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NASA NTRSDate not supplied

Understanding Variability in Mechanical Behavior of Adhesively Bonded Sandwich Joints due to Stochastic Material Damage

A mesoscale progressive damage analysis was applied to the analysis of recently tested adhesively bonded sandwich panels, in which ten nominally identical tension loaded panels failed in three different failure modes, with peakloads ranging from 13.0 –16.1 kips. A parametric finite element model for progressive damage analysis of an adhesively bonded joint (ABJ) considering matrix and fiber damage, and delamination cracks in unidirectional and fabric composite sections of the joint, as well as core crushing, and adhesive fracture was developed. The model was developed using Abaqus/Explicit and utilized continuum damage mechanics material models for intralaminar damage in the facesheet and doubler plies, cohesive elements for delamination and adhesive debonding, and discretized cells considering plasticity to model crushing of the aluminum honeycomb core. Analysis predictions obtained with a pristine model agreed well with the average experimental peak load, strain in the joint, and post-test damage states. Then, various methods to incorporate stochastic material variability into ABJ model were evaluated. These methods included simulation of pre-existing matrix damage, pre-existing adhesive porosity, and uniform modification of adhesive properties. These material and manufacturing defects changed the damage mode predictions in some cases. The analysis of stochastic strength due to the considered defects revealed unintuitive damage mode interaction in the ABJ, explaining some structure-property relationships observed experimentally.

Richard Larson↗
NASA NTRS1995

Fatigue Crack Growth and Crack Bridging in SCS-6/Ti-24-11

Interfacial damage induced by relative fiber/matrix sliding was found to occur in the bridged zone of unidirectional SCS-6/Ti-24Al-11Nb intermetallic matrix composite specimens subjected to fatigue crack growth conditions. The degree of interfacial damage was not uniform along the bridged crack wake. Higher damage zones were observed near the machined notch in comparison to the crack tip. The interfacial friction shear strength tau(sub f) measured in the crack wake using pushout testing revealed lower values than the as-received interface. Interfacial wear also reduced the strength of the bridging fibers. The reduction in fiber strength is thought to be a function of the magnitude of relative fiber/matrix displacements ind the degree of interfacial damage. Furthermore, two different fiber bridging models were used to predict the influence of bridging on the fatigue crack driving force. The shear lag model required a variable tau(sub f) in the crack wake (reflecting the degradation of the interface) before its predictions agreed with trends exhibited by the experimental data. The fiber pressure model did an excellent job in predicting both the FCG data and the DeltaCOD in the bridged zone even though it does not require a knowledge of tau(sub f).

Ghosn, Louis J.↗
NASA NTRS1994

Development of the NASA/FLAGRO computer program for analysis of airframe structures

The NASA/FLAGRO (NASGRO) computer program was developed for fracture control analysis of space hardware and is currently the standard computer code in NASA, the U.S. Air Force, and the European Agency (ESA) for this purpose. The significant attributes of the NASGRO program are the numerous crack case solutions, the large materials file, the improved growth rate equation based on crack closure theory, and the user-friendly promptive input features. In support of the National Aging Aircraft Research Program (NAARP); NASGRO is being further developed to provide advanced state-of-the-art capability for damage tolerance and crack growth analysis of aircraft structural problems, including mechanical systems and engines. The project currently involves a cooperative development effort by NASA, FAA, and ESA. The primary tasks underway are the incorporation of advanced methodology for crack growth rate retardation resulting from spectrum loading and improved analysis for determining crack instability. Also, the current weight function solutions in NASGRO or nonlinear stress gradient problems are being extended to more crack cases, and the 2-d boundary integral routine for stress analysis and stress-intensity factor solutions is being extended to 3-d problems. Lastly, effort is underway to enhance the program to operate on personal computers and work stations in a Windows environment. Because of the increasing and already wide usage of NASGRO, the code offers an excellent mechanism for technology transfer for new fatigue and fracture mechanics capabilities developed within NAARP.

