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At least 361 records · Page 20

High-Cycle Fatigue Behavior of SiC-based Ceramic Matrix Composites (CMCs) at High Temperatures

High-cycle fatigue (HCF) behavior of a melt-infiltrated, pre-preg SiC/SiC ceramic matrix composite (CMC) was investigated using dogbone tensile specimens without and with simulated cooling holes at 1500 and 2400 °F. The CMC material used for this study was fabricated by GE Aviation and had a ply configuration of [0/90/0]3. HCF tests were conducted with an R-ratio of 0.6 and a cyclic frequency of 30 Hz. Runout in HCF was defined as 30 million cycles. Monotonic tensile tests were conducted at room temperature (RT) on as-received CMC specimens and on runout HCF specimens to determine residual tensile strengths. Digital image correlation (DIC) and acoustic emission (AE) techniques were used to monitor the initiation and progression of damage in RT tensile tests on specimens with and without holes. Microscopy was performed on the polished edge of specimens without cooling holes and on the polished face of specimens with cooling holes that were tested in HCF and achieved runout. Comparisons were made with baseline specimens. Fractography was performed to examine the fracture surfaces of samples that failed under different loading conditions.

Ceramic Matrix Composites↗

Tensile Behavior and High-Cycle Fatigue Durability of a SiC/SiC Ceramic-Matrix Composite Without and With Simulated Cooling Holes

High-cycle fatigue (HCF) behavior of a melt-infiltrated, prepreg SiC/SiC composite was investigated using specimens without and with simulated cooling holes at 816 and 1,316 °C. The ceramic-matrix composite (CMC) material used for this study was fabricated by GE Aviation and had a ply configuration of [0/90/0] 3 . HCF tests were conducted with an R-ratio of 0.6 and a cyclic frequency of 30 Hz. Maximum tensile gross-section stresses used in the HCF tests ranged from 152 to 359 MPa. Runout in HCF was defined as 30 million cycles (278 h) at both temperatures. Monotonic tensile tests were conducted at room temperature (RT) on as-received CMC specimens and on HCF runout specimens without and with holes to determine residual tensile strengths. Digital image correlation (DIC) and acoustic emission (AE) techniques were used to monitor progression of damage in RT tensile tests on specimens without and with holes. Fractography was performed on a limited number of specimens without and with holes to determine morphology of fracture surfaces. Representative RT stress-strain behavior, elevated temperature HCF behavior at the two temperatures, and RT residual tensile strengths of HCF runout specimens are documented in this report. Select examples of DIC and AE data from RT tensile tests on specimens without and with holes and typical features observed on fracture surfaces of specimens tested under tensile and HCF conditions are also discussed.

Ceramic matrix composite↗

Experimental Characterization of Non-Associative Plasticity Flow Rule Coefficients and Post-Peak Stress Degradation for the LS-DYNA MAT213 Model

This project is focused on developing an experimental framework for characterizing non-associative plasticity flow rule coefficients through coupon-scale tests for the LS-DYNA MAT213 model. The main objective is to characterize these coefficients based on the multi-scale (i.e., both microscopic and macroscopic) full-field measurement of the evolution of strain and stress fields. This paper focuses on presenting the experimental work on characterizing the full-scale stress-strain curves of T700/LM-PAEK composites under tension, compression, and shear loads. The experimental data set was intended to build a deformation sub-model in the MAT213 model for the material. The strain data were collected using both microscopic and macroscopic digital image correlation techniques. The microscopic technique was particularly useful for fracture cases under small strains. A preliminary simulation result obtained from the MAT213 model is also presented in the paper. The experimental framework herein will be extended to characterize post-peak stress degradation in the composite material and to develop a damage sub-model for the material. This project will contribute to developing a simulation tool based on the MAT213 model for simulating the rate-dependent impact damage in composites under multi-axial loading.

