Whitcomb, John D. | Engineering Papers

NASA NTRS2017

Experimental Characterization of a Composite Morphing Radiator Prototype in a Relevant Thermal Environment

For future long duration space missions, crewed vehicles will require advanced thermal control systems to maintain a desired internal environment temperature in spite of a large range of internal and external heat loads. Current radiators are only able to achieve turndown ratios (i.e. the ratio between the radiator's maximum and minimum heat rejection rates) of approximately 3:1. Upcoming missions will require radiators capable of 12:1 turndown ratios. A radiator with the ability to alter shape could significantly increase turndown capacity. Shape memory alloys (SMAs) offer promising qualities for this endeavor, namely their temperature-dependent phase change and capacity for work. In 2015, the first ever morphing radiator prototype was constructed in which SMA actuators passively altered the radiator shape in response to a thermal load. This work describes a follow-on endeavor to demonstrate a similar concept using highly thermally conductive composite materials. Numerous versions of this new concept were tested in a thermal vacuum environment and successfully demonstrated morphing behavior and variable heat rejection, achieving a turndown ratio of 4.84:1. A summary of these thermal experiments and their results are provided herein.

Bertagne, Christopher L.↗

NASA NTRS2017

Design and Fabrication of a Composite Morphing Radiator Panel Using High Conductivity Fibers

Upcoming crewed space missions will involve large internal and external heat loads and require advanced thermal control systems to maintain a desired internal environment temperature. Radiators with at least 12:1 turndown ratios (the ratio between the maximum and minimum heat rejection rates) will be needed. However, current technologies are only able to achieve turndown ratios of approximately 3:1. A morphing radiator capable of altering shape could significantly increase turndown capabilities. Shape memory alloys offer qualities that may be well suited for this endeavor; their temperature-dependent phase changes could offer radiators the ability to passively control heat rejection. In 2015, a morphing radiator prototype was constructed and tested in a thermal vacuum environment, where it successfully demonstrated the morphing behavior and variable heat rejection. Newer composite prototypes have since been designed and manufactured using two distinct types of SMA materials. These models underwent temperature cycling tests in a thermal vacuum chamber and a series of fatigue tests to characterize the lifespan of these designs. The focus of this paper is to present the design approach and testing of the morphing composite facesheet. The discussion includes: an overall description of the project background, definition of performance requirements, composite materials selection, use of analytic and numerical design tools, facesheet fabrication, and finally fatigue testing with accompanying results.

Wescott, Matthew T.↗

NASA NTRS1996

Analysis of New Composite Architectures

Efficient and accurate specialty finite elements methods to analyze textile composites were developed and are described. Textile composites present unique challenges to the analyst because of the large, complex 'microstructure'. The geometry of the microstructure is difficult to model and it introduces unusual free surface effects. The size of the microstructure complicates the use of traditional homogenization methods. The methods developed constitute considerable progress in addressing the modeling difficulties. The details of the methods and attended results obtained therefrom, are described in the various chapters included in Part 1 of the report. Specific conclusions and computer codes generated are included in Part 2 of the report.

Whitcomb, John D.↗

NASA NTRS1994

Analysis of new composite architectures

Global/local method in conjunction with a special macro finite element is used to gain computational efficiency in the simulation of textile composites behavior. Results are included to demonstrate the effectiveness of the method. Also, 2D finite elements are used to study boundary effects in plain weave composite specimens subjected to extension, shear, and flexure loads. Effective extension, shear, and flexural moduli were found to be quite sensitive to specimen size. For extension and flexure loads stress distributions were affected by a free surface, but the free surface boundary effect did not appear to propagate very far into the interior. For shear load, the boundary effect appeared to propagate much further into the interior. The report is in the form of two technical articles, the first describes the global/local method while the second describes the use of the 2D finite elements.

Whitcomb, John D.↗

NASA NTRS1992

Open hole and postimpact compressive fatigue of stitched and unstitched carbon-epoxy composites

The performance is studied of a stitched uniweave fabric composite and that of a toughened tape composite. The effects of stitching on compression fatigue life are addressed. Post impact compression fatigue and open hole fatigue tests were run on an AS4/3501-6 uniweave with stitching and a toughened IM7/8551-7 tape without stitching. Stitching was found to increase the thickness and consequently the weight of the composite material. The two materials were compared on an equal carbon content basis as well as on an equal weight basis. The excess thickness in the stitched uniweave composite was responsible for the lower fatigue life, on an equal carbon basis, compared to the toughened resin tape composite. Comparison of fatigue lives on an equal carbon content basis indicated that puncture or crimp type damage from stitching has very little effect on compression failure. Post impact fatigue test showed that although the damage area in the stitched uniweave composite was twice that of the toughened tape composite, the fatigue lives of the stitched composite were significantly longer than those of the toughened composite. Thus, it appears that the increase in thickness from stitching is much more of a penalty than crimped fibers or puncture type damage from stitching.