Forman, R. G.↗
NASA NTRS2017

Estimating Consequences of MMOD Penetrations on ISS

The threat from micrometeoroid and orbital debris (MMOD) impacts on space vehicles is often quantified in terms of the probability of no penetration (PNP). However, for large spacecraft, especially those with multiple compartments, a penetration may have a number of possible outcomes. The extent of the damage (diameter of hole, crack length or penetration depth), the location of the damage relative to critical equipment or crew, crew response, and even the time of day of the penetration are among the many factors that can affect the outcome. For the International Space Station (ISS), a Monte-Carlo style software code called Manned Spacecraft Crew Survivability (MSCSurv) is used to predict the probability of several outcomes of an MMOD penetration-broadly classified as loss of crew (LOC), crew evacuation (Evac), loss of escape vehicle (LEV), and nominal end of mission (NEOM). By generating large numbers of MMOD impacts (typically in the billions) and tracking the consequences, MSCSurv allows for the inclusion of a large number of parameters and models as well as enabling the consideration of uncertainties in the models and parameters. MSCSurv builds upon the results from NASA's Bumper software (which provides the probability of penetration and critical input data to MSCSurv) to allow analysts to estimate the probability of LOC, Evac, LEV, and NEOM. This paper briefly describes the overall methodology used by NASA to quantify LOC, Evac, LEV, and NEOM with particular emphasis on describing in broad terms how MSCSurv works and its capabilities and most significant models.

Evans, H.↗
NASA NTRS2018

Predicting the Consequences of MMOD Penetrations on the International Space Station

The threat from micrometeoroid and orbital debris (MMOD) impacts on space vehicles is often quantified in terms of the probability of no penetration (PNP). However, for large spacecraft, especially those with multiple compartments, a penetration may have a number of possible outcomes. The extent of the damage (diameter of hole, crack length or penetration depth), the location of the damage relative to critical equipment or crew, crew response, and even the time of day of the penetration are among the many factors that can affect the outcome. For the International Space Station (ISS), a Monte-Carlo style software code called Manned Spacecraft Crew Survivability (MSCSurv) is used to predict the probability of several outcomes of an MMOD penetration-broadly classified as loss of crew (LOC), crew evacuation (Evac), loss of escape vehicle (LEV), and nominal end of mission (NEOM). By generating large numbers of MMOD impacts (typically in the billions) and tracking the consequences, MSCSurv allows for the inclusion of a large number of parameters and models as well as enabling the consideration of uncertainties in the models and parameters. MSCSurv builds upon the results from NASA's Bumper software (which provides the probability of penetration and critical input data to MSCSurv) to allow analysts to estimate the probability of LOC, Evac, LEV, and NEOM. This paper briefly describes the overall methodology used by NASA to quantify LOC, Evac, LEV, and NEOM with particular emphasis on describing in broad terms how MSCSurv works and its capabilities and most significant models.

Hyde, James↗
NASA NTRS2019

Consequences of MMOD Penetrations on the International Space Station

Risk from micrometeoroid and orbital debris (MMOD) impacts on space vehicles is often quantified in terms of the probability of no penetration (PNP). However, for large spacecraft, especially those with multiple compartments, a penetration may have a number of possible outcomes. The extent of the damage (diameter of hole, crack length or penetration depth), the location of the damage relative to critical equipment or crew, crew response, and even the time of day of the penetration are among the many factors that can affect the outcome. For the International Space Station (ISS), a Monte-Carlo style software code called Manned Spacecraft Crew Survivability (MSCSurv) is used to predict the probability of several outcomes of an MMOD penetration—broadly classified as loss of crew (LOC), crew evacuation (Evac), loss of escape vehicle (LEV), and nominal end of mission (NEOM). By generating large numbers of MMOD impacts (typically in the billions) and tracking the consequences, MSCSurv allows for the inclusion of a large number of parameters and models as well as enabling the consideration of uncertainties in the models and parameters. MSCSurv builds upon the results from NASA’s Bumper software (which provides the probability of penetration and critical input data to MSCSurv) to allow analysts to estimate the probability of LOC, Evac, LEV, and NEOM. This paper provides an overview of the methodology used by NASA to quantify LOC, Evac, LEV, and NEOM with particular emphasis on describing in broad terms how MSCSurv works and its capabilities and most significant models.

Evans, Hilary J.↗
NASA NTRS2020

Stochastic Simulation of Mudcrack Damage Formation in an Environmental Barrier Coating

