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At least 235 records · Page 13

All sources NASA NTRS DOE OSTI

NASA NTRS2010

Use of Modal Acoustic Emission to Monitor Damage Progression in Carbon Fiber/Epoxy and Implications for Composite Structures

Broad-band modal acoustic emission (AE) data was used to characterize micromechanical damage progression in uniaxial IM7 and T1000 carbon fiber-epoxy tows and an IM7 composite overwrapped pressure vessel (COPV) subjected to an intermittent load hold tensile stress profile known to activate the Felicity ratio (FR). Damage progression was followed by inspecting the Fast Fourier Transforms (FFTs) associated with acoustic emission events. FFT analysis revealed the occurrence of cooperative micromechanical damage events in a frequency range between 100 kHz and 1 MHz. Evidence was found for the existence of a universal damage parameter, referred to here as the critical Felicity ratio, or Felicity ratio at rupture (FR*), which had a value close to 0.96 for the tows and the COPV tested. The implications of using FR* to predict failure in carbon/epoxy composite materials and related composite components such as COPVs are discussed. Trends in the FFT data are also discussed; namely, the difference between the low and high energy events, the difference between early and late-life events, comparison of IM7 and T1000 damage progression, and lastly, the similarity of events occurring at the onset of significant acoustic emission used to calculate the FR.

Waller, J. M.↗

NASA NTRS2002

NASA Tech Briefs, April 2002

The contents include: 1) Application Briefs; 2) Sneak Preview of Sensors Expo; 3) The Complexity of the Diagnosis Problem; 4) Design Concepts for the ISS TransHab Module; 5) Characteristics of Supercritical Transitional Mixing Layers; 6) Electrometer for Triboelectric Evaluation of Materials; 7) Infrared CO2 Sensor With Built-In Calibration Chambers; 8) Solid-State Potentiometric CO Sensor; 9) Planetary Rover Absolute Heading Detection Using a Sun Sensor; 10) Concept for Utilizing Full Areas of STJ Photodetector Arrays; 11) Development of Cognitive Sensors; 12) Enabling Higher-Voltage Operation of SOl CMOS Transistors; 13) Estimating Antenna-Pointing Errors From Beam Squints; 14) Advanced-Fatigue-Crack-Growth and Fracture- Mechanics Program; 15) Software for Sequencing Spacecraft Actions; 16) Program Distributes and Tracks Organizational Memoranda; 16) Flat Membrane Device for Dehumidification of Air; 17) Inverted Hindle Mount Reduces Sag of a Large, Precise Mirror; 18) Heart-Pump-Outlet/Cannula Coupling; 19) Externally Triggered Microcapsules Release Drugs In Situ; 20) Combinatorial Drug Design Augmented by Information Theory; 21) Multiple-Path-Length Optical Absorbance Cell; 22) Model of a Fluidized Bed Containing a Mixture of Particles; 23) Refractive Secondary Concentrators for Solar Thermal Systems; 24) Cold Flow Calorimeter; 25) Methodology for Tracking Hazards and Predicting Failures; 26) Estimating Heterodyne-Interferometer Polarization Leakage; 27) An Efficient Algorithm for Propagation of Temporal- Constraint Networks; 28) Software for Continuous Replanning During Execution; 29) Surface-Launched Explorers for Reconnaissance/Scouting; 30) Firmware for a Small Motion-Control Processor; 31) Gear Bearings and Gear-Bearing Transmissions; and 32) Linear Dynamometer With Variable Stroke and Frequency.

Source record↗

NASA NTRS2011

Structural health monitoring apparatus and methodology

Disclosed is an apparatus and methodology for structural health monitoring (SHM) in which smart devices interrogate structural components to predict failure, expedite needed repairs, and thus increase the useful life of those components. Piezoelectric wafer active sensors (PWAS) are applied to or integrated with structural components and various data collected there from provide the ability to detect and locate cracking, corrosion, and disbanding through use of pitch-catch, pulse-echo, electro/mechanical impedance, and phased array technology. Stand alone hardware and an associated software program are provided that allow selection of multiple types of SHM investigations as well as multiple types of data analysis to perform a wholesome investigation of a structure.

