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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 19 records
All sourcesNASA NTRSDOE OSTI
NASA NTRS1989

Fiber-matrix interface failures

Interface fractures of aluminum-graphite composites under transverse loading are expected to occur within the graphite fibers, but very near the interface. Residual stresses in aluminum, reinforced with the new high modulus pitch-based fibers, are much lower than would be expected based on simple elasticity calculations. The excess stress may be relaxed by shearing internal to the fibers or at the interface rather than by plastic flow of the matrix. The internal shearing also occurs during repeated thermal cycling of these composites; the fibers are repeatedly intruded, then extruded, during repeated temperature excursions.

Rabenberg, Lew↗
NASA NTRS1993

An analysis of fiber-matrix interface failure stresses for a range of ply stress states

A graphite/bismaleimide laminate was prepared without the usual fiber treatment and was tested over a wide range of stress states to measure its ply cracking strength. These tests were conducted using off-axis flexure specimens and produced fiber-matrix interface failure data over a correspondingly wide range of interface stress states. The absence of fiber treatment, weakened the fiber-matrix interfaces and allowed these tests to be conducted at load levels that did not yield the matrix. An elastic micromechanics computer code was used to calculate the fiber-matrix interface stresses at failure. Two different fiber-array models (square and diamond) were used in these calculations to analyze the effects of fiber arrangement as well as stress state on the critical interface stresses at failure. This study showed that both fiber-array models were needed to analyze interface stresses over the range of stress states. A linear equation provided a close fit to these critical stress combinations and, thereby, provided a fiber-matrix interface failure criterion. These results suggest that prediction procedures for laminate ply cracking can be based on micromechanics stress analyses and appropriate fiber-matrix interface failure criteria. However, typical structural laminates may require elastoplastic stress analysis procedures that account for matrix yielding, especially for shear-dominated ply stress states.

Crews, J. H.↗
NASA NTRS1993

Determination of fiber-matrix interface failure parameters from off-axis tests

Critical fiber-matrix (FM) interface strength parameters were determined using a micromechanics-based approach together with failure data from off-axis tension (OAT) tests. The ply stresses at failure for a range of off-axis angles were used as input to a micromechanics analysis that was performed using the personal computer-based MICSTRAN code. FM interface stresses at the failure loads were calculated for both the square and the diamond array models. A simple procedure was developed to determine which array had the more severe FM interface stresses and the location of these critical stresses on the interface. For the cases analyzed, critical FM interface stresses were found to occur with the square array model and were located at a point where adjacent fibers were closest together. The critical FM interface stresses were used together with the Tsai-Wu failure theory to determine a failure criterion for the FM interface. This criterion was then used to predict the onset of ply cracking in angle-ply laminates for a range of laminate angles. Predictions for the onset of ply cracking in angle-ply laminates agreed with the test data trends.

Naik, Rajiv A.↗
NASA NTRS1986

Interfaces and failure mechanisms in Al-SiC composites

Aluminum alloys reinforced with silicon carbide whiskers exhibit significantly higher strength and modulus than the unreinforced alloys. However, the composites also exhibit low ductility and poor fracture toughness for reasons which are not well-understood. In this study, high resolution and conventional TEM techniques are used to analyze interface microstructure and failure mechanisms in P/M 2124 and 6061 aluminum alloys reinforced with silicon carbide whiskers. Interfacial oxides are typical of both composite materials, often distributed in clusters or in a discrete layer 2-5 nm thick along the whisker-matrix interface. Highly deformed regions beneath bulk tensile fracture surfaces reveal possible fracture nucleation centers as well as sites of stress concentration where intense plastic strain has occurred. Observations of such highly deformed regions include (1) void initiation at whisker ends, (2) interface decohesion involving the thin oxide layer, (3) transverse cracks in whiskers, and (4) cracks in large constituent particles. TEM results are presented and discussed in relation to mechanisms of composite failure.

Nutt, S. R.↗
NASA NTRS1979

Influence of interface on composite failure

The influence of the interface on the composite system behavior is investigated by analytical modeling. The stress analysis is based on the two-dimensional finite element procedure in which twelve-node isoparametric elements with cubic shape functions are used. The location of possible failure sites is predicted by the strain energy density (SED) failure theory which assumes failure to coincide with locations of minimum SED while the locations of maximum SED correspond to regions of excessive distortion or yielding. The results of the analysis show that the way in which the modulus of elasticity varies within the interface is as important in modeling as the average interface modulus.

