining a decent tensile and bending strength. Simulations using ANSYS software and experimental confirmation using universal testing machines and electrochemical analyzers are used to derive optimum ratios between EcA and EpA. Uniaxial tension test and 3-point bend test have been performed to optimize the tensile and bend strengths, whereas cyclic voltammetry, galvanic charge–discharge, and electrochemical impedance spectroscopy are used to determine the electrochemical performance of various design configurations by modulating the ratios of EcA versus EpA. Overall, the highest achieved energy storage per lamina is 2531 mWh m−2 for a maximum of 81.6% EcA with a tensile strength of 417.73 MPa and bending strength of 263.13 MPa. This study is highly beneficial for EVs and aerospace applications.

energy storage↗

NASA NTRS1984

Effects of high energy radiation on the mechanical properties of epoxy-graphite fiber reinforced composites

The effects of high energy radiation on the mechanical properties and on the molecular and structural properties of graphite fiber reinforced composites were assessed so that the durability of such composites in space applications could be predicted. Investigative techniques including ESR and infrared spectroscopy, ESCA, contact angle measurements, and dynamic and static mechanical testing (3-point bending and interlaminar shear) were employed. The results using these different techniques are individually described, and the implications of the data are discussed. The proposed plan of work for the next fiscal year is outlined.

Fornes, R. E.↗

NASA NTRS1999

Bone Blood Flow During Simulated Microgravity: Physiological and Molecular Mechanisms

Blood flow to bone has been shown to affect bone mass and presumably bone strength. Preliminary data indicate that blood flow to the rat femur decreases after 14 days of simulated microgravity, using hindlimb suspension (HLS). If adult rats subjected to HLS are given dobutamine, a synthetic catecholamine which can cause peripheral vasodilation and increased blood flow, the loss of cortical bone area usually observed is prevented. Further, mechanisms exist at the molecular level to link changes in bone blood flow to changes in bone cell activity, particularly for vasoactive agents like nitric oxide (NO). The decreases in fluid shear stress created by fluid flow associated with the shifts of plasma volume during microgravity may result in alterations in expression of vasoactive agents such as NO, producing important functional effects on bone cells. The primary aim of this project is to characterize changes in 1) bone blood flow, 2) indices of bone mass, geometry, and strength, and 3) changes in gene expression for modulators of nitric oxide activity (e.g., nitric oxide synthase) and other candidate genes involved in signal transduction of mechanical loading after 3, 7, 14, 21, and 28 days of HLS in the adult rat. Using a rat of at least 5 months of age avoids inadvertently studying effects of simulated microgravity on growing, rather than adult, bone. Utilizing the results of these studies, we will then define how altered blood flow contributes to changes in bone with simulated microgravity by administering a vasodilatory agent (which increases blood flow to tissues) during hindlimb suspension. In all studies, responses in the unloaded hindlimb bones (tibial shaft, femoral neck) will be compared with those in the weightbearing humeral shaft and the non-weightbearing calvarium (skull) from the same animal. Bone volumetric mineral density and geometry will be quantified by peripheral quantitative CT; structural and material properties of the long bones will be determined by 3-point bending (tibia, humerus) or compression (femoral neck) testing to failure. A unique aspect of these studies will be defining the time course of changes in gene expression in bone cell populations with unloading, accomplished with Northern blots, in situ hybridization, and immunohistochemistry. These studies have high relevance for concurrent protocols being proposed by investigators on NSBRI Cardiovascular and Muscle teams, with blood flow data available on a number of tissues other than bone. Further, dobutamine and other Beta-agonists have been tested as countermeasures for altered muscle and cardiovascular function. Results of the intervention tested in our studies have potential relevance for a number of systemic changes seen with prolonged spaceflight.

Bloomfield, Susan A.↗

NASA NTRS2010

Modeling Progressive Damage Using Local Displacement Discontinuities Within the FEAMAC Multiscale Modeling Framework

A method for performing progressive damage modeling in composite materials and structures based on continuum level interfacial displacement discontinuities is presented. The proposed method enables the exponential evolution of the interfacial compliance, resulting in unloading of the tractions at the interface after delamination or failure occurs. In this paper, the proposed continuum displacement discontinuity model has been used to simulate failure within both isotropic and orthotropic materials efficiently and to explore the possibility of predicting the crack path, therein. Simulation results obtained from Mode-I and Mode-II fracture compare the proposed approach with the cohesive element approach and Virtual Crack Closure Techniques (VCCT) available within the ABAQUS (ABAQUS, Inc.) finite element software. Furthermore, an eccentrically loaded 3-point bend test has been simulated with the displacement discontinuity model, and the resulting crack path prediction has been compared with a prediction based on the extended finite element model (XFEM) approach.

