A Refined Mechanical Impact (G86) Test and Data Analysis Strategy for Composites LOX Compatibility Evaluation
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Susana A Harper↗
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Low-Velocity Impact Performances of Healed Polymer Fiber Reinforced Plastics
Extending the lifecycle of traditional carbon or glass fiber-reinforced plastics is a complicated problem. The lack of sustainability limits the applications of the traditional composite materials in the vehicle industries where recycling and repurposing are critical issues. Alternatives for the low-stressed structural components are polymer fiber-reinforced plastics (PFRPs). In PFRPs, both the fibers and matrix are composed of thermoplastic polymers (e.g. polypropylene or polyethylene). They are lightweight, easy to manufacture, and cost-effective. Additionally, recycling and repurposing thermoplastic polymers are well understood. Therefore, the PFRPs have strong advantages compared to the traditional fiber-reinforced composites in low-stressed structural applications. In this study, we investigated the low-velocity impact (LVI) performances of the PFRPs and compared them with carbon fiber-reinforced plastics (CFRPs). A semi-spherical impactor was dropped to flat, square panels, and the absorbed impact energy was measured. The damage mechanisms were examined using a Xray µCT scan. The PFRPs outperformed the CFRPs in terms of perforation energy normalized by plate thickness and density. After the perforation, we healed the fractured plates by leveraging the recyclability of the thermoplastic polymers. The healing process of the panels was identical to the initial panel manufacturing process. No additional materials were added during the healing process. The healed PFRP panels were impacted again and substantially recovered energy absorption capability. We also conducted the repeated-impact test with several different impact energies. Unlike the CFRPs where the impact peak load decreased as the impacts repeated, the PFRPs showed an increasing trend. Such a unique mechanism was due to the strain-hardening behavior of the polymer fibers and matrix. As a result, the repeated-impact life of the PFRPs was significantly enhanced. These results are particularly interesting in the automotive or aerospace industries where repeated LVI is frequently observed.
Ko, Seunghyun↗
Vertical Drop Testing and Simulation of Anthropomorphic Test Devices
A series of 14 vertical impact tests were conducted using Hybrid III 50th Percentile and Hybrid II 50th Percentile Anthropomorphic Test Devices (ATDs) at NASA Langley Research Center. The purpose of conducting these tests was threefold: to compare and contrast the impact responses of Hybrid II and Hybrid III ATDs under two different loading conditions, to compare the impact responses of the Hybrid III configured with a nominal curved lumbar spine to that of a Hybrid III configured with a straight lumbar spine, and to generate data for comparison with predicted responses from two commercially available ATD finite element models. The two loading conditions examined were a high magnitude, short duration acceleration pulse, and a low magnitude, long duration acceleration pulse, each created by using different paper honeycomb blocks as pulse shape generators in the drop tower. The test results show that the Hybrid III results differ from the Hybrid II results more for the high magnitude, short duration pulse case. The comparison of the lumbar loads for each ATD configuration show drastic differences in the loads seen in the spine. The analytical results show major differences between the responses of the two finite element models. A detailed discussion of possible sources of the discrepancies between the two analytical models is also provided.
Polanco, Michael A.↗
Boride-Carbon Hybrid Technology for Ultra-Wear and Corrosive Conditions
This work discusses a study on a surface treatment for creating extremely durable low-friction, wear and corrosion-resistant surfaces for tribological components in harsh conditions. A duplex surface treatment was developed that combines the advantages of ultra-fast electrochemical boriding with those of hard tetrahedral amorphous carbon coatings. The friction and wear properties of the duplex treatment are compared to the boride-only treatment of AISI 1045 steel, while corrosion and contact fatigue behaviors of the duplex layer are compared to that of the single-layer carbon coating on low carbon steel. The duplex treatment yields wear rates as low as 6 × 10−8 mm3·N−1·m−1 and a coefficient of friction of 0.14 when tested against a steel counter face. The contact fatigue impact tests reveal that the high hardness of 1200 HV0.05 of the borided layer in the duplex treatment leads to higher resistance against indentation but is accompanied by a higher incidence of crack initiation, being in good agreement with the finite-element modeling of nanoindentation results. The duplex coatings exhibit resistance to pinhole corrosion as evidenced by a 3 h exposure to 15% HCl at room temperature.
