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At least 19 records

All sources NASA NTRS DOE OSTI

NASA NTRS2014

Use of a New Portable Instrumented Impactor on the NASA Composite Crew Module Damage Tolerance Program

Damage tolerance performance is critical to composite structures because surface impacts at relatively low energies may result in a significant strength loss. For certification, damage tolerance criteria require aerospace vehicles to meet design loads while containing damage at critical locations. Data from standard small coupon testing are difficult to apply to larger more complex structures. Due to the complexity of predicting both the impact damage and the residual properties, damage tolerance is demonstrated primarily by testing. A portable, spring-propelled, impact device was developed which allows the impact damage response to be investigated on large specimens, full-scale components, or entire vehicles. During impact, both the force history and projectile velocity are captured. The device was successfully used to demonstrate the damage tolerance performance of the NASA Composite Crew Module. The impactor was used to impact 18 different design features at impact energies up to 35 J. Detailed examples of these results are presented, showing impact force histories, damage inspection results, and response to loading.

Jackson, Wade C.↗

NASA NTRS2002

A Novel Approach to Rotorcraft Damage Tolerance

Damage-tolerance methodology is positioned to replace safe-life methodologies for designing rotorcraft structures. The argument for implementing a damage-tolerance method comes from the fundamental fact that rotorcraft structures typically fail by fatigue cracking. Therefore, if technology permits prediction of fatigue-crack growth in structures, a damage-tolerance method should deliver the most accurate prediction of component life. Implementing damage-tolerance (DT) into high-cycle-fatigue (HCF) components will require a shift from traditional DT methods that rely on detecting an initial flaw with nondestructive inspection (NDI) methods. The rapid accumulation of cycles in a HCF component will result in a design based on a traditional DT method that is either impractical because of frequent inspections, or because the design will be too heavy to operate efficiently. Furthermore, once a HCF component develops a detectable propagating crack, the remaining fatigue life is short, sometimes less than one flight hour, which does not leave sufficient time for inspection. Therefore, designing a HCF component will require basing the life analysis on an initial flaw that is undetectable with current NDI technology.

Forth, Scott C.↗

NASA NTRSDate not supplied

Best Practices, Lessons Learned, and Examples on the Application of Damage Tolerance in Space Structures

Damage tolerance is an important consideration in space structures applications. The intent of damage tolerance is to demonstrate that the structure is robust to the presence of flaws over the service life of the space vehicle. Damage tolerance requirements in documents such as those in NASA, AIAA, and ISO can be challenging to implement. The intent of this paper is three-fold: (1) Provide best practices in the application of damage tolerance requirements for space applications, (2) Provide lessons learned for each of class of hardware, (3) Provide examples of challenging situations encountered in the application of damage tolerance. Examples cover additive manufacturing, composite overwrapped pressure vessels, pressurized structures, liquid rocket engines, thermal protection systems, and other classes of hardware. The philosophy and limitations of leak before burst and proof test logic are also discussed. Finally, a discussion on elastic-plastic fracture mechanics with comparisons to test data will be presented.

Best Practices↗

NASA NTRS1992

Damage-Tolerant Composites Made By Stitching Carbon Fabrics

Work conducted at NASA Langley Research Center to investigate stitching combined with resin transfer molding to make composites more tolerant of damage and potentially cost competitive with metals. Composite materials tailored for damage tolerance by stitching layers of dry carbon fabric with closely spaced threads to provide reinforcement through thickness. Epoxy resin then infused into stitched preforms, and epoxy was cured. Various stitching patterns and thread materials evaluated by use of flat plate specimens. Also, blade-stiffened structural elements fabricated and tested. Stitched flat laminates showed outstanding damage tolerance, excellent compression strength in notched specimens, and acceptable fatigue behavior. Development of particular interest to aircraft and automotive industries.

Dow, Marvin B.↗

NASA NTRS2006

Composites Damage Tolerance Workshop

The Composite Damage Tolerance Workshop included participants from NASA, academia, and private industry. The objectives of the workshop were to begin dialogue in order to establish a working group within the Agency, create awareness of damage tolerance requirements for Constellation, and discuss potential composite hardware for the Crew Launch Vehicle (CLV) Upper Stage (US) and Crew Module. It was proposed that a composites damage tolerance working group be created that acts within the framework of the existing NASA Fracture Control Methodology Panel. The working group charter would be to identify damage tolerance gaps and obstacles for implementation of composite structures into manned space flight systems and to develop strategies and recommendations to overcome these obstacles.