Sih, G. C.↗
NASA NTRS1992

Application of fiber bridging models to fatigue crack growth in unidirectional titanium matrix composites

Several fiber bridging models were reviewed and applied to study the matrix fatigue crack growth behavior in center notched (0)(sub 8) SCS-6/Ti-15-3 and (0)(sub 4) SCS-6/Ti-6Al-4V laminates. Observations revealed that fatigue damage consisted primarily of matrix cracks and fiber matrix interfacial failure in the (0)(sub 8) SCS-6/Ti-15-3 laminates. Fiber-matrix interface failure included fracture of the brittle reaction zone and cracking between the two carbon rich fiber coatings. Intact fibers in the wake of the matrix cracks reduce the stress intensity factor range. Thus, an applied stress intensity factor range is inappropriate to characterize matrix crack growth behavior. Fiber bridging models were used to determine the matrix stress intensity factor range in titanium metal matrix composites. In these models, the fibers in the wake of the crack are idealized as a closure pressure. An unknown constant frictional shear stress is assumed to act along the debond or slip length of the bridging fibers. The frictional shear stress was used as a curve fitting parameter to available data (crack growth data, crack opening displacement data, and debond length data). Large variations in the frictional shear stress required to fit the experimental data indicate that the fiber bridging models in their present form lack predictive capabilities. However, these models provide an efficient and relatively simple engineering method for conducting parametric studies of the matrix growth behavior based on constituent properties.

Bakuckas, J. G., Jr.↗
NASA NTRS2011

Interfaces - Weak Links, Yet Great Opportunities

Inadequate turbomachine interface design can rapidly degrade system performance, yet provide great opportunity for improvements. Engineered coatings of seals and bearing interfaces are major issues in the operational life of power systems. Coatings, films, and combined use of both metals and ceramics play a major role in maintaining component life. Interface coatings, like lubricants, are sacrificial for the benefit of the component. Bearing and sealing surfaces are routinely protected by tribologically paired coatings such as silicon diamond like coatings (SiDLC) in combination with an oil lubricated wave bearing that prolongs bearing operational life. Likewise, of several methods used or researched for detecting interface failures, dopants within coatings show failures in functionally graded ceramic coatings. The Bozzolo-Ferrante-Smith (BFS) materials models and quantum mechanical tools, employed in interface design, are discussed.

Hendricks, Robert C.↗
NASA NTRS1992

Measurement of multiaxial ply strength by an off-axis flexure test

An off-axis flexure (OAF) test was performed to measure ply strength under multiaxial stress states. This test involves unidirectional off-axis specimens loaded in bending, using an apparatus that allows these anisotropic specimens to twist as well as flex without the complications of a resisting torque. A 3D finite element stress analysis verified that simple beam theory could be used to compute the specimen bending stresses at failure. Unidirectional graphite/epoxy specimens with fiber angles ranging from 90 deg to 15 deg have combined normal and shear stresses on their failure planes that are typical of 45 deg plies in structural laminates. Tests for a range of stress states with AS4/3501-6 specimens showed that both normal and shear stresses on the failure plane influenced cracking resistance. This OAF test may prove to be useful for generating data needed to predict ply cracking in composite structures and may also provide an approach for studying fiber-matrix interface failures under stress states typical of structures.

Crews, John H., Jr.↗
NASA NTRS1992

Advanced composites structural concepts and materials technologies for primary aircraft structures: Structural response and failure analysis

Non-linear analysis methods were adapted and incorporated in a finite element based DIAL code. These methods are necessary to evaluate the global response of a stiffened structure under combined in-plane and out-of-plane loading. These methods include the Arc Length method and target point analysis procedure. A new interface material model was implemented that can model elastic-plastic behavior of the bond adhesive. Direct application of this method is in skin/stiffener interface failure assessment. Addition of the AML (angle minus longitudinal or load) failure procedure and Hasin's failure criteria provides added capability in the failure predictions. Interactive Stiffened Panel Analysis modules were developed as interactive pre-and post-processors. Each module provides the means of performing self-initiated finite elements based analysis of primary structures such as a flat or curved stiffened panel; a corrugated flat sandwich panel; and a curved geodesic fuselage panel. This module brings finite element analysis into the design of composite structures without the requirement for the user to know much about the techniques and procedures needed to actually perform a finite element analysis from scratch. An interactive finite element code was developed to predict bolted joint strength considering material and geometrical non-linearity. The developed method conducts an ultimate strength failure analysis using a set of material degradation models.