36 MATERIALS SCIENCE↗
DROP DURABILITY ASSESSMENT OF ELECTRONIC ASSEMBLIES UNDER OFF-AXIS LOADING WITH SKEWED FIXTURES
This thesis studies drop durability of electronic assemblies when the acceleration vector is oriented at 45° to the out-of-plane direction of the circuit card. The off-axis drop tests are accomplished with a skewed fixture and are conducted as a proxy for multiaxial drop testing. Advanced shock testing and vibration test methods have been developed over the last few decades to better represent real-world field environments during ground-based laboratory testing. However, many of these test methods require expensive and specialized equipment not available in most laboratories. An alternative approach for approximating simultaneous loading along multiple axes on conventional equipment utilizes skewed fixtures which have seen use in off-axis random vibration and drop impact testing. These methods generally rely on the conversion of a uniaxial input load from the test equipment (using a uniaxial drop tower or shaker) into a multiaxial load when resolved in the reference frame of the test article (mounted on a skewed fixture). Skewed fixture design is presented and recommendations for conducting skewed angle drop testing are introduced based on local measurements along the skewed face of the fixture to accurately monitor the impact event. Characterization tests were performed with a skewed fixture, at simultaneous acceleration loads from 500 to 3,000 g in two (in-plane and out-of-plane) directions, while meeting standard time domain tolerances. Upon experimental characterization, drop shock durability tests were conducted on a printed circuit assembly (PCA). Mean drops-to-failure were measured and quantified with Weibull statistics. Dominant solder joint failure modes were identified via failure analysis. Prior work on inclined angle impact testing is limited, and the majority of solder joint interconnect level fatigue studies are conducted considering perpendicular loading normal the circuit card. Low-cycle fatigue curves are generated based on plastic strain and plastic work density within the solder joint. A multiscale nonlinear finite element model is used to relate board-level flexure to solder joint interconnect level plastic strain. A high strain rate solder constitutive model allows for accurate modeling of solder plasticity resulting from high-impact drop shock. Fatigue parameters are computed from the Coffin-Manson relation and Palmgren-Miner damage accumulation. This work serves to apply established low-cycle fatigue methods for conventional drop shock loading (impact normal to circuit card) to non-perpendicular loading with a skewed fixture.
Hower, Jonathan [Kansas City National Security Cam↗
Impact damage resistance and residual property assessment of (0/+/-45/90)s SCS-6/Timetal 21S
The impact damage resistance and residual mechanical properties of (0/ +/- 45/90)s SCS-6/Timetal 21S composites were evaluated. Both quasi-static indentation and drop-weight impact tests were used to investigate the impact behavior at two nominal energy levels (5.5 and 8.4 J) and determine the onset of internal damage. Through x-ray inspection, the extent of internal damage was characterized non-destructively. The composite strength and constant amplitude fatigue response were evaluated to assess the effects of the sustained damage. Scanning electron microscopy was used to characterize internal damage from impact in comparison to damage that occurs during mechanical loading alone. The effect of stacking sequence was examined by using specimens with the long dimension of the specimen both parallel (longitudinal) and perpendicular (transverse) to the 0 deg fiber direction. Damage in the form of longitudinal and transverse cracking occurred in all longitudinal specimens tested at energies greater than 6.3 J. Similar results occurred in the transverse specimens tested above 5.4 J. Initial load drop, characteristic of the onset of damage, occurred on average at 6.3 J in longitudinal specimens and at 5.0 J in transverse specimens. X-ray analysis showed broken fibers in the impacted region in specimens tested at the higher impact energies. At low impact energies, visible matrix cracking may occur, but broken fibers may not. Matrix cracking was noted along fiber swims and it appeared to depend on the surface quality of composite. At low impact energies, little damage has been incurred by the composite and the residual strength and residual life is not greatly reduced as compared to an undamaged composite. At higher impact energies, more damage occurred and a greater effect of the impact damage was observed.
Miller, Jennifer L.↗
Micro-Structural Response of DP 600 to High Strain Rate Deformation
The object of this study was to investigate the micro-structural response of DP 600 subjected to high strain rate, ballistic impact tests. The ballistic tests were conducted using normal impact of a hardened steel penetrator into a 2 mm thick sheet of DP 600. The average strain rates produced from this test method are on the order of 10(exp 5)/s. Electron microscopy was used to investigate the microstructure before and after high strain rate deformation. A variation in material response was observed between tests conducted at 0.8 x 105 and 25 x 10(exp 5)/s.
Hamburg, Brian↗
BALLIST: A computer program to empirically predict the bumper thickness required to prevent perforation of the Space Station by orbital debris
A computer program called BALLIST that is intended to be a design tool for engineers is described. BALLlST empirically predicts the bumper thickness required to prevent perforation of the Space Station pressure wall by a projectile (such as orbital debris) as a function of the projectile's velocity. 'Ballistic' limit curves (bumper thickness vs. projectile velocity) are calculated and are displayed on the screen as well as being stored in an ASCII file. A Whipple style of spacecraft wall configuration is assumed. The predictions are based on a database of impact test results. NASA/Marshall Space Flight Center currently has the capability to generate such test results. Numerical simulation results of impact conditions that can not be tested (high velocities or large particles) can also be used for predictions.
