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At least 325 records · Page 18

Failure analysis of woven and braided fabric reinforced composites

A general purpose micromechanics analysis that discretely models the yarn architecture within the textile repeating unit cell was developed to predict overall, three dimensional, thermal and mechanical properties, damage initiation and progression, and strength. This analytical technique was implemented in a user-friendly, personal computer-based, menu-driven code called Textile Composite Analysis for Design (TEXCAD). TEXCAD was used to analyze plain weave and 2x2, 2-D triaxial braided composites. The calculated tension, compression, and shear strengths correlated well with available test data for both woven and braided composites. Parametric studies were performed on both woven and braided architectures to investigate the effects of parameters such as yarn size, yarn spacing, yarn crimp, braid angle, and overall fiber volume fraction on the strength properties of the textile composite.

Naik, Rajiv A.↗

Effects of edge-seal design on the mechanical and thermal performance of vacuum-insulated glazing

Although vacuum-insulated glazing (VIG) has been proposed as a promising solution towards developing energy-efficient buildings, VIGs have not become popular in the market due to several technical challenges including the complexity of the fabrication process. In particular, the edge-seal is a key component that significantly affects the thermal insulation and mechanical performance, and the development of edge-seal with adequate thermal insulation, mechanical strength, and reasonable processing cost is essential to overcome such technical issues in VIG. For this purpose, effects of edge-seal design parameters on the VIG performance should be identified. In this research, we analyzed the edge-seal for thermal transport as well as structural stresses to study the effects, and then identified and evaluated the material mixes for the edge-seal requirements. Here, the finite element simulations showed the significance of VIG corner calculation on overall thermal transmittance and the importance of seal conductivity below 1 W/m.K. The experiments with the flexible seals with different ratios of fine glass powder demonstrated that the measured shear strength values for the seal with less than 30% glass powder were more than 10 times larger than the calculated shear stress values. Based on these simulation and experimental results, a flexible sealant was developed using a proprietary mix of ceramic materials that meets the requirements of the designed VIG edge-seal, including structural as well as thermal stress resistance and a low conductivity. Moreover, the sealant is self-curing under atmospheric conditions, and thus it does not require costly inline process of laser curing or oven baking.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

A generalized power-law criterion for rocks based on Mohr failure theory

Nonlinearity of Mohr envelopes confirmed by past laboratory test data can be of considerable importance in theoretical interpretation of rock strength behaviors and many practical applications. Current nonlinear failure criteria are introduced with parameters to empirically fit test data, and the physical and mechanical meanings of these fitting parameters are often not known. Predicted strengths by theoretical criteria (e.g., Griffith criterion) generally do not agree well with test data. Considering the nonlinear properties of a Mohr envelope, a nonlinear failure criterion in a generalized power-law form is derived in this paper based on strength magnitude coefficient (a) and failure envelope curvature coefficient (n) which are expressed in terms of uniaxial tensile strength, uniaxial compressive strength, and angle of internal friction. Test data on granite, marble, dolomite, and andesite from published literature were chosen to test the performance of the proposed criterion along with Griffith and Hoek-Brown criteria. Statistical analysis was performed to evaluate the application of different criteria in predicting the strength of rocks. In addition, some Griffith-typed criteria are mathematically shown to be the special cases of the proposed criterion. The proposed and Hoek-Brown criteria have similar power-law forms with a significant difference in the coefficient functions that govern the shear strength magnitude of rock. The different tensile and compressive failure mechanisms are also investigated from the perspective of the relationship between the uniaxial tension Mohr circle and the proposed failure envelope.

58 GEOSCIENCES↗

Temperature Effects on Adhesive Bond Strengths and Modulus for Commonly Used Spacecraft Structural Adhesives

A study was performed to observe how changes in temperature and substrate material affected the strength and modulus of an adhesive bondline. Seven different adhesives commonly used in aerospace bonded structures were tested. Aluminum, titanium and Invar adherends were cleaned and primed, then bonded using the manufacturer's recommendations. Following surface preparation, the coupons were bonded with the adhesives. The single lap shear coupons were then pull tested per ASTM D 1002 Standard Test Method for Apparent Shear Strength of Single- Lap-Joint over a temperature range from -150 deg C up to +150 deg C. The ultimate strength was calculated and the resulting data were converted into B-basis design allowables. Average and Bbasis results were compared. Results obtained using aluminum adherends are reported. The effects of using different adherend materials and temperature were also studied and will be reported in a subsequent paper. Dynamic Mechanical Analysis (DMA) was used to study variations in adhesive modulus with temperature. This work resulted in a highly useful database for comparing adhesive performance over a wide range of temperatures, and has facilitated selection of the appropriate adhesive for spacecraft structure applications.