Dorris, William J.↗
NASA NTRS1990

Characterization of unnotched SCS-6/Ti-15-3 metal matrix composites at 650 C

Ti-15-3 reinforced with SCS-6 silicon carbide fibers, in five different layups, was tested at 650 C to determine monotonic and fatigue strengths, basic mechanical properties, and damage initiation and progression. The elevated temperature results were compared to those obtained at room temperature. Analytical predictions were made of the monotonic stress-strain response as well as cyclic stress-strain hysteresis. The fiber reinforcement was found to significantly increase the static and fatigue strengths of the laminates over that of the matrix material at elevated temperature while the increase was insignificant at room temperature. Initial damage, in either the fibers or the matrix, was partitioned as a function of the life and applied strain range in the constituents. High strains and short lives resulted in multiple fiber failure with no signs of matrix fatigue cracking. Low strains and long lives resulted in extensive matrix cracking and no fiber breaks away from the fracture surface. At 650 C the matrix was too weak to cause fiber-matrix interface failure prior to matrix yielding. Laminate fatigue lives were hypothesized to be a function of the 0 deg fiber stress. More scatter was found in the 0 deg fiber stress vs. high temperature fatigue life data than for the room temperature data. An initial unloading modulus that was greater than the initial loading modulus was observed in the elevated temperature fatigue tests.

Pollock, W. D.↗
NASA NTRS1992

Characterization of unnotched SCS-6/Ti-15-3 metal matrix composites at 650 C

Ti-15-3 reinforced with SCS-6 silicon carbide fibers, in five different layups, was tested at 650 C to determine monotonic and fatigue strengths, basic mechanical properties, and damage initiation and progression. The elevated temperature results were compared to those obtained at room temperature. Analytical predictions were made of the monotonic stress-strain response as well as cyclic stress-strain hysteresis. The fiber reinforcement was found to significantly increase the static and fatigue strengths of the laminates over that of the matrix material at elevated temperature while the increase was insignificant at room temperature. Initial damage, in either the fibers or the matrix, was partitioned as a function of the life and applied strain range in the constituents. High strains and short lives resulted in multiple fiber failure with no signs of matrix fatigue cracking. Low strains and long lives resulted in extensive matrix cracking and no fiber breaks away from the fracture surface. At 650 C the matrix was too weak to cause fiber-matrix interface failure prior to matrix yielding. Laminate fatigue lives were hypothesized to be a function of the 0 deg fiber stress. More scatter was found in the 0 deg fiber stress vs. high temperature fatigue life data than for the room temperature data. An initial unloading modulus that was greater than the initial loading modulus was observed in the elevated temperature fatigue tests.

Pollock, William D.↗
NASA NTRS1988

Damage initiation and growth in fiber-reinforced MMCs

On the basis of the simplifying assumption of equivalent constituent strain rates in the absence of damage, a strain-based failure criterion can be applied to the phenomena of damage-initiation and growth in fiber-reinforced MMCs to ascertain when and where the initial damage will occur. The failure modes fall into four categories, depending on the relative fatigue behavior of the reinforcing fibers and their matrix. Attention is given to experimental results illustrating current understanding of fiber-dominated damage, self-similar fatigue damage growth, and fiber/matrix interface failures, for such MMCs as B/Al alloy, SiC/Al alloy, and SiC/Ti-15-3 alloy.

Saff, C. R.↗
NASA NTRS1973

Basic failure mechanisms in advanced composites

The fundamental failure mechanisms which result from the interaction of thermal cycling and mechanical loading of carbon-epoxy composites were studied. This work was confined to epoxy resin uniderictionally reinforced with HTS carbon fibers, and consists of first identifying local fiber, matrix and interface failure mechanisms using the model composite specimen containing a small number of fibers so that optical techniques can be used for characterization. After the local fracture process has been established for both mechanical loading and thermal cycling, engineering composite properties and gross fracture modes are then examined to determine how the local events contribute to real composite performance. Flexural strength in high fiber content specimens shows an increase in strength with increased thermal cycling. Similar behavior is noted for 25 v/o material up to 200 cycles; however, there is a drastic reduction after 200 cycles indicating a major loss of integrity probably through the accumulation of local cleavage cracks in the tensile region.