Rule, William Keith↗
Characterization of Orbital Debris via Hyper-Velocity Laboratory-Based Tests
Existing DoD and NASA satellite breakup models are based on a key laboratory test, Satellite Orbital debris Characterization Impact Test (SOCIT), which has supported many applications and matched on-orbit events involving older satellite designs reasonably well over the years. In order to update and improve these models, the NASA Orbital Debris Program Office, in collaboration with the Air Force Space and Missile Systems Center, The Aerospace Corporation, and the University of Florida, replicated a hypervelocity impact using a mock-up satellite, DebriSat, in controlled laboratory conditions. DebriSat is representative of present-day LEO satellites, built with modern spacecraft materials and construction techniques. Fragments down to 2 mm in size will be characterized by their physical and derived properties. A subset of fragments will be further analyzed in laboratory radar and optical facilities to update the existing radar-based NASA Size Estimation Model (SEM) and develop a comparable optical-based SEM. A historical overview of the project, status of the characterization process, and plans for integrating the data into various models will be discussed herein.
Cowardin, Heather↗
Characterization of Orbital Debris via Hyper-Velocity Laboratory-Based Tests
Existing DOD and NASA satellite breakup models are based on a key laboratory test, Satellite Orbital debris Characterization Impact Test (SOCIT), which has supported many applications and matched on-orbit events involving older satellite designs reasonably well over the years. In order to update and improve these models, the NASA Orbital Debris Program Office, in collaboration with the Air Force Space and Missile Systems Center, The Aerospace Corporation, and the University of Florida, replicated a hypervelocity impact using a mock-up satellite, DebriSat, in controlled laboratory conditions. DebriSat is representative of present-day LEO satellites, built with modern spacecraft materials and construction techniques. Fragments down to 2 mm in size will be characterized by their physical and derived properties. A subset of fragments will be further analyzed in laboratory radar and optical facilities to update the existing radar-based NASA Size Estimation Model (SEM) and develop a comparable optical-based SEM. A historical overview of the project, status of the characterization process, and plans for integrating the data into various models will be discussed herein.
Cowardin, Heather↗
Characterization of Oribtal Debris via Hyper-Velocity Ground-Based Tests
Existing DoD and NASA satellite breakup models are based on a key laboratory-based test, Satellite Orbital debris Characterization Impact Test (SOCIT), which has supported many applications and matched on-orbit events involving older satellite designs reasonably well over the years. In order to update and improve the break-up models and the NASA Size Estimation Model (SEM) for events involving more modern satellite designs, the NASA Orbital Debris Program Office has worked in collaboration with the University of Florida to replicate a hypervelocity impact using a satellite built with modern-day spacecraft materials and construction techniques. The spacecraft, called DebriSat, was intended to be a representative of modern LEO satellites and all major designs decisions were reviewed and approved by subject matter experts at Aerospace Corporation. DebriSat is composed of 7 major subsystems including attitude determination and control system (ADCS), command and data handling (C&DH), electrical power system (EPS), payload, propulsion, telemetry tracking and command (TT&C), and thermal management. To reduce cost, most components are emulated based on existing design of flight hardware and fabricated with the same materials. All fragments down to 2 mm is size will be characterized via material, size, shape, bulk density, and the associated data will be stored in a database for multiple users to access. Laboratory radar and optical measurements will be performed on a subset of fragments to provide a better understanding of the data products from orbital debris acquired from ground-based radars and telescopes. The resulting data analysis from DebriSat will be used to update break-up models and develop the first optical SEM in conjunction with updates into the current NASA SEM. The characterization of the fragmentation will be discussed in the subsequent presentation.
Cowardin, H.↗
Outcome of Recent Satellite Impact Experiments
This paper summarizes three satellite impact tests completed in early 2007 through collaboration between Kyushu University and the NASA Orbital Debris Program Office. The previous experiments completed in late 2005 aimed to compare low- and hyper-velocity impacts on identical target satellites, whereas the new tests used larger satellites as targets and aimed to investigate the effects of impact directions. Three identical micro satellites equipped with fully-functional electronic devices were prepared as targets. Their dimensions were 20 cm by 20 cm by 20 cm, and the mass of each was approximately 1.3 kilograms. Aluminum alloy solid spheres, with diameters of 3 cm and masses of 39 grams were prepared as projectiles. The impact velocity was approximately 1.7 km/s. The impact tests were carried out at the two-stage light gas gun facility at the Kyushu Institute of Technology. All three target satellites were completely fragmented, but there were noticeable differences among the three sets of fragments due to the different impact directions. More than 1000 fragments from each test were collected, measured, photographed, and documented with material descriptions. The analysis of the fragments is currently in progress. Preliminary results of the new data and comparisons with previous data will be included in the paper.