structural adhesives testing↗

Non-Newtonian Fluid Model Incorporated into Elastohydrodynamic Lubrication of Rectangular Contacts

A procedure is outlined for the numerical solution of the complete elastohydrodynamic lubrication of rectangular contacts incorporating a non-Newtonian fluid model. The approach uses a Newtonian model as long as the shear stress is less than a limiting shear stress. If the shear stress exceeds the limiting value, the shear stress is set equal to the limiting value. The numerical solution requires the coupled solution of the pressure, film shape, and fluid rheology equations from the inlet to the outlet. Isothermal and no-side-leakage assumptions were imposed in the analysis. The influence of dimensionless speed, load, materials, and sliding velocity and limiting-shear-strength proportionality constant on dimensionless minimum film thickness was investigated. Fourteen cases were used in obtaining the minimum-film-thickness equation for an elastohydrodynamically lubricated rectangular contact incorporating a non-Newtonian fluid model. Computer plots are also presented that indicate in detail pressure distribution, film shape, shear stress at the surfaces, and flow throughout the conjunction.

Jacobson, B. O.↗

Non-Newtonian fluid model incorporated into elastohydrodynamic lubrication of rectangular contacts

A procedure is outlined for the numerical solution of the complete elastohydrodynamic lubrication of rectangular contacts incorporating a non-Newtonian fluid model. The approach uses a Newtonian model as long as the shear stress is less than a limiting shear stress. If the shear stress exceeds the limiting value, the shear stress is set equal to the limiting value. The numerical solution requires the coupled solution of the pressure, film shape, and fluid rheology equations from the inlet to the outlet. Isothermal and no-side-leakage assumptions were imposed in the analysis. The influence of dimensionless speed, load, materials, and sliding velocity and limiting-shear-strength proportionality constant on dimensionless minimum film thickness was investigated. Fourteen cases were used in obtaining the minimum-film-thickness equation for an elastohydrodynamically lubricated rectangular contact incorporating a non-Newtonian fluid model. Computer plots are also presented that indicate in detail pressure distribution, film shape, shear stress at the surfaces, and flow throughout the conjunction.

Jacobson, B. O.↗

Adhesive evaluation of thin films of LARC-TPI and LARC-TPI with 5 mol % ODA

A commercially available LARC-TPI film and an experimentally prepared film of LARC-TPI with 5 mol % of 4,4'-oxydianiline (ODA), designated as LARC-TPI/ODA in the report, supplied by Mitsui Toatsu Chemicals, Incorporated (MTCI), Japan, were evaluated as thermoplastic adhesive films for bonding Ti-6Al-4V. The LARC-TPI/ODA had been shown by MTCI to possess more flow than thermoplastic LARC-TPI and was, therefore, evaluated and compared to the LARC-TPI. Lap shear strength was used to evaluate the materials as adhesives. They were characterized after fracture by determining the glass transition temperature, Tg. The mode of failure was also reported. Thermal exposure at 204C for 500 and 1000 hrs and a 72-hour water-boil were conducted on lap shear specimens prepared with the two adhesive films. Lap shear tests were conducted at RT, 177C, 204C, and 232C before and after exposures.