MAT213↗

Advances in Integrally Formed Metallic Structures

NASA Langley Research Center (LaRC) is applying flow forming technology to aerospace aluminum alloys for the manufacture of integrally stiffened cylinders that meet aircraft fuselage or launch vehicle specifications. High-strength 2xxx series alloys, in various temper/product form conditions, are being compared with medium-strength, very formable AA 6061 as the benchmark. Screening of candidate materials traditionally relies on empirical forming trials, but more recently on metrics derived from constant nominal strain rate tensile testing. In this work, the established hierarchy of formability metrics is adopted as the baseline; tensile area reduction, work hardening exponent, and modulus of resilience. The suite of metrics can be expanded based on phenomenological and mechanistic considerations of plastic flow instabilities to incorporate anisotropy ratio, rate of work hardening, and dynamic strain aging effects. Separate research thrusts at LaRC are aimed at formulating a protocol for scalable production of fully formed, defect-free components: 1) quantifying the extended set of formability metrics from constant and jump strain rate tensile tests with digital image correlation (DIC); 2) using statistically designed experiments on a vertical spin/flow forming facility (WF VUD-600®) to isolate the effect of convenient process variables, such as axial feed rate and thickness reduction; and 3) predicting the effect of feed ratio (roller translation relative to mandrel rotation speeds) on material response via process modeling using the DEFORM® simulation software. Current results will be discussed in terms of correlating intrinsic material properties with the bulk workability characteristics to successfully fabricate cylinders with complex cross-sections.

Aluminum↗

Pull-off Behavior of Stitched Composite T-Joints

T-joints are key structural elements that connect opposing surfaces, thereby providing the load path between flat or curved panels (i.e., upper and lower wing skins) and transverse components (i.e., stiffeners). Due to the low interlaminar strength of polymer matrix composites and their geometrical discontinuities, these joints are vulnerable to pull-off loads. To address these issues, through-thickness reinforcements can be employed to enhance the interlaminar capability of these type of joints. In this study, T-joints were manufactured using through-thickness stitching in dry carbon preforms and cured using the vacuum-assisted resin transfer molding (VARTM) process. Stitched and unstitched T-joints were tested under pull-off loading conditions, and surface strain fields were obtained using a 3D digital image correlation system. The ultimate load, displacement, and absorbed energy of the stitched T-joints were greater than their unstitched counterparts by approximately 16%, 34%, and 58%, respectively. Failure mechanisms were identified by examining fracture surfaces using optical microscopy. Results demonstrate that through-thickness stitching significantly improves the damage tolerance of T-joints, which highlights the effectiveness of stitching to enhance the structural integrity of large aerospace components.

VARTM↗

Using DIC for Long Slender Structures

High-strain composite deployable structures have been developed for systems such as solar arrays, camera masts or solar sailing propulsion elements. Composite booms in such applications are often flattened and then rolled into a small footprint for low-packaged volume and are then deployed in space. There is a need to obtain deformation for long, slender composite booms on earth through gravity offloading by suspending them vertically and applying distal end (tip) loads. Three-dimensional digital image correlation (3D-DIC), along with other measurement techniques, were used to obtain strain and displacement along the length of a 7.5 m subscale composite Triangular, Rollable, and Collapsible (TRAC) boom in preparation for full scale testing of a 30 m boom. However, incorporating 3D-DIC as a primary measurement tool on long, slender, high-aspect-ratio boom structures presents significant challenges. Challenges include small correlated area due to high aspect ratio, limited standoff distance due to size of test area, coordinate system alignment of multiple camera systems along the length of the boom, nodal mesh extraction for adequate test/analysis correlation, as well as measurement comparison between DIC and other instrumentation used such as fiber optic strain sensing (FOSS) and laser displacement tracking. The contents of the proposed paper will focus on techniques and methods for overcoming the previously mentioned challenges associated with applying 3D-DIC to long, slender boom structures. Results from subscale test along with lessons learned will be discussed.

Deployable Boom↗

Simulating High Energy Dynamic Impact of IM7/PEKK Continuous Fiber Laminated Thermoplastic Composite using Open Hole Coupon Experiments

The use of advanced thermoplastic composites (TPC) for structural applications in the aerospace and automotive industries has grown increasingly popular due to their high performance, high manufactured part output, and sustainability. Enhancing verification simulations of the progressive failure in TPCs at the coupon scale is needed to better validate advanced composite material models at larger length scales, such as element level panels. MAT_213, a tabulated composite material model, has been applied to simulate high velocity dynamic impact (HEDI) and is integrated in the LS-DYNA explicit finite element (FE) software. Previous efforts using MAT_213 have calibrated HEDI simulated failures with experimental data. Traditionally simulations have relied on a structured mesh to represent quasi-isotropic panels. For this study, a continuous fiber unidirectional tape, IM7/PEKK, was analyzed through a series of verification studies of notched laminate coupons, then validation analyses of quasi-isotropic panels under HEDI were compared with experimental data. Experiments using unidirectional TPC were performed to obtain tabulated stress vs strain curves using Digital Image Correlation (DIC) for input into MAT_213. Next, notched coupon experiments were used as an intermediate step to calibrate the damage and failure behavior in MAT_213. Lastly, investigations into differences between HEDI simulations using a fiber aligned mesh were compared with experimental failure patterns and damage sizes. The use of experimentally generated material behavior along with selective mesh layout improved HEDI predictions with minimal material parameter calibration.