The FEAMAC/CARES program, which integrates finite element analysis (FEA) with the MAC/GMC (Micromechanics Analysis Code with Generalized Method of Cells) and the CARES/Life (Ceramics Analysis and Reliability Evaluation of Structures / Life Prediction) programs, was used to simulate the formation of mudcracks during the cooling of a multilayered environmental barrier coating (EBC) deposited on a silicon carbide substrate. FEAMAC/CARES combines the MAC/GMC multiscale micromechanics analysis capability (primarily developed for composite materials) with the CARES/Life probabilistic multiaxial failure criteria (developed for brittle ceramic materials) and Abaqus (Dassault Systèmes) FEA. In this report, elastic modulus reduction of randomly damaged finite elements was used to represent discrete cracking events. The use of many small-sized low-aspect-ratio elements enabled the formation of crack boundaries, leading to development of mudcrack-patterned damage. Finite element models of a disk-shaped three-dimensional specimen and a twodimensional model of a through-the-thickness cross section subjected to progressive cooling from 1,300 °C to an ambient temperature of 23 °C were made. Mudcrack damage in the coating resulted from the buildup of residual tensile stresses between the individual material constituents because of thermal expansion mismatches between coating layers and the substrate. A two-parameter Weibull distribution characterized the coating layer stochastic strength response and allowed the effect of the Weibull modulus on the formation of damage and crack segmentation lengths to be studied. The spontaneous initiation of cracking and crack coalescence resulted in progressively smaller mudcrack cells as cooling progressed, consistent with a fractal-behaved fracture pattern. Other failure modes such as delamination, and possibly spallation, could also be reproduced. The physical basis assumed and the heuristic approach employed, which involves a simple stochastic cellular automaton methodology to approximate the crack growth process, are described. The results ultimately show that a selforganizing mudcrack formation can derive from a Weibull distribution that is used to describe the stochastic strength response of the bulk brittle ceramic material layers of an EBC.

Nemeth, Noel N.↗
NASA NTRS2005

High-Frequency, High-Temperature Fretting Experiments

Fretting is a structural damage mechanism observed when two nominally clamped surfaces are subjected to an oscillatory loading. A critical location for fretting induced damage has been identified at the blade/disk and blade/damper interfaces of gas turbine engine turbomachinery and space propulsion components. The high-temperature, high-frequency loading environment seen by these components lead to severe stress gradients at the edge-of-contact. These contact stresses drive crack nucleation and propagation in fretting and are very sensitive to the geometry of the contacting bodies, the contact loads, materials, temperature, and contact surface tribology (friction). To diagnose the threat that small and relatively undetectable fretting cracks pose to damage tolerance and structural integrity of in-service components, the objective of this work is to develop a well-characterized experimental fretting rig capable of investigating fretting behavior of advanced aerospace alloys subjected to load and temperature conditions representative of such turbomachinery components.

Matlik, J. F.↗
NASA NTRSDate not supplied

Characterization of Composite Damage Using Passive Thermography

Passive thermography is used to monitor small increases in temperature on a composite structure during loading. A rise in temperature can be attributed to damage formation due to matrix cracking and fiber breaks. An infrared camera allows for imaging the damage location, size, and shape. Recently, a technique has been developed to estimate the depth of the damage in a composite hat-stiffened panel during quasi-static loading. This technique is based on two heat generation components. The first component is an instantaneous thermoelastic response due to a strain release. The second component is mechanical heating, at the interface of failure, due to fracture damage. This second component produces a transient rise in temperature that is a function of the damage depth and thermal diffusivity. The first component defines the thermal start time for the transient response. A one-dimensional thermal model is used to determine the damage depth for a known thermal diffusivity. The results are compared to ultrasonic and X-ray CT data and show good agreement for damage depth.

Thermal nondestructive evaluation↗
NASA NTRS1977

Theory of ultrasonic diffraction by damage developed in thin laminated composites

The apparent attenuation which would result if certain damage states (transverse cracks and delaminations) are introduced into a graphite/epoxy laminate through which an ultrasonic wave passes is investigated. Experimental data for two different laminates are presented which shows changes in the apparent attenuation of about one db. These changes generally occur at loads which correspond to the range predicted for the formation of the damage. The predicted changes in the attenuation for several simple and common damage states are well within the range of experimental values.

