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NASA NTRS2013

Simulation Based Investigation of Hidden Delamination Damage Detection in CFRP Composites

Guided wave (GW) based damage detection methods have shown promise in structural health monitoring (SHM) and hybrid SHM-nondestructive evaluation (NDE) techniques. Much previous GW work in the aerospace field has been primarily focused on metallic materials, with a growing focus on composite materials. The work presented in this paper demonstrates how realistic three-dimensional (3D) GW simulations can aid in the development of GW based damage characterization techniques for aerospace composites. 3D elastodynamic finite integration technique is implemented to model GW interaction with realistic delamination damage. A local wavenumber technique is applied to simulation data in order to investigate the detectability of hidden delamination damage to enable accurate characterization of damage extent.

Leckey, Cara A. C.↗

NASA NTRS1994

Modeling of delamination damage evolution in laminated composites subjected to low velocity impact

This study examines the delamination evolution, under quasi-static conditions, of laminated polymeric composites with mechanically nonlinear resin rich interfaces. The constitutive behavior of the interface is represented by two models developed by Needleman and Tvegaard. These models assumed that the interfacial tractions, a function of only the interfacial displacement, will behave similarly to the interatomic forces generated during the interatomic seperation. The interface material's parameters control the load at which the delamination growth initiates and the final delamination size. A wide range of damage accumulation responses have been obtained by varying the model parameters. These results show that Tvergaard's model has been found to be better suited of the two models in predicting damage evolution for the configurations examined.

Lo, David C.↗

NASA NTRS1993

Delamination, durability, and damage tolerance of laminated composite materials

Durability and damage tolerance may have different connotations to people from different industries and with different backgrounds. Damage tolerance always refers to a safety of flight issue where the structure must be able to sustain design limit loads in the presence of damage and return to base safely. Durability, on the other hand, is an economic issue where the structure must be able to survive a certain life under load before the initiation of observable damage. Delamination is typically the observable damage mechanism that is of concern for durability, and the growth and accumulation of delaminations through the laminate thickness is often the sequence of events that leads to failure and the loss of structural integrity.

Obrien, T. Kevin↗

NASA NTRS2007

The Effect of Delamination on Damage Path and Failure Load Prediction for Notched Composite Laminates

The influence of delamination on the progressing damage path and initial failure load in composite laminates is investigated. Results are presented from a numerical and an experimental study of center-notched tensile-loaded coupons. The numerical study includes two approaches. The first approach considers only intralaminar (fiber breakage and matrix cracking) damage modes in calculating the progression of the damage path. In the second approach, the model is extended to consider the effect of interlaminar (delamination) damage modes in addition to the intralaminar damage modes. The intralaminar damage is modeled using progressive damage analysis (PDA) methodology implemented with the VUMAT subroutine in the ABAQUS finite element code. The interlaminar damage mode has been simulated using cohesive elements in ABAQUS. In the experimental study, 2-3 specimens each of two different stacking sequences of center-notched laminates are tensile loaded. The numerical results from the two different modeling approaches are compared with each other and the experimentally observed results for both laminate types. The comparisons reveal that the second modeling approach, where the delamination damage mode is included together with the intralaminar damage modes, better simulates the experimentally observed damage modes and damage paths, which were characterized by splitting failures perpendicular to the notch tips in one or more layers. Additionally, the inclusion of the delamination mode resulted in a better prediction of the loads at which the failure took place, which were higher than those predicted by the first modeling approach which did not include delaminations.

Satyanarayana, Arunkumar↗

NASA NTRS2017

Thermal Inspection of a Composite Fuselage Section Using a Fixed Eigenvector Principal Component Analysis Method

A composite fuselage aircraft forward section was inspected with flash thermography. The fuselage section is 24 feet long and approximately 8 feet in diameter. The structure is primarily configured with a composite sandwich structure of carbon fiber face sheets with a Nomex(Trademark) honeycomb core. The outer surface area was inspected. The thermal data consisted of 477 data sets totaling in size of over 227 Gigabytes. Principal component analysis (PCA) was used to process the data sets for substructure and defect detection. A fixed eigenvector approach using a global covariance matrix was used and compared to a varying eigenvector approach. The fixed eigenvector approach was demonstrated to be a practical analysis method for the detection and interpretation of various defects such as paint thickness variation, possible water intrusion damage, and delamination damage. In addition, inspection considerations are discussed including coordinate system layout, manipulation of the fuselage section, and the manual scanning technique used for full coverage.