Gregg, Wayne↗

NASA NTRS1985

Multiaxial and thermomechanical fatigue considerations in damage tolerant design

In considering damage tolerant design concepts for gas turbine hot section components, several challenging concerns arise: Complex multiaxial loading situations are encountered; Thermomechanical fatigue loading involving very wide temperature ranges is imposed on components; Some hot section materials are extremely anisotropic; and coatings and environmental interactions play an important role in crack propagation. The effects of multiaxiality and thermomechanical fatigue are considered from the standpoint of their impact on damage tolerant design concepts. Recently obtained research results as well as results from the open literature are examined and their implications for damage tolerant design are discussed. Three important needs required to advance analytical capabilities in support of damage tolerant design become readily apparent: (1) a theoretical basis to account for the effect of nonproportional loading (mechanical and mechanical/thermal); (2) the development of practical crack growth parameters that are applicable to thermomechanical fatigue situations; and (3) the development of crack growth models that address multiple crack failures.

Leese, G. E.↗

NASA NTRS2008

Damage Tolerance Testing of a NASA TransHab Derivative Woven Inflatable Module

Current options for Lunar habitat architecture include inflatable habitats and airlocks. Inflatable structures can have mass and volume advantages over conventional structures. Inflatable structures are perceived to carry additional risk because they are at a lower Technical Readiness Level (TRL) than conventional metallic structures. One of the risks associated with inflatable structures is understanding the tolerance to component damage and the resulting behavior of the system after the damage is introduced. The Damage Tolerance Test (DTT) is designed to study the structural integrity of an expandable structure during and subsequent to induced damage. The TransHab Project developed an experimental inflatable module developed at Johnson Space Center in the 1990's. The TransHab design was originally envisioned for use in Mars Transits but was also studied as a potential habitat for the International Space Station (ISS). The design of the TransHab module was based on a woven design using an Aramid fabric. Testing of this design demonstrated a high level of predictability and repeatability and good correlation with analytical predictions of stresses and deflections. Based on JSC's experience with the design and analysis of woven inflatable structures, the Damage Tolerance Test article was designed and fabricated using a woven design. The Damage Tolerance Test Article consists of a load bearing restraint layer, a bladder or gas barrier, and a structural metallic core. The test article restraint layer is fabricated from one inch wide Kevlar webbing that is woven in a basket weave pattern. Underneath the structural restraint layer is the bladder or gas barrier. For this test the bladder was required to maintain pressure for testing only and was not representative of a flight design. The bladder and structural restraint layer attach to the structural core of the module at steel bulkheads at each end. The two bulkheads are separated by a 10 foot center tube which provides the structural support for the module when in a non-inflated state as well as resists a portion of the axial load when pressurized. The longitudinal members of the structural restraint layer are attached to the bulkheads using a series of clevises that are bolted to the bulkheads. Strain gages are placed on the clevises that can measure change in load when the structural restraint is inflated. The test module is 88 inches in diameter and 120 inches in height. The objectives of the DTT are to (1) verify the structural integrity of the assembled and pressurized structure when a section of the structural restraint layer is cut by a foreign object, and (2) verify the load distribution of the structural restraint layer during pressurization, before and after the structural restraint layer is severed. For this test, a longitudinal structural restraint strap will be severed using a linear shape charge. The linear shape charge was designed specifically for this application to cut only a single longitudinal strap, while not damaging the bladder. An array of strain gages were located at the bulkhead mounted clevises where the longitudinal restraint layer straps are attached. The DTT article was inflated to 45 psig, 25% of the ultimate design pressure, and one of the one-inch wide longitudinal structural members was severed. Strain gage measurements of loading in an array of longitudinal straps were taken throughout pressurization of the module to 45 psig, before firing of the linear shape charge, and after firing of the shape charge and separation of the strap. During testing not only were the original objectives met but better than expected results occurred. This paper will discuss space inflatable structures, damage tolerance analysis, test results, and applicability to the Lunar architecture.

Edgecombe, John↗

NASA NTRS1991

Damage tolerance for commuter aircraft

The damage tolerance experience in the United States Air Force with military aircraft and in the commercial world with large transport category aircraft indicates that a similar success could be achieved in commuter aircraft. The damage tolerance process is described for the purpose of defining the approach that could be used for these aircraft to ensure structural integrity. Results of some of the damage tolerance assessments for this class of aircraft are examined to illustrate the benefits derived from this approach. Recommendations are given for future damage tolerance assessment of existing commuter aircraft and on the incorporation of damage tolerance capability in new designs.

