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NASA NTRS2014

Structural Characterization of Lateral-grown 6H-SiC am-plane Seed Crystals by Hot Wall CVD Epitaxy

The performance of commercially available silicon carbide (SiC) power devices is limited due to inherently high density of screw dislocations (SD), which are necessary for maintaining polytype during boule growth and commercially viable growth rates. The NASA Glenn Research Center (GRC) has recently proposed a new bulk growth process based on axial fiber growth (parallel to the c-axis) followed by lateral expansion (perpendicular to the c-axis) for producing multi-faceted m-plane SiC boules that can potentially produce wafers with as few as one SD per wafer. In order to implement this novel growth technique, the lateral homoepitaxial growth expansion of a SiC fiber without introducing a significant number of additional defects is critical. Lateral expansion is being investigated by hot wall chemical vapor deposition (HWCVD) growth of 6H-SiC am-plane seed crystals (0.8mm x 0.5mm x 15mm) designed to replicate axially grown SiC single crystal fibers. The post-growth crystals exhibit hexagonal morphology with approximately 1500 m (1.5 mm) of total lateral expansion. Preliminary analysis by synchrotron white beam x-ray topography (SWBXT) confirms that the growth was homoepitaxial, matching the polytype of the respective underlying region of the seed crystal. Axial and transverse sections from the as grown crystal samples were characterized in detail by a combination of SWBXT, transmission electron microscopy (TEM) and Raman spectroscopy to map defect types and distribution. X-ray diffraction analysis indicates the seed crystal contained stacking disorders and this appears to have been reproduced in the lateral growth sections. Analysis of the relative intensity for folded transverse acoustic (FTA) and optical (FTO) modes on the Raman spectra indicate the existence of stacking faults. Further, the density of stacking faults is higher in the seed than in the grown crystal. Bundles of dislocations are observed propagating from the seed in m-axis lateral directions. Contrast extinction analysis of these dislocation lines reveals they are edge type basal plane dislocations that track the growth direction. Polytype phase transition and stacking faults were observed by high-resolution TEM (HRTEM), in agreement with SWBXT and Raman scattering.

Single Crystal↗

NASA NTRS1985

The dynamic response of composite beams to axial impact

Large deformation response of simple composite structural elements to intense dynamic loadings is studied by focusing on the response of beams. Overall goals are to: design a simple test fixture to introduce crash related bending loads in beams; determine any difference between large deformation static and large deformation dynamic response; determine the influence of laminate stacking arrangements on the dynamic response, failure mode, and energy absorbed; and predict the dynamic response. Twelve different laminate orientations were investigated. Modeling of the response was done with an existing finite element program. The program computed nonlinear transient response analysis of a structure objected to a time varying load.

Derian, E. J.↗

NASA NTRS1990

Experimental observations and finite element analysis of the initiation of fiber microbuckling in notched composite laminates

A better understanding of the factors that affect the semi-circular edge-notched compressive strength is developed, and the associated failure mode(s) of thermoplastic composite laminates with multidirectional stacking sequences are identified. The primary variables in this investigation are the resin nonlinear shear constitutive behavior, stacking sequence (orientation of plies adjacent to the 0 degree plies), resin-rich regions between the 0 degree plies and the off-axis supporting plies, fiber/matrix interfacial bond strength, and initial fiber waviness. Two thermoplastic composite material systems are used in this investigation. The materials are the commercial APC-2 (AS4/PEEK) and a poor interface experimental material, AU4U/PEEK, designed for this investigation. Notched compression specimens are studied at 21, 77, and 132 C. Geometric and material nonlinear two-dimensional finite element analysis is used to model the initiation of fiber microbuckling of both the ideal straight fiber and the more realistic initially wavy fiber. The effects of free surface, fiber constitutive properties, matrix constitutive behavior, initial fiber curvature, and fiber/matrix interfacial bond strength on fiber microbuckling initiation strain levels are considered.