Giurgiutiu, Victor↗

NASA NTRS2012

Effects of Subscale Size and Shape on Global Energy Dissipation in a Multiscale Model of a Fiber-Reinforced Composite Exhibiting Post-Peak Strain Softening Using Abaqus and FEAMAC

A mesh objective crack band model is implemented in the generalized method of cells (GMC) micromechanics model to predict failure of a composite repeating unit cell (RUC). The micromechanics calculations are achieved using the MAC/GMC core engine within the ImMAC suite of micromechanics codes, developed at the NASA Glenn Research Center. The microscale RUC is linked to a macroscale Abaqus/Standard finite element model using the FEAMAC multiscale framework (included in the ImMAC suite). The effects of the relationship between the characteristic length of the finite element and the size of the microscale RUC on the total energy dissipation of the multiscale model are investigated. A simple 2-D composite square subjected to uniaxial tension is used to demonstrate the effects of scaling the dimensions of the RUC such that the length of the sides of the RUC are equal to the characteristic length of the finite element. These results are compared to simulations where the size of the RUC is fixed, independent of the element size. Simulations are carried out for a variety of mesh densities and element shapes, including square and triangular. Results indicate that a consistent size and shape must be used to yield preserve energy dissipation across the scales.

Pineda, Evan, J.↗

NASA NTRS2008

Overview of the Smart Network Element Architecture and Recent Innovations

In industrial environments, system operators rely on the availability and accuracy of sensors to monitor processes and detect failures of components and/or processes. The sensors must be networked in such a way that their data is reported to a central human interface, where operators are tasked with making real-time decisions based on the state of the sensors and the components that are being monitored. Incorporating health management functions at this central location aids the operator by automating the decision-making process to suggest, and sometimes perform, the action required by current operating conditions. Integrated Systems Health Management (ISHM) aims to incorporate data from many sources, including real-time and historical data and user input, and extract information and knowledge from that data to diagnose failures and predict future failures of the system. By distributing health management processing to lower levels of the architecture, there is less bandwidth required for ISHM, enhanced data fusion, make systems and processes more robust, and improved resolution for the detection and isolation of failures in a system, subsystem, component, or process. The Smart Network Element (SNE) has been developed at NASA Kennedy Space Center to perform intelligent functions at sensors and actuators' level in support of ISHM.

Perotti, Jose M.↗

NASA NTRS2018

Composite Technology for Exploration (CTE) Briefing to RUAG

Technology Product Capability: The CTE project will develop and demonstrate critical composites technologies with a focus on weight-saving, performance-enhancing bonded joint technology for Space Launch System (SLS)-scale composite hardware to support future NASA exploration missions. (a) Improve the analytical capabilities required to predict failure modes in composite structures. (b) Support SLS payload adapters and fittings by maturing composite bonded joint technology and analytical tools to enable risk reduction.

manufacturing technology↗

NASA NTRS2019

Myco-Architecture off Planet: Growing Surface Structures at Destination

Our work focused on filling major select key technical knowledge gaps, and technical aspects to be addressed in a Phase II proposal were identified such as the secretion of glues or plastics by the fungi or bacteria to form biocomposites. Specifically, we raised the technical TRL by assessing the growth of in-house mycelial-producing strains on potential food substrates and analyzed the advantages and disadvantages to their use off planet. Growth of the mycelia on sawdust and powdered nutrients including dried, powdered algae, was used as a baseline. We measured growth as a function of temperature, tested the relevant material properties of the mycelia products produced, and measured the mass of input and output volume for production per volume of material. Mycotecture was produced in a bag simulating the proposed mission implementation. Post-production such as heat treatment (as is done with terrestrial mycotecture)was assessed.The material properties of the dried, frozen and baked mycelial outputs included density, strength,thermal insulation and flame retardation. Tensile/compression testing on biocomposite material specimens was performed to obtain three-dimensional elastic constants, as well as to examine deformation and fracture behavior. These mechanical tests were performed on both dormant and activated samples to understand the evolution of the structural material. In addition, experimental data obtained from the mechanical testing was used to build a failure prediction model that accounts for material anisotropy. This aided in future structural design through a quantitative understanding of the mechanical limits of the material. To examine the texture, defects, fracture surfaces of the material, high-resolution microstructural imaging was utilized before and after the mechanical tests. This microstructural analysis informed us about the macro-structural behavior and influenced structural design. Thermal decomposition analysis was also performed tounderstand the thermal limits.