Hayford, D. T.↗
NASA NTRS1993

Explicit 3D continuum fracture modeling with smooth particle hydrodynamics

Impact phenomena shaped our solar system. As usual for most solar system processes, the scales are far different than we can address directly in the laboratory. Impact velocities are often much higher than we can achieve, sizes are often vastly larger, and most impacts take place in an environment where the only gravitational force is the mutual pull of the impactors. The Smooth Particle Hydrodynamics (SPH) technique has been applied in the past to the simulations of giant impacts. In these simulations, the colliding objects were so massive (at least a sizeable fraction of the Earth's mass) that material strength was negligible compared to gravity. This assumption can no longer be made when the bodies are much smaller. To this end, we have developed a 3D SPH code that includes a strength model to which we have added a von Mises yielding relation for stresses beyond the Hugoniot Elastic Limit. At the lower stresses associated with brittle failure, we use a rate-dependent strength based on the nucleation of incipient flaws whose number density is given by a Weibull distribution. Following Grady and Kipp and Melosh et al., we introduce a state variable D ('damage'), 0 less than D less than 1, which expresses the local reduction in strength due to crack growth under tensile loading. Unfortunately for the hydrodynamics, Grady and Kipp's model predicts which fragments are the most probable ones and not the ones that are really formed. This means, for example, that if a given laboratory experiment is modeled, the fragment distribution obtained from the Grady-Kipp theory would be equivalent to a ensemble average over many realizations of the experiment. On the other hand, the hydrodynamics itself is explicit and evolves not an ensemble average but very specific fragments. Hence, there is a clear incompatibility with the deterministic nature of the hydrodynamics equations and the statistical approach of the Grady-Kipp dynamical fracture model. We remedy these shortcomings by making the incipient flaw distribution explicit, i.e., particles carry activation strains which are distributed at random with a probability of occurrence given by the Weibull distribution. If the local principal axis strain exceeds this limit, damage starts to grow. By growing explicit cracks together with statistical cracks (damage) at the sub-particle scale, we ensure that material strength and fragmentation is independent of model resolution. We tested our scheme by simulating laboratory impact experiments on basalt spheres.

Benz, W.↗
NASA NTRSDate not supplied

Martian Dust Abrasion Damage on Solar Arrays: HALT Experimental Investigation and Opportunity Rover Performance Analysis

We explored the utility of ground-based highly accelerated life testing (HALT) on epitaxial lift-off (ELO) triple-junction coverglass interconnected cells (CICs) after exposure to simulated Martian dust storms. Dust storm impingement was replicated by sandblasting CICs with Mars dust simulant replicating conditions similar to the weather conditions reported by the Viking landers. We observed that even in cases when there are no observable open circuit voltage (VOC) losses, the minority carrier lifetime is reduced. Short circuit current (JSC) losses can be recovered upon cleaning, suggesting JSC losses are not linked to permanent damage, like cell cracking. This suggests a permanent degradation could be determined by quantifying the difference between recoverable and non-recoverable power loss. We mined field data from the Mars Exploration Rover, Opportunity and extracted a degradation rate to compare to our experimental data. We found exceptional agreement between 4.9 Martian years of mined field data (9.4%) and the irreversible damage observed in our HALT experiment (9.7%). We demonstrate that the laboratory method for exposing CICs to Martian dust storm conditions well represents the physical reality of long duration CIC operation on Mars.

Lyndsey McMillon-Brown↗
NASA NTRS2003

Methods Developed by the Tools for Engine Diagnostics Task to Monitor and Predict Rotor Damage in Real Time

Tools for Engine Diagnostics is a major task in the Propulsion System Health Management area of the Single Aircraft Accident Prevention project under NASA s Aviation Safety Program. The major goal of the Aviation Safety Program is to reduce fatal aircraft accidents by 80 percent within 10 years and by 90 percent within 25 years. The goal of the Propulsion System Health Management area is to eliminate propulsion system malfunctions as a primary or contributing factor to the cause of aircraft accidents. The purpose of Tools for Engine Diagnostics, a 2-yr-old task, is to establish and improve tools for engine diagnostics and prognostics that measure the deformation and damage of rotating engine components at the ground level and that perform intermittent or continuous monitoring on the engine wing. In this work, nondestructive-evaluation- (NDE-) based technology is combined with model-dependent disk spin experimental simulation systems, like finite element modeling (FEM) and modal norms, to monitor and predict rotor damage in real time. Fracture mechanics time-dependent fatigue crack growth and damage-mechanics-based life estimation are being developed, and their potential use investigated. In addition, wireless eddy current and advanced acoustics are being developed for on-wing and just-in-time NDE engine inspection to provide deeper access and higher sensitivity to extend on-wing capabilities and improve inspection readiness. In the long run, these methods could establish a base for prognostic sensing while an engine is running, without any overt actions, like inspections. This damage-detection strategy includes experimentally acquired vibration-, eddy-current- and capacitance-based displacement measurements and analytically computed FEM-, modal norms-, and conventional rotordynamics-based models of well-defined damages and critical mass imbalances in rotating disks and rotors.