Mazzio, V. F.↗
NASA NTRS1989

Metal matrix composites: Testing, analysis, and failure modes; Proceedings of the Symposium, Sparks, NV, Apr. 25, 26, 1988

The present conference discusses the tension and compression testing of MMCs, the measurement of advanced composites' thermal expansion, plasticity theory for fiber-reinforced composites, a deformation analysis of boron/aluminum specimens by moire interferometry, strength prediction methods for MMCs, and the analysis of notched MMCs under tensile loading. Also discussed are techniques for the mechanical and thermal testing of Ti3Al/SCS-6 MMCs, damage initiation and growth in fiber-reinforced MMCs, the shear testing of MMCs, the crack growth and fracture of continuous fiber-reinforced MMCs in view of analytical and experimental results, and MMC fiber-matrix interface failures.

Johnson, W. S.↗
NASA NTRS1975

High reliability bond program using small diameter aluminum wire

The program was undertaken to characterize the performance of small diameter aluminum wire ultrasonically bonded to conductors commonly encountered in hybrid assemblies, and to recommend guidelines for improving this performance. Wire, 25.4, 38.1 and 50.8 um (1, 1.5 and 2 mil), was used with bonding metallization consisting of thick film gold, thin film gold and aluminum as well as conventional aluminum pads on semiconductor chips. The chief tool for evaluating the performance was the double bond pull test in conjunction with a 72 hour - 150 C heat soak and -65 C to +150 C thermal cycling. In practice the thermal cycling was found to have relatively little effect compared to the heat soak. Pull strength will decrease after heat soak as a result of annealing of the aluminum wire; when bonded to thick film gold, the pull strength decreased by about 50% (weakening of the bond interface was the major cause of the reduction). Bonds to thin film gold lost about 30 - 40% of their initial pull strenth; weakening of the wire itself at the bond heel was the predominant cause. Bonds to aluminum substrate metallization lost only about 22%. Bonds between thick and thin film gold substrate metallization and semiconductor chips substantiated the previous conclusions but also showed that in about 20 to 25% of the cases, bond interface failure occurred at the semiconductor chip.

Macha, M.↗
NASA NTRS1979

Effects of isothermal and cyclic exposures on interface structure and mechanical properties of FPalpha-Al2O3/aluminum composites

The microstructural and interface stability of FPalpha-Al203/Al-Li composites are investigated as a function of isothermal exposure at 500 C or thermal cycling between 140 and 500 C with hold time at Tmax. Interfacial morphology, growth kinetics, crystal structure, and composition of interfacial reaction products are characterized. Strength is monitored in the transverse orientation, and fracture mechanics is analyzed in terms of interface reaction products. The interfacial reaction product in FP/Al is Li2O.5Al2O3. Significant fiber-matrix reaction occurs during fabrication. The number of thermal cycles rather than total time at Tmax is the determining factor in strength degradation, thermal cycling giving rise to voids at the fiber-matrix interface. Extensive interface failures occur at composite fracture stresses below about 128 MPa; above this stress level failure is attributed to ductile matrix fracture.

Kim, W. M.↗
NASA NTRS1989

Effects of aging condition on the fracture toughness of 2XXX and 7XXX series aluminum alloy composites

Results are presented on the effects of matrix aging condition (i.e., matrix temper) on the fracture toughness of 2XXX and 7XXX Al matrix alloys reinforced with SiC particulates, and the results are compared with the mechanical behavior. Fracture toughness testing was conducted on fatigue precracked bend specimens, and fracture surfaces were examined using SEM. Results revealed dramatic differences in the effect of matrix microstructure on the fracture properties of the two composite series. In the 7XXX material, the toughness values decreased from the underaged (UA) condition to the overaged (OA) condition by approximately 40 percent, while in the 2XXX series composite, the effect of matrix microstructure was marginal. In the 7XXX series composites, a transition in fracture mode from particle cracking (in UA) to matrix and linear-interface failure (in OA) was observed, while the 2XXX series composite failed predominantly by particle cracking.

Manoharan, M.↗