Biocomposites↗

NASA NTRS2018

Quantification of Error Associated with Using Misaligned Meshes in Continuum Damage Mechanics Material Models for Matrix Crack Growth Predictions in Composites

The ability of a material model to capture in-plane matrix mode I and mode II crack growth is an essential component for modeling ply level damage evolution in composite structures. Previous studies using a continuum damage mechanics (CDM) approach have shown success in satisfying benchmark solutions for mode I and II crack growth. However, success was shown using a fiber-aligned meshing strategy, which encourages matrix cracks to propagate in a single band of elements, along the fiber direction. Generating a fiber-aligned mesh becomes a highly involved process for laminates including off-axis (non 0° or 90°) plies. The objective of this study is to quantify the effect of non-fiber aligned mesh discretization on predictions of in-plane matrix crack propagation. The approach taken incrementally varies the mesh orientation angle relative to the fiber orientation; more specifically, misaligned meshes are used to quantify the effect of element angle orientation relative to the initial crack orientation on the energy released during matrix crack propagation simulations using a CDM method. CDM solutions obtained with the misaligned meshes are evaluated against known benchmarks for mode I and II matrix crack growth. The CDM solutions reveal a near-polynomial trend of increased predicted failure stress with increased mesh misalignment angle; hence implying a potential relationship between element orientation angle and apparent fracture toughness.

Justusson, Brian↗

NASA NTRSDate not supplied

Application of a Rapid Design Tool to a 3D Woven Structural Joint

The optimization of composite structural joints is an iterative process and a multiscale problem. High fidelity finite element modeling of joints with 3D woven and laminated materials can become computationally expensive. The aim of this paper is to establish a reliable analysis process for the optimization of a composite Y-joint (curved Pi-joint), to be used in an aircraft fuselage, using commercial rapid joint design, analysis, and optimization software. The rapid joint design tool was investigated as a substitute and/or complement to a finite element analysis software. A composite Pi-joint and a composite Y-joint were evaluated using the rapid joint design tool to determine the applicability and limits of the software. Furthermore, three main preliminary parametric studies were performed to better understand the capability of the tool in predicting the stress distributions and trends in the Y-joint. The parameters investigated were the joint curvature, the laminated skin thickness, the adhesive systems, and the ply composition. Lastly, trends in predicted failure load were produced as a function of skin thickness (16ply, 24ply and 32ply). Failure loads were found with varying joint curvature and skin thickness using stress-based adherend failure criterion. The rapid joint design tool was also validated against existing experimental results.

Bonded Joints↗

NASA NTRSDate not supplied

Modeling the Stochastic Response of Fiber Reinforced Composites with Varied Representative Volume Element Sizes

Fiber reinforced composites are desirable in applications where low weight and high strength are needed, but are susceptible to variability and flaws during manufacturing, making failure predictions difficult. These flaws may occur at the microscale where mechanical properties vary locally due to regions of fiber clusters and matrix pockets. In this study, a multiscale approach was taken to model 3-point bend, 4-point bend, and tensile experiments of a unidirectional composite from only having microstructure scans of these samples and constituent properties from literature. These scans were sampled with different sized windows, and statistically equivalent microstructures were generated, then simulated for stiffness, strength, and fracture toughness using a reduced order micromechanical model and NASA’s Multiscale Analysis Tool (NASMAT). Mesoscale models were created with equivalent element sizes to microstructures and properties sampled from microscale simulation results. Results showed how microscale size affects certain mechanical properties. Also shown is how well mesoscale models agree to experiments when using stochastic element properties and varying element size.

microstructure↗

NASA NTRSDate not supplied

Innovations in Continuous Ultrasonic Welding of Thermoplastic Composites and Evaluation for Space Applications