Baaklini, George Y.↗
NASA NTRS2024

Impact Response of Thermoplastic Composites – Experiments and Modeling

This study investigates the impact response of thermoplastic composite materials. The material system under consideration is a carbon fiber reinforced low melt semi-crystalline resin TC1225 LMPAEK reinforced with T700G (T700/LMPAEK ). Several High Energy Dynamic Impact (HEDI) tests were performed wherein an aluminum projectile impacted T700/LMPAEK panels at different velocities. In the impact experiment studied herein, the projectile impacted the T700/LMAPEK panel at 73.2 m/s and rebounded. The ensuing damage to the T700/LMPAEK panel was characterized via ultrasonic C-scans, visualizing damage modes including matrix cracking and delaminations. Since the projectile rebounded, the fiber breakage damage mode was not evident. The impact event was modeled using a combined continuum damage mechanics and cohesive zone analysis approach with the commercially available hydrocode LS-DYNA®. The dynamic deformation and damage of the continuum, i.e., the plies in the T700/LMPAEK laminate, was modeled using a Deformation Gradient Decomposition (DGD) material model, i.e., MAT299 available within LS-DYNA. The interlaminar regions were treated as zero-thickness cohesive zones, wherein the dynamic delamination mechanics was modeled using a traction-separation formulation. Mixed-mode delamination growth was captured using the Benzegaggh-Kenane (B-K) traction-separation interpolation law. Strain-rate sensitivity of interlaminar fracture toughness was included using approximations based on published literature. The outcomes of the modeling effort are discussed herein which demonstrate good correlations with test data regarding panel deflection, panel-projectile interactions, damage modes and damage extent.

Impact modeling↗
NASA NTRS1983

Fracture behavior of unidirectional boron/aluminum composite laminates

An experiment was conducted to verify the results of mathematical models which predict the stresses and displacements of fibers and the amount of damage growth in a center-notched lamina as a function of the applied remote stress and the matrix and fiber material properties. A brittle lacquer coating was used to detect the yielding in the matrix while X-ray techniques were used to determine the number of broken fibers in the laminate. The notched strengths and the amounts of damage found in the specimens agree well with those predicted by the mathematical model. It is shown that the amount of damage and the crack opening displacement does not depend strongly on the number of plies in the laminate for a given notch width. By heat-treating certain laminates to increase the yield stress of the alumina matrix, the effect of different matrix properties on the fracture behavior was investigated. The stronger matrix is shown to weaken the notched laminate by decreasing the amount of matrix damage, thereby making the laminate more notch sensitive.

Goree, J. G.↗
NASA NTRS1994

A probabilistic fatigue analysis of multiple site damage

The variability in initial crack size and fatigue crack growth is incorporated in a probabilistic model that is used to predict the fatigue lives for unstiffened aluminum alloy panels containing multiple site damage (MSD). The uncertainty of the damage in the MSD panel is represented by a distribution of fatigue crack lengths that are analytically derived from equivalent initial flaw sizes. The variability in fatigue crack growth rate is characterized by stochastic descriptions of crack growth parameters for a modified Paris crack growth law. A Monte-Carlo simulation explicitly describes the MSD panel by randomly selecting values from the stochastic variables and then grows the MSD cracks with a deterministic fatigue model until the panel fails. Different simulations investigate the influences of the fatigue variability on the distributions of remaining fatigue lives. Six cases that consider fixed and variable conditions of initial crack size and fatigue crack growth rate are examined. The crack size distribution exhibited a dominant effect on the remaining fatigue life distribution, and the variable crack growth rate exhibited a lesser effect on the distribution. In addition, the probabilistic model predicted that only a small percentage of the life remains after a lead crack develops in the MSD panel.

Rohrbaugh, S. M.↗
NASA NTRS1984

Theoretical model of impact damage in structural ceramics

This paper presents a mechanistically consistent model of impact damage based on elastic failures due to tensile and shear overloading. An elastic axisymmetric finite element model is used to determine the dynamic stresses generated by a single particle impact. Local failures in a finite element are assumed to occur when the primary/secondary principal stresses or the maximum shear stress reach critical tensile or shear stresses, respectively. The succession of failed elements thus models macrocrack growth. Sliding motions of cracks, which closed during unloading, are resisted by friction and the unrecovered deformation represents the 'plastic deformation' reported in the literature. The predicted ring cracks on the contact surface, as well as the cone cracks, median cracks, radial cracks, lateral cracks, and damage-induced porous zones in the interior of hot-pressed silicon nitride plates, matched those observed experimentally. The finite element model also predicted the uplifting of the free surface surrounding the impact site.

Liaw, B. M.↗