Progar, D. J.↗

Adhesion Capabilities of Permanent Foaming Fixatives

DOE-EM have identified an operational requirement for a fixative that can immobilize and/or encapsulate residual contamination in 3D void volumes (pipes, gloveboxes, waste containers, etc.) during D and D activities. Failure to safely and effectively immobilize residual contamination can: Put workers at risk; Contaminate the public and environment; Drive up costs. Commercial-off-the-shelf (COTS) polyurethane (PU) foams is one possible solution and is currently being investigated by Savannah River National Lab (SRNL). Adhesion testing will dictate how well PU foams will adhere and immobilize residual contamination onto a substrate. Results can provide a performance criteria for Section 5 of ASTM E3191: Standard Specification for Permanent Foaming Fixatives Used to Mitigate Spread of Radioactive Contamination. Initial mechanical testing showed intumescent rigid PU foams were best in class (tensile, compression, TGA/DSC) Application of intumescent rigid PU foam in pipe scenario with 'contamination' showed excellent adhesion capabilities as long as foam had contact with pipe. The foam, however, was not able to penetrate 'contamination' but created pockets where the contamination interacted with the substrate. Pretreatment options of pipe were considered to produce better immobilization capabilities. Pretreatment options included COTS products like baking spray, rubber cement, and soap. Foam was still able to immobilize on a global sense, but not a local sense. Essentially acted as a mechanical plug. A tensile tester (MTS Criterion Series 43) was utilized to evaluate the tensile adhesion strength of 6 COTS PU foams. ASTM D1623: Tensile and Tensile Adhesion Properties of Rigid Cellular Plastics. Procedures: PU foams were cured between two smooth 2'' x 2'' 304 stainless steel coupons with hinges glued on plates for gripping support. Parameters Used: Pull rate of 0.1 in/min. Calculations: Tensile adhesion strength, elongation, and ImageJ analysis of how PU foam is left on substrate. Outcome: The PU foam with the best adhesion capabilities would be downselected for further evaluation to be used as a permanent foaming fixative. The rigid PU foams had the best adhesion capabilities with the R1 foam having a max load of 236 N. One of the I-R2 samples reached almost 450 N and another sample reached 2500 N before slipping. The other intumescent foam, I-F4, had the most coverage on the stainless steel coupon's surface from the ImageJ results (61.43% surface coverage). The intumescent foam, I-R2, will be the foam of choice for future testing due its fire retardant and adhesion capabilities. Future directions: Conduct the following experiment in a pipe scenario with the down-selected PU foam. Procedures: PU foam will be cured between in a 304 stainless steel pipe (ID: 4'', OD: 4.5'', Height: 4''). Parameters Used: Compression testing results will be referenced to determine if foam's adhesion strength would be greater its compression strength as its being compressed. Calculations: Compression strength, shear stress, total time elapsed. Conduct further adhesion testing with the down-selected PU foam (I-R2) to be treated as a permanent foaming fixative (PFF). Determine the minimum contact the PFF should have with the substrate for adequate results. Evaluate if PFF's adhesion capabilities is time dependent (3.1.5 of ASTM E3911). Subject PFF to seismic stressors addressed in Safety Basis of Interim Operation documents (SBIO) to further evaluate adhesion capabilities.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

Evaluation of polyimide films as adhesives

A commercially available LARC-TPI film and an experimentally prepared film of LARC-TPI with 5 mol pct of 4,4-prime-oxydianiline (ODA), designated as LARC-TPI/ODA, were evaluated as thermoplastic adhesive films for bonding Ti-6Al-4V. Lap shear strength was used to evaluate the materials as adhesives. They were characterized after fracture by determining the glass transition temperature, T(g). The mode of failure is also reported. Thermal exposure at 240 C for 500 and 1000 h and a 72-h water-boil were conducted on lap shear specimens prepared with the two adhesive films. Lap shear tests were conducted at room temperature, 177 C, 204 C, and 232 C before and after exposures.

Progar, Donald J.↗

The role of the margins in ice stream dynamics

At first glance, it would appear that the bed of the active ice stream plays a much more important role in the overall force balance than do the margins, especially because the ratio of the half-width to depth for a typical ice stream is large (15:1 to 50:1). On the other hand, recent observations indicate that at least part of the ice stream is underlain by a layer of very weak till (shear strength about 2 kPa), and this weak basal layer would then imply that some or all of the resistive drag is transferred to the margins. In order to address this question, a detailed velocity profile near Upstream B Camp, which extends from the center of the ice stream, across the chaotic shear margin, and onto the Unicorn, which is part of the slow-moving ice sheet was measured. Comparison of this observed velocity profile with finite-element models of flow shows several interesting features. First, the shear stress at the margin is on the order of 130 kPa, while the mean value along the bed is about 15 kPa. Integration of these stresses along the boundaries indicates that the margins provide 40 to 50 percent, and the bed, 60 to 40 percent of the total resistive drag needed to balance the gravitational driving stress in this region. (The range of values represents calculations for different values of surface slope.) Second, the mean basal stress predicted by the models shows that the entire bed cannot be blanketed by the weak till observed beneath upstream B - instead there must be a distribution of weak till and 'sticky spots' (e.g., 85 percent till and 15 percent sticky spots of resistive stress equal to 100 kPa). If more of the bed were composed of weak till, then the modeled velocity would not match that observed. Third, the ice must exhibit an increasing enhancement factor as the margins are approached (E equals 10 in the chaotic zone), in keeping with laboratory measurements on ice under prolonged shear strain. Also, there is either a narrow zone of somewhat stiffer ice (E equals 5) outward of the shear margin, or the bed is frozen there. And last, the high shear stress and strain rate found at the margin are likely to cause significant viscous heating (q) in the marginal ice. The increase in temperature is proportional to qX/u, where X is the width of the shear zone and u is the transverse velocity component bringing cold ice in from the ice sheet outside the shear zone. Near upstream B, this heating is likely to cause an increase in temperature of 4 to 10 K. Plans are to measure this temperature increase in a series of bore holes near the margin during the 1992-93 field season, as well as to provide a more detailed description of the velocity field there.