The goals of NASA’s Thermoplastic Development for Exploration Applications (TDEA) Project include and assessment of thermoplastic composite joints for space structures by developing and maturing design capabilities, analysis tools and techniques, and manufacturing processes for thermoplastic composites. Through this effort the TDEA project will expand NASA’s in-house thermoplastic composite manufacturing capabilities, develop an understanding of advanced thermoplastic joining techniques relevant to space environments, evaluate the feasibility of reconfigurable composite structures, and advance structural analysis capabilities, including failure prediction of thermoplastic composites including joints. This presentation will provide an overview of the materials and manufacturing effort within the TDEA project. Three semi-crystalline and one amorphous thermoplastic composite system were selected for initial screening and provided an opportunity to gain manufacturing experience across a range of processing temperatures, rheological behavior, and composite properties. Equivalency to the National Center for Advanced Materials Performance (NCAMP) test report for Toray’s TC1225 material was established to provide confidence in in-house manufacturing and material properties were generated through baseline mechanical tests for each material. Material characterization data was generated for a subset of materials to (1) provide data for analysis and model development and (2) generate thermal, rheological and conductivity data across relevant temperatures. A key objective of the TDEA project is evaluation of thermoplastic composite joining processes suitable for in-space operations. This presentation will outline the project’s progress in fusion bonding candidate materials by common welding techniques to assess the quality, reproducibility and strength of the bond, as well as identify limitations to in-space manufacturing. The feasibility of joint disassembly and reassembly will be discussed.

thermoplastic composite↗

NASA NTRSDate not supplied

Assessment of Segmentation-Induced Deviations of Porosity Metrics in Powder Bed Fusion Additively Manufactured Components

Post processing X-ray computational tomography (CT) inspection data for additively manufactured (AM) components can induce deviations in defect quantification, affecting subsequent fatigue and failure predictions. To assess the influence and potential impact of segmentation-induced measurement deviations, this paper applies several segmentation techniques to X-ray CT data for powder bed fusion Ti-6Al-4V specimens exhibiting porosity conditions. X-ray CT reconstructions were segmented with varying techniques including Otsu’s thresholding, random forest, k-nearest neighbors, and the multilayer perceptron. Metrics such as pore size and global porosity were compared for internal validity. Then, top-down X-ray CT measurements of surface-breaking porosity were compared to optical profilometry for cross-validation.

Data fusion↗

NASA NTRSDate not supplied

Manufacture, Characterization, and Fusion Welding of Thermoplastic Composites for Space Applications

thermoplastic composite↗

NASA NTRSDate not supplied

Microscale Constitutive Model Sensitivity on Multiscale Modeling of Fiber Reinforced Composites

Fiber reinforced composites are desirable in applications where low weight and high strength are needed, but are susceptible to microscale variability during manufacturing, making failure predictions difficult. The impact microscale variability has on macroscale mechanical response is difficult to predict due to the computational efficiency needed to simulate many, large, high fidelity, microscale models. In this study, a multiscale approach was taken to model 3-point bend, 4-point bend, and tensile experiments of a unidirectional composite from only having microstructure scans of these samples and constituent properties from literature. These scans were sampled with different sized windows, and statistically equivalent microstructures were generated, then simulated for stiffness, strength, and fracture toughness using an efficient micromechanical. Mesoscale models were created where element sizes equaled microstructure size, and properties were assigned through sampling of microscale simulation results. First, this study showed the effect of using Weibull scaling on constituent matrix strength on macroscale response. Then, a comparison was made between different element sizes and experiments. Finally, model dimensions were fixed, and the effect of randomly distributed local properties alone was examined. Results showed that the scatter of strength and stiffness in the experiments could be predicted well using images of the microscale fiber morphologies and that using stochastic properties produced a 3% coefficient of variation of strength for all experiments.

statistical microstructure↗

DOE OSTI2022

Damage Evolution of Double-Sided Copper Conductor on Multi-layer Flexible Substrate Under Bending