Zalameda, Joseph N.↗

NASA NTRS2015

Impact Induced Delamination Detection and Quantification With Guided Wavefield Analysis

This paper studies impact induced delamination detection and quantification by using guided wavefield data and spatial wavenumber imaging. The complex geometry impact-like delamination is created through a quasi-static indentation on a CFRP plate. To detect and quantify the impact delamination in the CFRP plate, PZT-SLDV sensing and spatial wavenumber imaging are performed. In the PZT-SLDV sensing, the guided waves are generated from the PZT, and the high spatial resolution guided wavefields are measured by the SLDV. The guided wavefield data acquired from the PZT-SLDV sensing represent guided wave propagation in the composite laminate and include guided wave interaction with the delamination damage. The measured guided wavefields are analyzed through the spatial wavenumber imaging method, which generates an image containing the dominant local wavenumber at each spatial location. The spatial wavenumber imaging result for the simple single layer Teflon insert delamination provided quantitative information on delamination damage size and location. The location of delamination damage is indicated by the area with larger wavenumbers in the spatial wavenumber image. The impact-like delamination results only partially agreed with the damage size and shape. The results also demonstrated the dependence on excitation frequency. Future work will further investigate the accuracy of the wavenumber imaging method for real composite damage and the dependence on frequency of excitation.

Tian, Zhenhua↗

NASA NTRS2014

Guided Wave Propagation Study on Laminated Composites by Frequency-Wavenumber Technique

Toward the goal of delamination detection and quantification in laminated composites, this paper examines guided wave propagation and wave interaction with delamination damage in laminated carbon fiber reinforced polymer (CFRP) composites using frequency-wavenumber (f-kappa) analysis. Three-dimensional elastodynamic finite integration technique (EFIT) is used to acquire simulated time-space wavefields for a CFRP composite. The time-space wavefields show trapped waves in the delamination region. To unveil the wave propagation physics, the time-space wavefields are further analyzed by using two-dimensional (2D) Fourier transforms (FT). In the analysis results, new f-k components are observed when the incident guided waves interact with the delamination damage. These new f-kappa components in the simulations are experimentally verified through data obtained from scanning laser Doppler vibrometer (SLDV) tests. By filtering the new f-kappa components, delamination damage is detected and quantified.

Tian, Zhenhua↗

NASA NTRS1985

Role of delamination and damage development on the strength of thick notched laminates

A large, comprehensive program is being conducted at Virginia Tech to study the effect of laminate thickness on the fracture strength of notched laminated composites. Part of this program has been the study of the chracteristics and development of subcritical crack-tip damage prior to failure. The study has concentrated on the center-cracked tension specimen geometry. Subcritical crack-tip damage has been studied using enhanced X-ray radiography and the laminate deply technique. This paper examines he role that delamination plays in affecting the fracture of (0/+ or - 45/90)ns and (0/+ or - 45)ns laminates at various values of n. The study has found that delaminations do occur in thin laminates (n = 1) and affect the strength of the laminate. However, in thick laminates such as (0/+ or 45)90ns, and (0/+ or - 45)20s, there is sufficient constraint to prevent delaminations from occurring in the interior region of he specimen. The final fracture surface is uniform in the interior and self-similar (collinear with the original starter notch), with 'shear-lip' type damage in the form of delaminations and matrix cracking in the first several plies at the surface. These differences in the type of fracture of the thin and thick laminates greatly affect the fracture strength.

Harris, C. E.↗

NASA NTRS1994

Computational simulation of composite structures with and without damage

A methodology is described which uses finite element analysis of various laminates to computationally simulate the effects of delamination damage initiation and growth on the structural behavior of laminated composite structures. The delamination area is expanded according to a set pattern. As the delamination area increases, how the structural response of the laminate changes with respect to buckling and strain energy release rate are investigated. Rules are presented for laminates of different configurations, materials and thickness. These results demonstrate that computational simulation methods can provide alternate methods to investigate the complex delamination damage mechanisms found in composite structures.