Echelmeyer, Keith↗

Interfacial stress state present in a 'thin-slice' fibre push-out test

An analysis of the stress distributions along the fiber-matrix interface in a 'thin-slice' fiber push-out test is presented for selected test geometries. For the small specimen thicknesses often required to displace large-diameter fibers with high interfacial shear strengths, finite element analysis indicates that large bending stresses may be present. The magnitude of these stresses and their spatial distribution can be very sensitive to the test configuration. For certain test geometries, the specimen configuration itself may alter the interfacial failure process from one which initiates due to a maximum in shear stress near the top surface adjacent to the indentor, to one which involves mixed mode crack growth up from the bottom surface and/or yielding within the matrix near the interface.

Kallas, M. N.↗

Coatings for Graphite Fibers

Several approaches for applying high resistance coatings continuously to graphite yarn were investigated. Two of the most promising approaches involved (1) chemically vapor depositing (CVD) SiC coatings on the surface of the fiber followed by oxidation, and (2) drawing the graphite yarn through an organo-silicone solution followed by heat treatments. In both methods, coated fibers were obtained which exhibited increased electrical resistances over untreated fibers and which were not degraded. This work was conducted in a previous program. In this program, the continuous CVD SiC coating process used on HTS fiber was extended to the coating of HMS, Celion 6000, Celion 12000 and T-300 graphite fiber. Electrical resistances three order of magnitude greater than the uncoated fiber were measured with no significant degradation of the fiber strength. Graphite fibers coated with CVD Si3N4 and BN had resistances greater than 10(exp 6) ohm/cm. Lower pyrolysis temperatures were used in preparing the silica-like coatings also resulting in resistances as high as three orders of magnitude higher than the uncoated fiber. The epoxy matrix composites prepared using these coated fibers had low shear strengths indicating that the coatings were weak.

Galasso, F. S.↗

Molecular-orbital model for metal-sapphire interfacial strength

Self-consistent-field X-Alpha scattered-wave cluster molecular-orbital models have been constructed for transition and noble metals (Fe, Ni, Cu, and Ag) in contact with a sapphire (Al2O3) surface. It is found that a chemical bond is established between the metal d-orbital electrons and the nonbonding 2p-orbital electrons of the oxygen anions on the Al2O3 surface. An increasing number of occupied metal-sapphire antibonding molecular orbitals explains qualitatively the observed decrease of contact shear strength through the series Fe, Ni, Cu, and Ag.

Johnson, K. H.↗

Fabrication of a High Chromium Cast Iron/Low Carbon Steel Bimetal: Diffusion Behavior and Bonding Strength

In the present study, a high chromium cast iron (HCCI) alloyed with Mo (16 wt.% Cr-6 wt.% Mo-2.4 wt.% C) with excellent wear resistance was bonded to a low carbon steel (LCS) by surface liquid-phase sintering. The bimetal was also subjected to a quenching + tempering treatment. The diffusion behavior of the atoms between the HCCI and LCS was analyzed. The bonding strength of the bimetal was investigated before and after heat treatment. The results show that the bimetal had a good bonding quality due to the uphill diffusion of C atoms. A diffusion zone with a width of approximately 37 μm and a troostite structure formed on the HCCI side by the interface. With different bonding times, there was no obvious change in the width of the diffusion zone. The shear strength of the bimetal at all holding times was reduced from a high level after heat treatment and decreased with increasing tempering temperature. The impact toughness of the bimetal substantially increased compared with that of the HCCI. After a quenching treatment, the impact toughness of the bimetal decreased, and the microhardness of the diffusion zone improved. As the tempering temperature increased, the microhardness and impact toughness decreased and increased, respectively.