Polymer matrix composites↗

Direct Impact Split-Hopkinson Bar Experiment for Compression Testing at Strain Rate of 50,000 S-1

A direct impact Hopkinson compression bar experiment is used for compression testing at strain rates in the order of 50,000 s-1. A short specimen mounted on the cross-section surface of a transmitter bar is impacted directly by a projectile (the incident bar in the classical split Hopkinson bar is eliminated).The quantities measured in the test are the projectile impact velocity, the force in the transmitter bar and the strain on the surface of the specimen, which is measured using the digital image correlation method with high-speed cameras. The deformation measurements show a nonuniform deformation in the specimen. To study the strain rate sensitivity properties of the specimen’s material, the experiment is simulated using an assumed material model properties which is validated by comparing the calculated and measured quantities. For aluminum 2024-T351 the results show a small strain rate sensitivity (increase of stress with strain rate) at strain rates above 10,000 s-1.

Nathan Spulak↗

An Overview of Nuclear Thermal Rocket Element Environmental Simulator (NTREES) Capabilities, Upgrades, and Overlaps in Advanced Material Testing Areas

The Nuclear Thermal Rocket Element Environmental Simulator (NTREES) was designed to perform non-nuclear testing of nuclear thermal rocket (NTR) fuel elements and materials. NTREES can simulate the thermal hydraulic environment within the reactor of an NTR and has been leveraged to provide data on the thermochemical, thermomechanical and thermohydraulic performance of components and materials. Active upgrades to the NTREES facility include installing a DC power supply for DC powered joule heating, a supply gas chiller for a cryogenically cool gas supply, gas pre-heaters with sample holders for testing samples too small to be inductively heated by bathing them in hot gas, and a high temperature digital image correlation (DIC) capability for measuring high temperature strains real time. In addition to NTR testing, given the commonality of high enthalpy flow environments between the reactor of an NTP engine and the aerothermal heating of high-speed flight, the unique capabilities of NTREES to provide high temperature gas flows at high pressure without combustion or electrode spallation byproducts may lend itself to additional usage of the facility beyond the original intent.

Michael P Schoenfeld↗

In-Situ Scanning Electron Microscope Experiments for Microscale Mechanical Testing and Validated Modeling of Fiber Reinforced Thermoplastics

A novel, in-situ, scanning electron microscope (SEM) mechanical testing capability for materials at the microscale which provides experimental validation to a machine learning (ML) toolset for full-field validation of physics-based micromechanics models is being developed by researchers at NASA Glenn Research Center. These are enabling technologies for the integration of multiscale digital twins for materials into system level models which will result in the improved performance, material discovery, reduced production cost and time, rapid characterization, and prognostic structural health monitoring (SHM) for materials and structures for extreme environments in support of NASA space exploration missions. In order to bridge the material structure-to-system gap for digital twins, physics-based models must be experimentally validated at multiple length scales. Seminal microscale experiments, conducted at the Air Force Research Laboratory (AFRL), were limited to transverse compression of single-layer, unidirectional thermoset polymer matrix composite (PMC) micropillar specimens [1]. The early phases of the current project followed those initial results and setup to reproduce the compression testing of PMC material on the custom-built piezoelectric actuated micromechanical testing rig built by MicroTesting Solutions LLC. In this work, samples of thermoplastic PMC material were first machined into 3 mm cubes, and then further machining and final milling was done using a Focused Ion Beam (FIB). The initial experiment was done on a pillar roughly 20 µm x 20 µm x 40 µm tall. Additional pillars were milled with final sizes ranging from 20 µm x 20 µm x 40 µm tall to 40 µm x 40 µm x 65 µm tall. A speckle pattern for in-situ full-field measurements using Digital Image Correlation (DIC) was applied with platinum, which was coated on the surface, and then the FIB was used to mill away some of the coating to produce an irregular pattern of Pt on the pillar surface. The samples were loaded into the custom testing rig and placed into the SEM and loaded under compression until failure. Images were collected in the SEM during testing. Post-processing of the images was conducted using DIC to obtain full-field displacement and strain measurements elucidating the role of the matrix as well as fiber-fiber interaction at the microscale within the composite subjected to compression loading well into the non-linear regime of the material. Moreover, the evolution of fiber-matrix debonding and matrix cracking is observed in-situ at the microscale. This data, along with images segmented with a newly developed ML toolset [2], was used to create and validate physics-based micromechanics models. An image of the failed micropillar is shown in Figure 1. The techniques developed in the initial compression experiment was tailored to the validation needs of the models and expanded to include different sized samples as well as possibly tension and fatigue.