Abstract—Thin-film conductors continue to play an important role in flexible electronics, and thus, the performance and reliability of such conductors under mechanical loading such as stretch, bend, and twist need to be studied through experiments as well as simulations. This paper focuses on the damage evolution of the thin-film conductors under cyclic bending. Four types of double-sided copper conductors: straight trace without coverlay, straight trace with coverlay, notched trace without coverlay, and notched trace with coverlay on multi-layer substrates were studied in this work. The adaptive curvature flexure test method, which is suitable for thin-film bending, was employed in this work. Adaptive curvature flexure test is one where the flexible substrate with its conductor is positioned between two parallel plates, and the parallel plates are moved relative to each other such that the gap distance between the parallel plates changes in one of the configurations of the adaptive curvature flexure test. Different strain levels can be achieved easily in such an adaptive curvature flexure test by controlling the gap distance between the parallel plates. By subjecting flexible substrates with thin conductors to such bend tests, the fatigue life of the specimen was determined for different magnitudes of strain ranges. The results were then compared among the four types of conductors. Specimens were designed such that the conductors were placed on both sides of the substrate so that the one of the conductors would undergo tensile straining, while the other one would undergo compressive straining. It was shown that the fatigue life was highly dependent on the magnitude of strain range, and that the conductor on the compressive side failed sooner than that on the tensile side. The failed specimens were examined in a microscope at different number of cycles. Also, the resistance of the conductors, which is directly related to the reliability of thin-film conductors, was monitored in-situ during bending. The resistance change with the strain range change as well as the resistance progression with the number of cycles in tensile as well as compressive mode were determined, and such information is then used to create failure prediction models for thin-film conductors on flexible substrates.

damage evolution, flexible conductor, multi-layer ↗

DOE OSTI2025

AGR TRISO Fuel Performance Modeling in FY-25

This report summarizes the activities performed in FY-25 to support fuel performance modeling for the Advanced Gas Reactor (AGR) Fuel Development and Qualification Program. This includes implementation of a new uranium oxycarbide (UCO) kernel swelling rate model, inner pyrolytic carbon (IPyC) cracking behavior and failure predictions, development of new UCO and silicon carbide (SiC) cesium diffusion parameters, and the thermomechanical behavior of particle layers using experimental data from micro-tensile strength testing.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2025

Probabilistic Predictions for Fastener Failure in the Sandia Mechanics Challenge Using the Discrete-Direct Uncertainty Quantification Approach

This paper documents the blind and post-blind analysis predictions for the 2023 Sandia Mechanics Challenge (SMC), which involved predicting the behavior of a threaded fastener joint structure subjected to shock loading. Utilizing repeat sets of fastener calibration data from various experimental configurations including tension, double shear, and joint tension, we developed a library of calibrated models which were propagated through the application model using the Discrete-Direct (DD) uncertainty quantification (UQ) approach. Although the initial blind predictions did not incorporate spare-sample processing to quantify fastener failure probabilities, the analyses yielded reasonable conclusions aligned with experimental results. In the post-blind analysis phase, we focused on enhancing the fidelity of the aluminum constitutive model and innovating the DD approach to obtain probabilistic predictions for fastener failure, particularly when quantities of interest (QoIs) approach their bounds. The improved aluminum model captures the behavior of the cantilever under shock loading more accurately, predicting both partial and complete cracks, although it tends to underpredict failure propagation. The enhanced DD approach facilitates probabilistic predictions that reflect the interdependent failure mechanisms of the fasteners and the cantilever, revealing that while certain fasteners are more likely to fail, the failure does not necessarily follow a progressive pattern. Overall, the post-blind analyses significantly improved the predictive capabilities of the model, providing valuable insights into the SMC application and establishing a robust foundation for informed engineering decisions. The methodology demonstrates a cost-effective and extensible approach suitable for a wide range of applications, highlighting the importance of uncertainty quantification to provide context for engineering decision making.

42 ENGINEERING↗

NASA NTRS1991

Progressive failure methodologies for predicting residual strength and life of laminated composites

Two progressive failure methodologies currently under development by the Mechanics of Materials Branch at NASA Langley Research Center are discussed. The damage tolerance/fail safety methodology developed by O'Brien is an engineering approach to ensuring adequate durability and damage tolerance by treating only delamination onset and the subsequent delamination accumulation through the laminate thickness. The continuum damage model developed by Allen and Harris employs continuum damage laws to predict laminate strength and life. The philosophy, mechanics framework, and current implementation status of each methodology are presented.

Harris, Charles E.↗