Ranatunga, Vipul↗

NASA NTRS2011

Carbon Nanotube Coatings as Used in Strain Sensors for Composite Tanks

The next generation of cryogenic fuel tanks, crew habitats and other components for future spacecraft will focus on the usc of lightweight carbon fiber composite materials. A critical issue in the design and optimization of such tanks and structures will bc in structural health monitoring, however, current strain sensors have limitations. In this study, a novel carbon nanotube thin film was applied to carbon fiber composites for structural monitoring. Applying a load using a 3-point bend test to simulate bowing of a tank wall, induced significant increases in the film's electrical resistance at small deflections. Upon release of the load, the resistance returned to its approximate start value and was reproducible over multiple tests. The results show that a carbon nanotube thin film has great potential for the health monitoring of composite structures.

Trigwell, Steve↗

NASA NTRS2016

Effects of Zoledronate and Mechanical Loading during Simulated Weightlessness on Bone Structure and Mechanical Properties

Space flight modulates bone remodeling to favor bone resorption. Current countermeasures include an anti-resorptive drug class, bisphosphonates (BP), and high-force loading regimens. Does the combination of anti-resorptives and high-force exercise during weightlessness have negative effects on the mechanical and structural properties of bone? In this study, we implemented an integrated model to mimic mechanical strain of exercise via cyclical loading (CL) in mice treated with the BP Zoledronate (ZOL) combined with hindlimb unloading (HU). Our working hypothesis is that CL combined with ZOL in the HU model induces additive structural and mechanical changes. Thirty-two C57BL6 mice (male,16 weeks old, n8group) were exposed to 3 weeks of either HU or normal ambulation (NA). Cohorts of mice received one subcutaneous injection of ZOL (45gkg), or saline vehicle, prior to experiment. The right tibia was axially loaded in vivo, 60xday to 9N in compression, repeated 3xweek during HU. During the application of compression, secant stiffness (SEC), a linear estimate of slope of the force displacement curve from rest (0.5N) to max load (9.0N), was calculated for each cycle once per week. Ex vivo CT was conducted on all subjects. For ex vivo mechanical properties, non-CL left femurs underwent 3-point bending. In the proximal tibial metaphysis, HU decreased, CL increased, and ZOL increased the cancellous bone volume to total volume ratio by -26, +21, and +33, respectively. Similar trends held for trabecular thickness and number. Ex vivo left femur mechanical properties revealed HU decreased stiffness (-37),and ZOL mitigated the HU stiffness losses (+78). Data on the ex vivo Ultimate Force followed similar trends. After 3 weeks, HU decreased in vivo SEC (-16). The combination of CL+HU appeared additive in bone structure and mechanical properties. However, when HU + CL + ZOL were combined, ZOL had no additional effect (p0.05) on in vivo SEC. Structural data followed this trend with ZOL not modulating trabecular thickness in CL + NAHU mice. In summary, our integrated model simulates the combination of weightlessness, exercise-induced mechanical strain, and anti-resorptive treatment that astronauts experience during space missions. Based on these results, we conclude that, at the structural and stiffness level, zoledronate treatment during simulated spaceflight does not impede the skeletal response to axial compression. In contrast to our hypothesis, our data show that zoledronate confers no additional mechanical or structural benefit beyond those gained from cyclical loading.