Portanova, Marc A.↗

NASA NTRS1991

A comparison of experimental observations and numerical predictions for the initiation of fiber microbuckling in notched composite laminates

The results of the present experimental study of fiber microbuckling indicates that free surfaces, ply orientations, and resin-rich regions affect the strain level for the initiation of in-plane fiber microbuckling. Nonlinear matrix constitutive behavior, in conjunction with initial fiber waviness, cause significant reductions of fiber microbuckling initiation strain level; these two factors generate nonlinear global stress-strain responses in the models. The fiber microbuckling initiation strains correlate well with the applied strain associated with asymptotic local shear strains.

Guynn, E. G.↗

NASA NTRS1990

Open hole and post-impact compression fatigue of stitched and unstitched carbon/epoxy composites

The performance is studied of a stitched uniweave fabric composite and that of a toughened tape composite. The effects of stitching on compression fatigue life are addressed. Post impact compression fatigue and open hole fatigue tests were run on an AS4/3501-6 uniweave with stitching and a toughened IM7/8551-7 tape without stitching. Stitching was found to increase the thickness and consequently the weight of the composite material. The two materials were compared on an equal carbon content basis as well as on an equal weight basis. The excess thickness in the stitched uniweave composite was responsible for the lower fatigue life, on an equal carbon basis, compared to the toughened resin tape composite. Comparison of fatigue lives on an equal carbon content basis indicated that puncture or crimp type damage from stitching has very little effect on compression failure. Post impact fatigue test showed that although the damage area in the stitched uniweave composite was twice that of the toughened tape composite, the fatigue lives of the stitched composite were significantly longer than those of the toughened composite. Thus, it appears that the increase in thickness from stitching is much more of a penalty than crimped fibers or puncture type damage from stitching.

Portanova, M. A.↗

NASA NTRS1990

Mechanics of instability-related delamination growth

Local buckling of a delaminated group of plies can lead to higher interlaminar stresses and delamination growth. The mechanics of instability-related delamination growth (IRDG) had been described previously for the through-width delamination. This paper describes the mechanics of IRDG for the embedded delamination subjected to either uniaxial or axisymmetric loads. The mechanics of IRDG are used to explain the dramatic differences in strain-energy release rates observed for the through-width, the axisymmetrically loaded embedded delamination, and the uniaxially loaded embedded delamination.

Whitcomb, John D.↗

NASA NTRS1989

Three-dimensional stress analysis of plain weave composites

Techniques were developed and described for performing three-dimensional finite element analysis of plain weave composites. Emphasized here are aspects of the analysis which are different from analysis of traditional laminated composites, such as the mesh generation and representative unit cells. The analysis was used to study several different variations of plain weaves which illustrate the effects of tow waviness on composite moduli, Poisson's ratios, and internal strain distributions. In-plane moduli decreased almost linearly with increasing tow waviness. The tow waviness was shown to cause large normal and shear strain concentrations in composites subjected to uniaxial load. These strain concentrations may lead to earlier damage initiation than occurs in traditional cross-ply laminates.

Whitcomb, John D.↗

NASA NTRS1989

Three-dimensional analysis of a postbuckled embedded delamination

Delamination growth caused by local buckling of a delaminated group of plies was investigated. Delamination growth was assumed to be governed by the strain energy release rates, G(1), G(2) and G(3). The strain energy release rates were calculated using a geometrically nonlinear three-dimensional finite element analysis. The program is described and several checks of the analysis are discussed. Based on a limited parametric study, the following conclusions were reached: (1) the problem is definitely mixed mode (in some cases G(1) is larger than G(2), for other cases the opposite is true); (2) in general, there is a large gradient in the strain energy release rates along the delamination front; (3) the locations of maximum G(1) and G(2) depend on the delamination shape and the applied strain; (4) the mode 3 component was negligible for all cases considered; and (5) the analysis predicted that parts of the delamination would overlap. The results presented did not impose contact constraints to prevent overlapping. Further work is needed to determine the effects of allowing the overlapping.

Whitcomb, John D.↗

NASA NTRS1989

Strain-energy release rate analysis of plates with postbuckled delaminations

The objectives are to present the derivation of the new virtual crack closure technique, evaluate the accuracy of the technique, and finally to present the results of a limited parametric study of laminates with a postbuckled delamination. Although the new virtual crack closure technique is general, only homogeneous, isotropic laminates were analyzed. This was to eliminate the variation of flexural stiffness with orientation, which occurs even for quasi-isotropic laminates. This made it easier to identify the effect of geometrical parameters on G. The new virtual crack closure technique is derived. Then the specimen configurations are described. Next, the stress analyses is discussed. Finally, the virtual crack closure technique is evaluated and then used to calculate the distribution of G along the delamination front of several laminates with a postbuckled delamination.