Guynn, E. Gail↗

NASA NTRS1991

Evaluation of some scale effects in the response and failure of composite beams

The feasibility of using scale model testing for predicting full-scale behavior of composite beams loaded in tension and flexure was investigated. Classical laws of similitude were applied to fabricate and test replica model beams to identify scaling effects in the load response, strength, and mode of failure. Experiments were conducted using graphite-epoxy composite beams having different laminate stacking sequences and a range of scaled sizes. Results indicated that the elastic response of scaled composite beams was independent of specimen size. However, a significant scale effect in strength was observed. In addition, a transition in failure mode was observed among scaled beams of certain laminate stacking sequences. Weibull statistical and fracture mechanics based models were applied to predict the strength scale effect since standard failure criteria cannot account for the influence of absolute specimen size in failure.

Jackson, Karen E.↗

NASA NTRS1992

Scale effects in the response and failure of fiber reinforced composite laminates loaded in tension and in flexure

The feasibility of using scale model testing for predicting the full-scale behavior of flat composite coupons loaded in tension and beam-columns loaded in flexure is examined. Classical laws of similitude are applied to fabricate and test replica model specimens to identify scaling effects in the load response, strength, and mode of failure. Experiments were performed on graphite-epoxy composite specimens having different laminate stacking sequences and a range of scaled sizes. From the experiments it was deduced that the elastic response of scaled composite specimens was independent of size. However, a significant scale effect in strength was observed. In addition, a transition in failure mode was observed among scaled specimens of certain laminate stacking sequences. A Weibull statistical model and a fracture mechanics based model were applied to predict the strength scale effect since standard failure criteria cannot account for the influence of absolute specimen size on strength.

Jackson, Karen E.↗

NASA NTRS1990

Damage states in laminated composite three-point bend specimens: An experimental-analytical correlation study

Damage states in laminated composites were studied by considering the model problem of a laminated beam subjected to three-point bending. A combination of experimental and theoretical research techniques was used to correlate the experimental results with the analytical stress distributions. The analytical solution procedure was based on the stress formulation approach of the mathematical theory of elasticity. The solution procedure is capable of calculating the ply-level stresses and beam displacements for any laminated beam of finite length using the generalized plane deformation or plane stress state assumption. Prior to conducting the experimental phase, the results from preliminary analyses were examined. Significant effects in the ply-level stress distributions were seen depending on the fiber orientation, aspect ratio, and whether or not a grouped or interspersed stacking sequence was used. The experimental investigation was conducted to determine the different damage modes in laminated three-point bend specimens. The test matrix consisted of three-point bend specimens of 0 deg unidirectional, cross-ply, and quasi-isotropic stacking sequences. The dependence of the damage initiation loads and ultimate failure loads were studied, and their relation to damage susceptibility and damage tolerance of the mean configuration was discussed. Damage modes were identified by visual inspection of the damaged specimens using an optical microscope. The four fundamental damage mechanisms identified were delaminations, matrix cracking, fiber breakage, and crushing. The correlation study between the experimental results and the analytical results were performed for the midspan deflection, indentation, damage modes, and damage susceptibility.

Starbuck, J. Michael↗

NASA NTRS1985

Fatigue Damage in Notched Composite Laminates Under Tension-Tension Cyclic Loads

The results are given of an investigation to determine the damage states which develop in graphite epoxy laminates with center holes due to tension-tension cyclic loads, to determine the influence of stacking sequence on the initiation and interaction of damage modes and the process of damage development, and to establish the relationships between the damage states and the strength, stiffness, and life of the laminates. Two quasi-isotropic laminates were selected to give different distributions of interlaminar stresses around the hole. The laminates were tested under cyclic loads (R=0.1, 10 Hz) at maximum stresses ranging between 60 and 95 percent of the notched tensile strength.

Stinchcomb, W. W.↗

NASA NTRS1990

The effects of transverse shearing and anisotropy on vibration frequencies of laminated cylinders

The natural vibration frequencies of orthotropic and anisotropic, simply supported right circular cylinders are predicted using a theory which takes into account higher-order transverse shear deformation effects. A comparison between results based on first-order transverse shear deformation theory and the higher-order theory indicates that an additional allowance for transverse shear deformation has a negligible effect on the predicted natural vibration frequencies associated with long wavelengths, but significantly reduces the natural vibration frequencies associated with short wavelengths. Results of a parametric study of ply orientation for two classes of laminates indicates that while stacking sequence affects natural vibration frequencies, cylinder geometry and mode shape are more important in accurately predicting transverse shear deformation effects. Transverse shearing effects are less important in predicting natural vibration frequencies associated with long wavelength than in predicting axial compressive buckling loads.