Laura Wilson↗

Shear Assisted Processing and Extrusion of Aluminum Alloy 7075 Tubing at High Speed

Conventional extrusion of aluminum alloy 7075 is limited to 1-2 meters per minute in order to avoid surface tearing and cracking. An emerging technique called Shear Assisted Processing and Extrusion (ShAPE) was used to extrude aluminum alloy 7075 tubing at a speed of 7.4 meters per minute without inducing surface defects. The faster extrusion speed is attributed to the unique flow characteristics inherent to the ShAPE process compared to conventional extrusion. Tubes with an inner diameter of 10 mm, outer diameter of 12 mm, and length of 2 meters were extruded at temperatures ranging from 340°C to 466°C. Tensile testing was performed per ASTM B557-15 with strain measured using digital image correlation. An ultimate tensile strength of 565 ± 4.6 MPa, yield strength of 496 ± 8.7 MPa, and elongation of 16.4 ± 1.0 % were measured for extrusion made at 362°C and heat treated to the T6 condition.

Shear Assisted Processing and Extrusion, Friction ↗

Development of scalable design optimization parameters for bi-component protective systems

Bi-component protection-systems need to withstand a variety of extreme loading conditions such as high-velocity projectile impact to shock and blast mitigation. The large number of parameters at each stage of bi-component protection system design process results in a near-infinite number of possible variables for optimization. The aim of this project is to identify the scaling laws linking material and geometric scales of the problem to the final impact performance, further including the effects of wave propagation/interaction and inter-component bonding. Specifically, the impact dynamics for different optimal projectile/target density ratios and relative component mass fractions are quantified for bonded ceramic/titanium alloy systems. The impact behavior such as wave mechanics and damage propagation within the target system is characterized and quantified via digital image correlation or via x-ray phase-contrast imaging.

36 MATERIALS SCIENCE↗

Baseline Graphite Characterization

Presentation will include baseline graphite characterization information, such as purpose and results, baseline property measurements, baseline graphite characterization method, baseline progress, split disc tensile strength: ASTM Tensile Strength Alternative, Identification of proper split disk fracture, baseline graphite ASTM D8289, horizontal orientation, digital image correlation, and DIC Analyzation.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Design, Fabrication and Testing of Surveillance Test Articles for MSR Materials Degradation Management

This report details the design, fabrication, and testing of surveillance test articles aimed at assessing material damage in reactor-relevant environments for effective degradation management. Two types of surveillance test articles with reduced sizes were developed based on design algorithms and finite element modeling: welded design and interlocking design. A furnace heating setup was adopted to apply multiple thermal cyclic loading profiles on the test articles with a temperature range of 500°C - 700°C, while the strain response was monitored using a digital image correlation technique. The testing results demonstrated the successful capturing of expected strain range for welded design while machining tolerance should be improved to engage strain coupling in the interlocking design. Mid-term (500 hours) and long-term (1500 hours) cyclic tests were conducted on welded test articles. A constant strain range of ~0.6% was observed at the specimen with testing under 500 hours, while a gradual decrease of strain at specimen was observed after 500 hours. Non-destructive evaluation through X-ray computed tomography confirmed the microcracks in the welds at specimen-driver joints after cyclic test that caused the strain change. Creep testing of the specimen after long-term cyclic test revealed a short creep life than expected. A multi-profile cyclic test was also conducted on a test article and demonstrated consistent strain response under different temperature ramp rates. The report also briefly discussed the challenges and future research efforts to advance test article development for material surveillance.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Advanced Manufactured Strain Sensors for Extreme Environments

Experimentation at irradiation test facilities are essential for reducing the innovation time of developmental fuels, fuel cladding, and structural materials employed in next-generation nuclear reactors. However, due to the harsh conditions generated in such reactors and limited instrumentation space, the evaluation of a material’s mechanical properties is often limited to characterization after the materials have been removed from reactor conditions, or post-irradiation examination. These experiments are costly, time-consuming, and fail to capture the critical time-evolving phenomena that occur during the irradiation experiments. Advanced manufactured digital image correlation patterns and strain sensor devices serve as two promising technologies that can be deployed in the confined and challenging orientations of these irradiation experiments while also providing key insight on salient materials phenomena (i.e., mechanical properties). To guide the development of the printed strain sensors prior to their deployment in critical experiments, the adhesion strength between the substrate and printed film interface is measured via tensile testing and a non-contact laser-induced spallation technique. The establishment of these process control steps helped guide the successful fabrication and testing of direct-write strain sensing devices discussed in this work. The fabrication process controls are necessary for enabling the sustained operation of these strain sensing device through experimentation and minimize the potential for premature failure.