Aging Aircraft↗

NASA NTRS2009

Damage Tolerance Testing of a NASA TransHab Derivative Woven Inflatable Module

Edgecombe, John↗

NASA NTRSDate not supplied

Proposed Reliability-Based Damage Tolerance Guidelines for Space Systems

Deterministic damage tolerance guidelines for highly reusable and efficiently designed launch systems can be challenging to meet and result in overly conservative assessments for tightly controlled manufacturing processes. Deterministic approaches may be unconservative when the structure is workmanship sensitive and there is a wide spread in fracture properties. Reliability-based damage tolerance assessments targeting a component reliability over the service life commensurate to mission risk posture is a promising alternative. Low production rates, short fleets, and lack of standards or guidance has slowed down widespread adoption of this method. Guidance for the robust application of reliability-based damage tolerance for space systems are proposed. These guidelines cover the treatment of uncertainty in damage tolerance analysis, the collection of data to develop probabilistic distributions, uncertainty propagation methods, and types of hardware.

Reliability-Based Damage Tolerance↗

NASA NTRS2013

Damage Tolerance Assessment Branch

The Damage Tolerance Assessment Branch evaluates the ability of a structure to perform reliably throughout its service life in the presence of a defect, crack, or other form of damage. Such assessment is fundamental to the use of structural materials and requires an integral blend of materials engineering, fracture testing and analysis, and nondestructive evaluation. The vision of the Branch is to increase the safety of manned space flight by improving the fracture control and the associated nondestructive evaluation processes through development and application of standards, guidelines, advanced test and analytical methods. The Branch also strives to assist and solve non-aerospace related NDE and damage tolerance problems, providing consultation, prototyping and inspection services.

Walker, James L.↗

NASA NTRS1984

A conceptual basis for the design of damage-tolerant structural systems

Researchers define damage-tolerant structural systems as those systems which not only have adeqate intact strength to withstand initial failure but also adequate residual strength to minimize the possibility of, and hence the consequences of, further failure. The incorporation of damage tolerance cannot be done in total isolation of the function being required of the system and the costs associated with obtaining improved damage tolerance. The approach, therefore, is to formulate multiple-objective, multi-level decision support problems (DSP), the solutions of which represent a compromise between higher costs and higher damage tolerance. Mulitple-objective decision support problems are easily solved in the linear domain. These formulations, however, include both linear and nonlinear constraints and goals, which in the past, have not been considered due to the resulting complexity. Here, researchers: (1) present a complete discussion and description of decision support problems; (2) identify what further research needs to be done in order to obtain information that is required but not known for solving problems using these models; and (3) identify what needs to be done to implement this prototype method in practice.

Mistree, F.↗

NASA NTRS2017

Fatigue Life and Damage Tolerance of Postbuckled Composite Stiffened Structures with Indentation Damage

The fatigue life and damage tolerance of composite stiffened panels with indentation damage are investigated experimentally using single-stringer compression specimens. The indentation damage was induced to one of the two flanges of the stringer of every panel. The advantages of indentation compared to impact are the simplicity of application, less dependence on boundary conditions, better controllability, and repeatability of the imparted damage. The tests were conducted using advanced instrumentation, including digital image correlation, passive thermography, and in situ ultrasonic scanning. Specimens with initial indentation damage ranging between 32 and 56 mm in length were tested quasi-statically and in fatigue, and the effects of cyclic load amplitude and damage size were studied. A means of comparison of the damage propagation rates and collapse loads based on a stress intensity measure and the Paris law is proposed. The stress intensity measure provides the means to compare the collapse loads of specimens with different damage types and damage sizes, while the Paris law is used to compare the damage propagation rates in specimens subjected to different cyclic loads. This approach enables a comparison of different tests and the potential identification of the effects that influence the fatigue lives and damage tolerance of postbuckled structures with defects.

Davila, Carlos G.↗

NASA NTRS1980

Damage tolerance research on composite compression panels

The damage tolerance of composites was investigated. Results show that severe degradation in material strength may occur due to impact damage and that reduced strain allowables should be considered to compensate for possible impact damage. The mechanisms of failure involved in impact so that local damage will be reduced and arrest of propagating fracture initiated at impact locations are examined. Compression strength reductions for damage due to impact by a 1.27 cm diameter spherical projectile in thick laminates representative of wing skin panels are presented. Also discussed are the results of concepts recently evaluated to improve damage tolerance. These concepts range from improvements at the materials level to advanced structural configurations designed to arrest or limit the growth of propagating fractures. The results indicate that substantial improvements in the damage tolerance of graphite-epoxy composite structures can be achieved through the proper combination of materials and structural design.