Wilt, Thomas F.↗

NASA NTRS2016

Composite Characterization Using Ultrasonic Wavefield Techniques

The large-scale use of composite components in aerospace applications is expected to continue due to the benefits of composite materials, such as reduced weight, increased strength, and tailorability. NASA's Advanced Composites Project (ACP) has the goals of reducing the timeline for certification of composite materials and enabling the expanded use of advanced composite materials. A key technical challenge area for accomplishing these goals is the need for nondestructive evaluation and materials characterization techniques that are optimized for rapid inspection and detailed defect/damage characterization in composite materials. This presentation will discuss ongoing research investigating the use of ultrasonic wavefield techniques for the characterization of defects such as fiber waviness and delamination damage. Ongoing work includes the development of realistic ultrasonic simulation tools for use in predicting the inspectability of composites and optimizing inspection methodologies. Recent studies on detecting/characterizing delamination damage and fiber waviness via wavefield methods will be described.

Leckey, Cara A. C.↗

NASA NTRS1992

The use of impact force as a scale parameter for the impact response of composite laminates

The building block approach is currently used to design composite structures. With this approach, the data from coupon tests is scaled up to determine the design of a structure. Current standard impact tests and methods of relating test data to other structures are not generally understood and are often used improperly. A methodology is outlined for using impact force as a scale parameter for delamination damage for impacts of simple plates. Dynamic analyses were used to define ranges of plate parameters and impact parameters where quasi-static analyses are valid. These ranges include most low velocity impacts where the mass of the impacter is large and the size of the specimen is small. For large mass impacts of moderately thick (0.35 to 0.70 cm) laminates, the maximum extent of delamination damage increased with increasing impact force and decreasing specimen thickness. For large mass impact tests at a given kinetic energy, impact force and hence delamination size depends on specimen size, specimen thickness, boundary conditions, and indenter size and shape. If damage is reported in terms of impact force instead of kinetic energy, large mass test results can be applied directly to other plates of the same size.

Jackson, Wade C.↗

NASA NTRS1992

The use of impact force as a scale parameter for the impact response of composite laminates

The building block approach is currently used to design composite structures. With this approach, the data from coupon tests are scaled up to determine the design of a structure. Current standard impact tests and methods of relating test data to other structures are not generally understood and are often used improperly. A methodology is outlined for using impact force as a scale parameter for delamination damage for impacts of simple plates. Dynamic analyses were used to define ranges of plate parameters and impact parameters where quasi-static analyses are valid. These ranges include most low-velocity impacts where the mass of the impacter is large, and the size of the specimen is small. For large-mass impacts of moderately thick (0.35-0.70 cm) laminates, the maximum extent of delamination damage increased with increasing impact force and decreasing specimen thickness. For large-mass impact tests at a given kinetic energy, impact force and hence delamination size depends on specimen size, specimen thickness, boundary conditions, and indenter size and shape. If damage is reported in terms of impact force instead of kinetic energy, large-mass test results can be applied directly to other plates of the same thickness.

Jackson, Wade C.↗

NASA NTRS2013

Damage Detection in Composite Structures with Wavenumber Array Data Processing

Guided ultrasonic waves (GUW) have the potential to be an efficient and cost-effective method for rapid damage detection and quantification of large structures. Attractive features include sensitivity to a variety of damage types and the capability of traveling relatively long distances. They have proven to be an efficient approach for crack detection and localization in isotropic materials. However, techniques must be pushed beyond isotropic materials in order to be valid for composite aircraft components. This paper presents our study on GUW propagation and interaction with delamination damage in composite structures using wavenumber array data processing, together with advanced wave propagation simulations. Parallel elastodynamic finite integration technique (EFIT) is used for the example simulations. Multi-dimensional Fourier transform is used to convert time-space wavefield data into frequency-wavenumber domain. Wave propagation in the wavenumber-frequency domain shows clear distinction among the guided wave modes that are present. This allows for extracting a guided wave mode through filtering and reconstruction techniques. Presence of delamination causes spectral change accordingly. Results from 3D CFRP guided wave simulations with delamination damage in flat-plate specimens are used for wave interaction with structural defect study.

Tian, Zhenhua↗

NASA NTRSDate not supplied

Delamination Depth Imaging for Quasi-Static and Fatigue Load Testing Using Passive Thermography

Passive thermography is used to monitor small increases in temperature resulting from delamination damage formation in composite hat-stiffened panels during both quasi-static and fatigue loading. It has been observed that rapid damage formation produces heating. This is composed of two heat generation components. The first component is an instantaneous response due to an irreversible thermoelastic strain release. The second component is mechanical heating, at the interface of failure, due to fracture damage. This produces a transient rise in temperature as the heat diffuses to the surface. The first component defines the thermal start time for the transient response. A one-dimensional thermal model is fitted to the data pixel by pixel, to produce imagery of the damage depth. The results are compared to ultrasonic and X-ray CT data.