Mechanical Loading↗

NASA NTRSDate not supplied

Modeling the Stochastic Response of Fiber Reinforced Composites with Varied Representative Volume Element Sizes

Fiber reinforced composites are desirable in applications where low weight and high strength are needed, but are susceptible to variability and flaws during manufacturing, making failure predictions difficult. These flaws may occur at the microscale where mechanical properties vary locally due to regions of fiber clusters and matrix pockets. In this study, a multiscale approach was taken to model 3-point bend, 4-point bend, and tensile experiments of a unidirectional composite from only having microstructure scans of these samples and constituent properties from literature. These scans were sampled with different sized windows, and statistically equivalent microstructures were generated, then simulated for stiffness, strength, and fracture toughness using a reduced order micromechanical model and NASA’s Multiscale Analysis Tool (NASMAT). Mesoscale models were created with equivalent element sizes to microstructures and properties sampled from microscale simulation results. Results showed how microscale size affects certain mechanical properties. Also shown is how well mesoscale models agree to experiments when using stochastic element properties and varying element size.

microstructure↗

NASA NTRS2006

Quasi-Static 3-Point Reinforced Carbon-Carbon Bend Test and Analysis for Shuttle Orbiter Wing Leading Edge Impact Damage Thresholds

Static 3-point bend tests of Reinforced Carbon-Carbon (RCC) were conducted to failure to provide data for additional validation of an LS-DYNA RCC model suitable for predicting the threshold of impact damage to shuttle orbiter wing leading edges. LS-DYNA predictions correlated well with the average RCC failure load, and were good in matching the load vs. deflection. However, correlating the detectable damage using NDE methods with the cumulative damage parameter in LS-DYNA material model 58 was not readily achievable. The difficulty of finding internal RCC damage with NDE and the high sensitivity of the mat58 damage parameter to the load near failure made the task very challenging. In addition, damage mechanisms for RCC due to dynamic impact of debris such as foam and ice and damage mechanisms due to a static loading were, as expected, not equivalent.

Fasanella, Edwin L.↗

NASA NTRS2001

Analysis of Ninety Degree Flexure Tests for Characterization of Composite Transverse Tensile Strength

Finite element (FE) analysis was performed on 3-point and 4-point bending test configurations of ninety degree oriented glass-epoxy and graphite-epoxy composite beams to identify deviations from beam theory predictions. Both linear and geometric non-linear analyses were performed using the ABAQUS finite element code. The 3-point and 4-point bending specimens were first modeled with two-dimensional elements. Three-dimensional finite element models were then performed for selected 4-point bending configurations to study the stress distribution across the width of the specimens and compare the results to the stresses computed from two-dimensional plane strain and plane stress analyses and the stresses from beam theory. Stresses for all configurations were analyzed at load levels corresponding to the measured transverse tensile strength of the material.

OBrien, T. Kevin↗

NASA NTRS1995

Flexure fatigue testing of 90 deg graphite/epoxy composites

A great deal of research has been performed characterizing the in-plane fiber-dominated properties, under both static and fatigue loading, of advanced composite materials. To the author's knowledge, no study has been performed to date investigating fatigue characteristics in the transverse direction. This information is important in the design of bonded composite airframe structure where repeated, cyclic out-of-plane bending may occur. Recent tests characterizing skin/stringer debond failures in reinforced composite panels where the dominant loading in the skin is flexure along the edge of the frame indicate failure initiated either in the skin or else the flange, near the flange tip. When failure initiated in the skin, transverse matrix cracks formed in the surface skin ply closest to the flange and either initiated delaminations or created matrix cracks in the next lower ply, which in turn initiated delaminations. When failure initiated in the flanges, transverse cracks formed in the flange angle ply closest to the skin and initiated delamination. In no configuration did failure propagate through the adhesive bond layer. For the examined skin/flange configurations, the maximum transverse tension stress at failure correlates very well with the transverse tension strength of the composites. Transverse tension strength (static) data of graphite epoxy composites have been shown to vary with the volume of material stressed. As the volume of material stressed increased, the strength decreased. A volumetric scaling law based on Weibull statistics can be used to predict the transverse strength measurements. The volume dependence reflects the presence of inherent flaws in the microstructure of the lamina. A similar approach may be taken to determine a volume scale effect on the transverse tension fatigue behavior of graphite/epoxy composites. The objective of this work is to generate transverse tension strength and fatigue S-N characteristics for composite materials using 3-point flexure tests of 90 deg graphite/epoxy specimens. Investigations will include the volume scale effect as well as frequency and span-to-thickness ratio effects. Prior to the start of the experimental study, an analytical study using finite element modeling will be performed to investigate the span-to-thickness effect. The ratio of transverse flexure stress to shear stress will be monitored and its values predicted by the FEM analysis compared with the value obtained using a 'strength of materials' based approach.

Peck, Ann Nancy W.↗