Jegley, D. C.↗

NASA NTRS1978

Configuration analysis of nickel hydrogen cell

The significance of various stack configurations and components on the cycle life for nickel hydrogen cells for synchronous orbit used was evaluated. Failure modes of electrolyte management and 02 management were solved by modifications in the reservoir, the wick, and/or the stack configuration.

Holleck, G.↗

NASA NTRS2008

Unitized regenerative fuel cell system

A Unitized Regenerative Fuel Cell system uses heat pipes to convey waste heat from the fuel cell stack to the reactant storage tanks. The storage tanks act as heat sinks/sources and as passive radiators of the waste heat from the fuel cell stack. During charge up, i.e., the electrolytic process, gases are conveyed to the reactant storage tanks by way of tubes that include dryers. Reactant gases moving through the dryers give up energy to the cold tanks, causing water vapor in with the gases to condense and freeze on the internal surfaces of the dryer. During operation in its fuel cell mode, the heat pipes convey waste heat from the fuel cell stack to the respective reactant storage tanks, thereby heating them such that the reactant gases, as they pass though the respective dryers on their way to the fuel cell stacks retrieve the water previously removed.

Burke, Kenneth A.↗

NASA NTRS1989

Experimental observations and finite element analysis of the initiation of fiber microbuckling in notched composite laminates

An understanding was developed of the factors that determine the semi-circular edge-notched compressive strength and the associated failure mode(s) were identified of thermoplastic composite laminates with multidirectional stacking sequences. The experimental observations and the detailed literature review suggest at least four factors that affected the determination of the strain levels at which fiber microbuckling initiates and thus, partially control the composite's compression strength. The dependent variables studied are the compressive strength of a reduced gage section compression specimen and the compression strength of a compression specimen with two semi-circular edge notches (no opposite free edges) centered along the gage section. In this research, specimens containing two semi-circular edge notches (no opposite free edges) were loaded in compression at a relatively slow rate to provide more stable development of fiber microbuckling damage. The results indicate that the local constraints (free surfaces, supporting ply orientation, and resin-rich regions) significantly affect the strain level for the initiation of in-plane fiber microbuckling. Preliminary results at an elevated temperature, 77 C, showed the shear stress yield strength of the resin was reduced and consequently, the resistance to fiber microbuckling was also reduced. The finite element analysis of the perfectly straight fiber problem indicates that the free surface effect causes a 10 percent reduction in the critical buckling strain. However, the experimentally measured reduction for fibers with an initial fiber curvature, was 35 percent.

Guynn, E. Gail↗

NASA NTRS1989

Damage and fracture of composite materials under cyclic loads

The response of composite laminates to long-term, cyclic loading conditions is dependent on mode and level of loading, material system, geometry, and laminate stacking sequence. An overview of basic damage mechanisms in notched laminates is presented. The relationships between damage and long-term response, specifically changes in residual tensile and compressive strength and life, are discussed for several composite systems with different matrix materials subjected to reversed cyclic loading.

Stinchcomb, Wayne W.↗

NASA NTRS1990

Strength Scaling in Fiber Composites

A research program was initiated to study and isolate the factors responsible for scale effects in the tensile strength of graphite/epoxy composite laminates. Four layups were chosen with appropriate stacking sequences so as to highlight individual and interacting failure modes. Four scale sizes were selected for investigation including full scale size, 3/4, 2/4, and 1/4, with n = to 4, 3, 2, and 1, respectively. The full scale specimen sizes was 32 piles thick as compared to 24, 16, and 8 piles for the 3/4, 2/4, and 1/4 specimen sizes respectively. Results were obtained in the form of tensile strength, stress-strain curves and damage development. Problems associated with strength degradation with increasing specimen sizes are isolated and discussed. Inconsistencies associated with strain measurements were also identified. Enhanced x ray radiography was employed for damage evaluation, following step loading. It was shown that fiber dominated layups were less sensitive to scaling effects compared to the matrix dominated layups.