36 - MATERIALS SCIENCE↗

Microstructural Characteristics, Mechanical Properties, and Corrosion Behavior of Field-Assisted Diffusion Welded Alloy 617

This study investigated the microstructural characteristics, mechanical response, and corrosion resistance of Alloy 617 diffusion welded by electric field-assisted sintering (EFAS). The microstructure exhibited good grain boundary (GB) migration across the interface and flat interface in the samples bonded at different conditions. Graded grain size was observed, with grain coarsening being more significant near sample surface due to EFAS-induced temperature gradient. Tensile testing revealed that the specimens fractured in the matrix away from the interface. The peak strength of 807 MPa was obtained in the samples welded at 1000°C. The materials obtained at 1100°C exhibited reduced tensile strength but improved ductility. Strain maps revealed by digital image correlation showed the flat interfaces were less ductile compared to the matrix. The hardness reduced near sample surfaces due to enlarged grains induced by temperature gradient. The interfaces with GB migration exhibited improved corrosion resistance in molten salt compared to the flat interfaces.

36 - MATERIALS SCIENCE↗

Advanced Manufactured Strain Sensors for Extreme Environments

Experimentation at irradiation test facilities are essential for reducing the innovation time of developmental fuels, fuel cladding, and structural materials employed in next-generation nuclear reactors. However, due to the harsh conditions generated in such reactors and limited instrumentation space, the evaluation of a material’s mechanical properties is often limited to characterization after the materials have been removed from reactor conditions, or post-irradiation examination. These experiments are costly, time-consuming, and fail to capture the critical time-evolving phenomena that occur during the irradiation experiments. Advanced manufactured digital image correlation patterns and strain sensor devices serve as two promising technologies that can be deployed in the confined and challenging orientations of these irradiation experiments while also providing key insight on salient materials phenomena (i.e., mechanical properties).To guide the development of the printed strain sensors prior to their deployment in critical experiments, the adhesion strength between the substrate and printed film interface is measured via tensile testing and a non-contact laser-induced spallation technique. The establishment of these process control steps helped guide the successful fabrication and testing of direct-write strain sensing devices discussed in this work. The fabrication process controls are necessary for enabling the sustained operation of these strain sensing device through experimentation and minimize the potential for premature failure.

36 - MATERIALS SCIENCE↗

ELASTOMERIC MICROVASCULAR SELF-HEALING MATERIALS

Damaged elastomeric diaphragms within pneumatic controllers used in the oil and gas industry lead to an unintended release of methane. Self-healing microvascular materials capable of healing various types of damage have been fabricated. These microvascular materials are designed to replace currently available commercial diaphragms found in pneumatic controllers and provide a solution to reduce unintended methane leaks. Poly(dimethylsiloxane) (PDMS) was used as the main matrix material, with additional testing conducted on polyurethane and flexibilised epoxy materials. Microvascular networks were implemented into the elastomeric membranes to act as ves- sels to deliver healing agents to the damaged areas. The complex, interdigitated channel networks were created using a 3D printed custom compounded filament composed of polylactic acid (PLA) and tin(II) oxalate. Two-part liquid casting polymers were poured around the channels into a mould to create samples with the scaffolding of the microvascular channels intact. Hollow microvascular networks were created by placing the samples within a vacuum oven at 250◦C which causes the thermal depolymerisation of PLA into its gaseous monomers. The manufactured materials were placed in test stands and pressurized using nitrogen gas to determine their healing and mechanical behaviour. Self-healing behaviour was demonstrated using PDMS matrix materials and healing chemistries within a pressure test cell. This test cell was designed to detect any damage to a sample by record- ing an outlet pressure. Damages including puncture holes, diagonal cuts and star-shaped central iv cuts were applied to the samples and a reduction in the outlet pressure was recorded for all sam- ples. A variation in channel spacing and diameter was studied to determine the optimal design of the microvascular network for self-healing performance. The mechanical performance of elastomeric membrane materials within a diaphragmatic pressurised stand was observed. Deformations and strains around the channels and channel inter- sections at the midplane of the materials were recorded using digital image correlation. Normal stresses were calculated using Hooke’s law and the material properties of the PDMS matrix. A reduction in leak rate, implying the success of self-healing, was recorded within manu- factured diaphragm samples tested within a commercial valve. PDMS is the favourable material when compared to polyurethane and flexibilised epoxy for creating

03 NATURAL GAS↗