Hanada, Toshiya↗
Production development of organic nonflammable spacecraft potting, encapsulating and conformal coating compounds. Volume 3: Appendices
Appendices are presented which include: statement of work; material vendor contacts; formulation/processing data sheet; upward propagation test; flammability test conditions/results sheet; odor test; vacuum stability requirements; flammability test facility; determination of offgassing products and carbon monoxide test; and pneumatic and mechanical impact test guidelines.
Lieberman, S. L.↗
Evaluation of the mechanical properties of electroslag refined iron alloys
Nitronic 40 (21Cr-6N-9Mn), HY-130, 9Ni-4Co, and D-6 alloys were prepared and evaluated in the form of 15.2 mm thick plates. Smooth bar tensile tests, double-edge sharp notch fracture toughness tests Charpy V-notch impact tests were conducted on appropriate heat treated specimens of the four steel plates at 22 C, -50 C, -100 C, -150 C, and -196 C. Similar material characterization, including metallographic evaluation studies on air melt and vacuum arc melt grades of same four alloy steels were conducted for comparative purposes. A cost analysis of manufacturing plates of air melt, electroslag remelt and vacuum arc remelt grades was performed. The results of both material characterization and cost analyses pointed out certain special benefits of electroslag processing iron base alloys.
Bhat, G. K.↗
Impact resistance of fiber composites: Energy absorbing mechanisms and environmental effects
Energy absorbing mechanisms were identified by several approaches. The energy absorbing mechanisms considered are those in unidirectional composite beams subjected to impact. The approaches used include: mechanic models, statistical models, transient finite element analysis, and simple beam theory. Predicted results are correlated with experimental data from Charpy impact tests. The environmental effects on impact resistance are evaluated. Working definitions for energy absorbing and energy releasing mechanisms are proposed and a dynamic fracture progression is outlined. Possible generalizations to angle-plied laminates are described.
Chamis, C. C.↗
Impact resistance of fiber composites - Energy-absorbing mechanisms and environmental effects
Energy absorbing mechanisms were identified by several approaches. The energy absorbing mechanisms considered are those in unidirectional composite beams subjected to impact. The approaches used include: mechanic models, statistical models, transient finite element analysis, and simple beam theory. Predicted results are correlated with experimental data from Charpy impact tests. The environmental effects on impact resistance are evaluated. Working definitions for energy absorbing and energy releasing mechanisms are proposed and a dynamic fracture progression is outlined. Possible generalizations to angle-plied laminates are described.
Chamis, C. C.↗
Advanced thermoplastic resins, phase 1
Eight thermoplastic polyimide resin systems were evaluated as composite matrix materials. Two resins were selected for more extensive mechanical testing and both were versions of LaRC-TPI (Langley Research Center - Thermoplastic Polyimide). One resin was made with LaRC-TPI and contained 2 weight percent of a di(amic acid) dopant as a melt flow aid. The second system was a 1:1 slurry of semicrystalline LaRC-TPI powder in a polyimidesulfone resin diglyme solution. The LaRC-TPI powder melts during processing and increases the melt flow of the resin. Testing included dynamic mechanical analysis, tension and compression testing, and compression-after-impact testing. The test results demonstrated that the LaRC-TPI resins have very good properties compared to other thermoplastics, and that they are promising matrix materials for advanced composite structures.
Hendricks, C. L.↗
Characterization of Orbital Debris Via Hyper-Velocity Ground-Based Tests
To replicate a hyper-velocity fragmentation event using modern-day spacecraft materials and construction techniques to better improve the existing DoD and NASA breakup models. DebriSat is intended to be representative of modern LEO satellites.Major design decisions were reviewed and approved by Aerospace subject matter experts from different disciplines. DebriSat includes 7 major subsystems. Attitude determination and control system (ADCS), command and data handling (C&DH), electrical power system (EPS), payload, propulsion, telemetry tracking and command (TT&C), and thermal management. To reduce cost, most components are emulated based on existing design of flight hardware and fabricated with the same materials. A key laboratory-based test, Satellite Orbital debris Characterization Impact Test (SOCIT), supporting the development of the DoD and NASA satellite breakup models was conducted at AEDC in 1992 .Breakup models based on SOCIT have supported many applications and matched on-orbit events reasonably well over the years.
Cowardin, Heather↗