Rhodes, M. D.↗

DOE OSTI2021

Alternative Damage Tolerant Materials for Wind Turbine Blades: An Overview

Current wind turbine blade materials may not be damage tolerant to the extent necessary to optimize the Levelized Cost of Energy (LCOE) of wind energy plants. Traditionally, wind turbine blades have been designed using a safe-life approach, but advances in inspection techniques and structural health monitoring solutions give rise to the opportunity to design wind turbine blades using a damage tolerant approach. Materials selection is a key element of da mage tolerant design, so the extent of the damage tolerance of alternative materials has been analyzed through a literature review and discussions with industry leaders. Fabrics and resin selection significantly affect the damage tolerance of composites. Changes to fabric architecture may include through-the-thickness (TTT) fibers, stretch-broken carbon fiber (SBCF) composites, and aligned discontinuous fiber reinforced composites (ADFRCs). Previous research has demonstrated that using TTT fibers in creases damage tolerance, but additional research is necessary to demonstrate the effectiveness of SBCFs and ADFRCs in mitigating damage. Several studies have demonstrated increased damage tolerance when toughened resin systems are used. In addition to toughened resin systems, thermoplastics have been shown to be tougher than thermosets. However, thermosets have been traditionally preferred in wind turbine blade manufacturing due to ease of manufacturing. Thermoplastic resin system s have been developed that can be used with conventional manufacturing methods but have yet to be studied for its damage tolerant capabilities. Furthermore, cost and stress analyses on where to effectively implement TTT fibers, SBCF composites, ADFRCs, and toughened resin systems must be executed prior to incorporating new materials into wind turbine blade manufacturing.

17 WIND ENERGY↗

NASA NTRS2009

Damage Tolerance of Composite Laminates from an Empirical Perspective

Damage tolerance consists of analysis and experimentation working together. Impact damage is usually of most concern for laminated composites. Once impacted, the residual compression strength is usually of most interest. Other properties may be of more interest than compression (application dependent). A damage tolerance program is application specific (not everyone is building aircraft). The "Building Block Approach" is suggested for damage tolerance. Advantage can be taken of the excellent fatigue resistance of damaged laminates to save time and costs.

Nettles, Alan T.↗

NASA NTRS2006

Damage Tolerance Analysis of a Pressurized Liquid Oxygen Tank

A damage tolerance assessment was conducted of an 8,000 gallon pressurized Liquid Oxygen (LOX) tank. The LOX tank is constructed of a stainless steel pressure vessel enclosed by a thermal-insulating vacuum jacket. The vessel is pressurized to 2,250 psi with gaseous nitrogen resulting in both thermal and pressure stresses on the tank wall. Finite element analyses were performed on the tank to characterize the stresses from operation. Engineering material data was found from both the construction of the tank and the technical literature. An initial damage state was assumed based on records of a nondestructive inspection performed on the tank. The damage tolerance analyses were conducted using the NASGRO computer code. This paper contains the assumptions, and justifications, made for the input parameters to the damage tolerance analyses and the results of the damage tolerance analyses with a discussion on the operational safety of the LOX tank.

Forth, Scott C.↗

NASA NTRS2007

Recent Advances in Durability and Damage Tolerance Methodology at NASA Langley Research Center

Durability and damage tolerance (D&DT) issues are critical to the development of lighter, safer and more efficient aerospace vehicles. Durability is largely an economic life-cycle design consideration whereas damage tolerance directly addresses the structural airworthiness (safety) of the vehicle. Both D&DT methodologies must address the deleterious effects of changes in material properties and the initiation and growth of damage that may occur during the vehicle s service lifetime. The result of unanticipated D&DT response is often manifested in the form of catastrophic and potentially fatal accidents. As such, durability and damage tolerance requirements must be rigorously addressed for commercial transport aircraft and NASA spacecraft systems. This paper presents an overview of the recent and planned future research in durability and damage tolerance analytical and experimental methods for both metallic and composite aerospace structures at NASA Langley Research Center (LaRC).

Ransom, J. B.↗