Kellas, Sotiris↗

NASA NTRS1991

Strength scaling in fiber composites

A research program was initiated to study and isolate the factors responsible for scale effects in the tensile strength of graphite/epoxy composite laminates. Four layups were chosen with appropriate stacking sequences so as to highlight individual and interacting failure modes. Four scale sizes were selected for investigation including full scale size, 3/4, 2/4, and 1/4, with n = to 4, 3, 2, and 1, respectively. The full scale specimen sizes was 32 piles thick as compared to 24, 16, and 8 piles for the 3/4, 2/4, and 1/4 specimen sizes respectively. Results were obtained in the form of tensile strength, stress-strain curves and damage development. Problems associated with strength degradation with increasing specimen sizes are isolated and discussed. Inconsistencies associated with strain measurements were also identified. Enchanced X-ray radiography was employed for damage evaluation, following step loading. It was shown that fiber dominated layups were less sensitive to scaling effects compared to the matrix dominated layups.

Kellas, Sotiris↗

NASA NTRS2010

Ares I-X Launch Vehicle Modal Test Overview

The first test flight of NASA's Ares I crew launch vehicle, called Ares I-X, is scheduled for launch in 2009. Ares IX will use a 4-segment reusable solid rocket booster from the Space Shuttle heritage with mass simulators for the 5th segment, upper stage, crew module and launch abort system. Flight test data will provide important information on ascent loads, vehicle control, separation, and first stage reentry dynamics. As part of hardware verification, a series of modal tests were designed to verify the dynamic finite element model (FEM) used in loads assessments and flight control evaluations. Based on flight control system studies, the critical modes were the first three free-free bending mode pairs. Since a test of the free-free vehicle is not practical within project constraints, modal tests for several configurations in the nominal integration flow were defined to calibrate the FEM. A traceability study by Aerospace Corporation was used to identify the critical modes for the tested configurations. Test configurations included two partial stacks and the full Ares I-X launch vehicle on the Mobile Launcher Platform. This paper provides an overview for companion papers in the Ares I-X Modal Test Session. The requirements flow down, pre-test analysis, constraints and overall test planning are described.

Buehrle, Ralph D.↗

NASA NTRS2007

Cohesive Elements for Shells

A cohesive element for shell analysis is presented. The element can be used to simulate the initiation and growth of delaminations between stacked, non-coincident layers of shell elements. The procedure to construct the element accounts for the thickness offset by applying the kinematic relations of shell deformation to transform the stiffness and internal force of a zero-thickness cohesive element such that interfacial continuity between the layers is enforced. The procedure is demonstrated by simulating the response and failure of the Mixed Mode Bending test and a skin-stiffener debond specimen. In addition, it is shown that stacks of shell elements can be used to create effective models to predict the inplane and delamination failure modes of thick components. The results indicate that simple shell models can retain many of the necessary predictive attributes of much more complex 3D models while providing the computational efficiency that is necessary for design.

Davila, Carlos G.↗

NASA NTRS2007

Effective Simulation of Delamination in Aeronautical Structures Using Shells and Cohesive Elements

Davila, Carlos G.↗

NASA NTRS2019

Characterization of IM7/8552 Thin-Ply and Hybrid Thin-Ply Composites

Composite materials have increasingly been used for aerospace applications due to improved performance and reduced weight compared to their metallic counterparts. Inclusion of thin-ply material, plies with cured thickness half or less than standard composites, have potential to improve performance and reduce structural weight. Limited characterization of thin-ply IM7/8552 material in 30 and 70 grams per square meter fiber areal weights has been carried out using a series of selected American Society for Testing and Materials (ASTM) tests. Tests included unnotched tension, unnotched compression, v-notched rail shear, open-hole tension, and open-hole compression. Unidirectional, cross-ply, quasiisotropic and hybrid hard laminates were included in the study, and were compared to standard-ply laminates. Properties compared include fiber volume, laminate moduli, and failure strength, with failure modes also being examined. The thin-ply specimens exhibited similar or superior performance to standard ply laminates in many of the cases compared. Improvements in strength for laminates containing thin-ply material were seen for unidirectional laminates under unnotched tension, quasi-isotropic laminates under unnotched tension and compression, and hard laminates under open hole tension. Additional investigation is required to determine appropriate ply stacking rules for hybrids of thin and standard plies to avoid undesirable failure modes such as axial splitting. However, the observed performance improvements demonstrated by the conducted ASTM tests of hybrid thin-ply hard laminates could have benefits for improved structural weight in aircraft.

Lovejoy, Andrew E.↗