Whitcomb, John D.↗

NASA NTRS1989

Comparison of full 3-D, thin-film 3-D, and thin-film plate analyses of a postbuckled embedded delamination

Strain-energy release rates are often used to predict when delamination growth will occur in laminates under compression. Because of the inherently high computational cost of performing such analyses, less rigorous analyses such as thin-film plate analysis were used. The assumptions imposed by plate theory restrict the analysis to the calculation of total strain energy, G(sub t). The objective is to determine the accuracy of thin-film plate analysis by comparing the distribution of G(sub t) calculated using fully three dimensional (3D), thin-film 3D, and thin-film plate analyses. Thin-film 3D analysis is the same as thin-film plate analysis, except 3D analysis is used to model the sublaminate. The 3D stress analyses were performed using the finite element program NONLIN3D. The plate analysis results were obtained from published data, which used STAGS. Strain-energy release rates were calculated using variations of the virtual crack closure technique. The results demonstrate that thin-film plate analysis can predict the distribution of G(sub t) quite well, at least for the configurations considered. Also, these results verify the accuracy of the strain-energy release rate procedure for plate analysis.

Whitcomb, John D.↗

NASA NTRS1989

Vector algorithms for geometrically nonlinear 3D finite element analysis

Algorithms for geometrically nonlinear finite element analysis are presented which exploit the vector processing capability of the VPS-32, which is closely related to the CYBER 205. By manipulating vectors (which are long lists of numbers) rather than individual numbers, very high processing speeds are obtained. Long vector lengths are obtained without extensive replication or reordering by storage of intermediate results in strategic patterns at all stages of the computations. Comparisons of execution times with those from programs using either scalar or other vector programming techniques indicate that the algorithms presented are quite efficient.

Whitcomb, John D.↗

NASA NTRS1989

Comparison of full 3-D, thin-film 3-D, and thin-film plate analyses of a postbuckled embedded delamination

Local buckling can cause large interlaminar stresses along the delamination front, which can lead to delamination growth. This paper examines several methods of calculating strain-energy release rates, which are often used to predict delamination growth. The thin-film plate analysis, which was least expensive, calculated the total strain-energy release rate G(T) quite accurately. However, the stress field along the delamination front is highly mixed-mode and has no fixed ratio of G(I) to G(II). Since plate analysis can only calculate G(T), it would not be useful for accurate predictions of delamination growth if mode mix is important.

Whitcomb, John D.↗

NASA NTRS1988

Instability-related delamination growth of embedded and edge delaminations

Compressive loads can cause local buckling in composite laminates that have a near surface delamination. This buckling causes load redistribution and secondary loads, which in turn cause interlaminar stresses and delamination growth. The goal of this research was to enhance the understanding of this instability-related delamination growth in laminates containing either an embedded or an edge delamination.

Whitcomb, John D.↗

NASA NTRS1988

Three-dimensional analysis of a postbuckled embedded delamination

Delamination growth caused by local buckling of a delaminated group of plies was investigated. Delamination growth was assumed to be governed by the strain energy release rates, G(1), G(2) and G(3). The strain energy release rates were calculated using a geometrically nonlinear three-dimensional finite element analysis. The program is described and several checks of the analysis are discussed. Based on a limited parametric study, the following conclusions were reached: (1) the problem is definitely mixed mode (in some cases G(1) is larger than G(2), for other cases the opposite is true); (2) in general, there is a large gradient in the strain energy release rates along the delamination front; (3) the locations of maximum G(1) and G(2) depend on the delamination shape and the applied strain; (4) the mode 3 component was negligible for all cases considered; and (5) the analysis predicted that parts of the delamination would overlap. The results presented did not impose contact constraints to prevent overlapping. Further work is needed to determine the effects of allowing the overlapping.

Whitcomb, John D.↗

NASA NTRS1988

Mechanics of instability-related delimination growth

Local buckling of a delaminated group of plies can lead to higher interlaminar stresses and delamination growth. The mechanics of instability-related delamination growth (IRDG) had been described previously for the through-width delamination. This paper describes the mechanics of IRDG for the embedded delamination subjected to either uniaxial or axisymmetric loads. The mechanics of IRDG are used to explain the dramatic differences in strain-energy release rates observed for the through-width, the axisymmetrically loaded embedded delamination, and the uniaxially loaded embedded delamination.

Whitcomb, John D.↗

NASA NTRS1988

Composite materials: Testing and design

The present conference discusses topics in the analysis of composite structures, composite materials' impact and compression behavior, composite materials characterization methods, composite failure mechanisms, NDE methods for composites, and filament-wound and woven composite materials' fabrication. Attention is given to the automated design of a composite plate for damage tolerance, the effects of adhesive layers on composite laminate impact damage, instability-related delamination growth in thermoset and thermoplastic composites, a simple shear fatigue test for unidirectional E-glass epoxy, the growth of elliptic delaminations in laminates under cyclic transverse shear, and the mechanical behavior of braided composite materials.

Whitcomb, John D.↗