36 MATERIALS SCIENCE↗

Braze alloy process and strength characterization studies for 18 nickel grade 200 maraging steel with application to wind tunnel models

A comprehensive study of braze alloy selection process and strength characterization with application to wind tunnel models is presented. The applications for this study include the installation of stainless steel pressure tubing in model airfoil sections make of 18 Ni 200 grade maraging steel and the joining of wing structural components by brazing. Acceptable braze alloys for these applications are identified along with process, thermal braze cycle data, and thermal management procedures. Shear specimens are used to evaluate comparative shear strength properties for the various alloys at both room and cryogenic (-300 F) temperatures and include the effects of electroless nickel plating. Nickel plating was found to significantly enhance both the wetability and strength properties for the various braze alloys studied. The data are provided for use in selecting braze alloys for use with 18 Ni grade 200 steel in the design of wind tunnel models to be tested in an ambient or cryogenic environment.

Bradshaw, James F.↗

Mechanics of Granular Materials (MGM)

The constitutive behavior of uncemented granular materials such as strength, stiffness, and localization of deformations are to a large extend derived from interparticle friction transmitted between solid particles and particle groups. Interparticle forces are highly dependent on gravitational body forces. At very low effective confining pressures, the true nature of the Mohr envelope, which defines the Mohr-Coulomb failure criterion for soils, as well as the relative contribution of each of non-frictional components to soil's shear strength cannot be evaluated in terrestrial laboratories. Because of the impossibility of eliminating gravitational body forces on earth, the weight of soil grains develops interparticle compressive stresses which mask true soil constitutive behavior even in the smallest samples of models. Therefore the microgravity environment induced by near-earth orbits of spacecraft provides unique experimental opportunities for testing theories related to the mechanical behavior of terrestrial granular materials. Such materials may include cohesionless soils, industrial powders, crushed coal, etc. This paper will describe the microgravity experiment, 'Mechanics of Granular Materials (MGM)', scheduled to be flown on Space Shuttle-MIR missions. The paper will describe the experiment's hardware, instrumentation, specimen preparation procedures, testing procedures in flight, as well as a brief summary of the post-mission analysis. It is expected that the experimental results will significantly improve the understanding of the behavior of granular materials under very low effective stress levels.

Alshibli, Khalid A.↗

Development of a compressive failure model for carbon fiber composites and associated uncertainties.

An approach to increase the value of carbon fiber for wind turbines blades, and other compressive strength driven designs, is to identify pathways to increase its cost-specific compressive strength. A finite element model has been developed to evaluate the predictiveness of current finite element methods and to lay groundwork for future studies that focus on improving the cost-specific compressive strength. Parametric studies are conducted to understand which uncertainties in the model inputs have the greatest impact on compressive strength predictions. Furthermore, a statistical approach is also presented that enables the micromechanical model, which is deterministic, to efficiently account for statistical variability in the fiber misalignment present in composite materials; especially if the results from the hexagonal and square pack models are averaged. The model was found to agree well with experimental results for a Zoltek PX-35 pultrusion. The sensitivity studies suggest that the fiber packing and the interface shear strength have the greatest impact on compressive strength prediction for the fiber reinforced polymer studied here. Based on the performance of the modeling approach presented in this work, it is deemed sufficient for future work which will seek to identify carbon fiber composites with improved cost-specific compressive strength.

36 MATERIALS SCIENCE↗

Correlation of fiber composite tensile strength with the ultrasonic stress wave factor

An ultrasonic-acoustic technique was used to indicate the strength variations of tensile specimens of a graphite-epoxy composite. A 'stress wave factor' was determined and its value was found to depend on variations of the fiber-resin bonding as well as fiber orientation. The fiber orientations studied were 0 deg (longitudinal), 10 deg (off-axis), 90 deg (transverse), (0 deg/+ or - 45 deg/0) symmetrical, and (+ or - 45 deg) symmetrical. The stress wave factor can indicate variations of the tensile and shear strengths of composite materials. The stress wave factor was also found to be sensitive to strength variations associated with microporosity and differences in fiber-resin ratio.

Vary, A.↗