Passive thermography↗

NASA NTRS1992

Compression of thick laminated composite beams with initial impact-like damage

While the study of compression after impact of laminated composites has been under consideration for many years, the complexity of the damage initiated by low velocity impact has not lent itself to simple predictive models for compression strength. The damage modes due to non-penetrating, low velocity impact by large diameter objects can be simulated using quasi-static three-point bending. The resulting damage modes are less coupled and more easily characterized than actual impact damage modes. This study includes the compression testing of specimens with well documented initial damage states obtained from three-point bend testing. Compression strengths and failure modes were obtained for quasi-isotropic stacking sequences from 0.24 to 1.1 inches thick with both grouped and interspersed ply stacking. Initial damage prior to compression testing was divided into four classifications based on the type, extent, and location of the damage. These classifications are multiple through-thickness delaminations, isolated delamination, damage near the surface, and matrix cracks. Specimens from each classification were compared to specimens tested without initial damage in order to determine the effects of the initial damage on the final compression strength and failure modes. A finite element analysis was used to aid in the understanding and explanation of the experimental results.

Breivik, N. L.↗

NASA NTRS1992

Acoustic emission monitoring of low velocity impact damage in graphite/epoxy laminates during tensile loading

An acoustic emission (AE) system was set up in a linear location data acquisition mode to monitor the tensile loading of eight-ply quasi-isotropic graphite/epoxy specimens containing low velocity impact damage. The impact damage was induced using an instrumented drop weight tower. During impact, specimens were supported by either an aluminum plate or a membrane configuration. Cross-sectional examinations revealed that the aluminum plate configuration resulted in primarily matrix cracking and back surface fiber failure. The membrane support resulted in only matrix cracking and delamination damage. Penetrant enhanced radiography and immersion ultrasonics were used in order to assess the amount of impact damage in each tensile specimen. During tensile loading, AE reliably detected and located the damage sites which included fiber failure. All specimens with areas of fiber breakage ultimately failed at the impact site. AE did not reliably locate damage which consisted of only delaminations and matrix cracking. Specimens with this type of damage did not ultimately fail at the impact site. In summary, AE demonstrated the ability to increase the reliability of structural proof tests; however, the successful use of this technique requires extensive baseline testing.

Parker, Bradford H.↗

NASA NTRS2008

Probability of Detection Study on Impact Damage to Honeycomb Composite Structure using Thermographic Inspection

A probability of detection study was performed for the detection of impact damage using flash heating infrared thermography on a full scale honeycomb composite structure. The honeycomb structure was an intertank structure from a previous NASA technology demonstration program. The intertank was fabricated from IM7/8552 carbon fiber/epoxy facesheets and aluminum honeycomb core. The intertank was impacted in multiple locations with a range of impact energies utilizing a spherical indenter. In a single blind study, the intertank was inspected with thermography before and after impact damage was incurred. Following thermographic inspection several impact sites were sectioned from the intertank and cross-sectioned for microscopic comparisons of NDE detection and actual damage incurred. The study concluded that thermographic inspection was a good method of detecting delamination damage incurred by impact. The 90/95 confidence level on the probability of detection was close to the impact energy that delaminations were first observed through cross-sectional analysis.

Hodge, Andrew J.↗

NASA NTRS2000

Impact Delamination and Fracture in Aluminum/Acrylic Sandwich Plates

Impact-induced delamination and fracture in 6061-T6 aluminum/cast acrylic sandwich plates adhered by epoxy were generated in an instrumented drop-weight impact machine. Although only a small dent was produced on the aluminum side when a hemispherical penetrator tup was dropped onto it from a couple of inches, a large ring of delamination at the interface was observed. The delamination damage was often accompanied by severe shattering in the acrylic substratum. Damage patterns in the acrylic layer include radial and ring cracks and, together with delamination at the interface, may cause peeling-off of acrylic material from the sandwich plate. Theory of stress-wave propagation can be used to explain these damage patterns. The impact tests were conducted at various temperatures. The results also show clearly that temperature effect is very important in impact damage. For pure cast acrylic nil-ductile transition (NDT) occurs between 185-195 F. Excessive impact energy was dissipated into fracture energy when tested at temperature below this range or through plastic deformation when tested at temperature above the NDT temperature. Results from this study will be used as baseline data for studying fiber-metal laminates, such as GLARE and ARALL for advanced aeronautical and astronautical applications.

Liaw, Benjamin↗