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At least 361 records · Page 20
All sourcesNASA NTRSDOE OSTI
NASA NTRS2016

Revisiting of Multiscale Static Analysis of Notched Laminates Using the Generalized Method of Cells

Composite material systems generally exhibit a range of behavior on different length scales (from constituent level to macro); therefore, a multiscale framework is beneficial for the design and engineering of these material systems. The complex nature of the observed composite failure during experiments suggests the need for a three-dimensional (3D) multiscale model to attain a reliable prediction. However, the size of a multiscale three-dimensional finite element model can become prohibitively large and computationally costly. Two-dimensional (2D) models are preferred due to computational efficiency, especially if many different configurations have to be analyzed for an in-depth damage tolerance and durability design study. In this study, various 2D and 3D multiscale analyses will be employed to conduct a detailed investigation into the tensile failure of a given multidirectional, notched carbon fiber reinforced polymer laminate. Threedimensional finite element analysis is typically considered more accurate than a 2D finite element model, as compared with experiments. Nevertheless, in the absence of adequate mesh refinement, large differences may be observed between a 2D and 3D analysis, especially for a shear-dominated layup. This observed difference has not been widely addressed in previous literature and is the main focus of this paper.

Materials Engineering↗
NASA NTRS2017

A Numerical Study on the Edgewise Compression Strength of Sandwich Structures with Facesheet-Core Disbonds

Damage tolerant design approaches require determination of critical damage modes and flaw sizes in order to establish nondestructive evaluation detection requirements. A finite element model is developed to assess the effect of circular facesheet-core disbonds on the strength of sandwich specimens subjected to edgewise compressive loads for the purpose of predicting the critical flaw size for a variety of design parameters. Postbuckling analyses are conducted in which an initial imperfection is seeded using results from a linear buckling analysis. Both the virtual crack closure technique (VCCT) and cohesive elements are considered for modeling disbond growth. Predictions from analyses using the VCCT and analyses using cohesive elements are in good correlation. A series of parametric analyses are conducted to investigate the effect of core thickness and material, facesheet layup, facesheet-core interface properties, and curvature on the criticality of facesheet-core disbonds of various sizes. The results from these analyses provide a basis for determining the critical flaw size for facesheet-core disbonds subjected to edgewise compression loads and, therefore, nondestructive evaluation flaw detection requirements for this configuration.

Bergan, Andrew C.↗
NASA NTRS2017

The Development of a Thermally Enhanced Emergency Fire Shelter

Since its founding in 1905, the U.S. Forest Service has been responsible for maintaining public lands. The Forest Service and other public lands agencies respond to an average of 73,000 wildfires per year, and responding firefighters are required to carry a number of safety gear items, including the M2002 emergency fire shelter. The emergency fire shelter is intended to serve as a last resort means of protection in case a firefighter's escape route has been compromised in the face of an approaching flame front. No fire shelter deployment tragedy has been more costly than the 2013 Yarnell Hill fire in Arizona, where 19 members of the Granite Mountain Hotshots perished. After the tragedy at Yarnell Hill, the Forest Service decided to expedite the next redesign cycle of the fire shelter in order to improve its ability to withstand direct contact with flames. Engineers at NASA Langley Research Center have spent the better part of a decade developing flexible thermal materials for use in inflatable aerodynamic decelerators and have demonstrated their performance in the IRVE-2 and IRVE-3 flight programs (Inflatable Reentry Vehicle Experiment). NASA engineers recognized an opportunity to leverage their experience and knowledge with flexible thermal protection systems to potentially improve the fire shelter's resistance to direct flame contact, and have been working directly with the U.S. Forest Service to achieve this goal. They launched the CHIEFS project (Convective Heating Improvement for Emergency Fire Shelters) in 2014. Over the past three years, CHIEFS has screened over 270 unique material layups, and tested over 30 unique full scale shelter concepts in an effort to achieve a game changing improvement to the thermal protection of the fire shelter, while maintaining minimal mass and volume. This paper will discuss CHIEFS' 1st and 2nd generation fire shelter development efforts and test results.

Fody, Joshua M.↗
NASA NTRS2015

Electrostatic Discharge Testing of Carbon Composite Solar Array Panels for Use in the Jovian Environment

NASA is currently considering a mission to investigate the moons of Jupiter. When designing a spacecraft for this type of mission, there are a number of engineering challenges, especially if the mission chooses to utilize solar arrays to provide the spacecraft power. In order for solar arrays to be feasible for the mission, their total mass needed to fit within the total budget for the mission, which strongly suggested the use of carbon composite facesheets on an aluminum core for the panel structure. While these composite structures are a good functional substitution for the metallic materials they replace, they present unique challenges when interacting with the harsh Jovian space environment. As a composite material, they are composed of more than one material and can show different base properties depending in differing conditions. Looking at the electrical properties, in an Earth-based environment the carbon component of the composite dominates the response of the material to external stimulus. Under these conditions, the structures strongly resembles a conductor. In the Jovian environment, with temperatures reaching 50K and under the bombardment from energetic electrons, the non-conducting pre-preg binding materials may come to the forefront and change the perceived response. Before selecting solar arrays as the baseline power source for a mission to Jupiter, the response of the carbon composites to energetic electrons while held at cryogenic temperatures needed to be determined. A series of tests were devised to exam the response of a sample solar array panel composed of an M55J carbon weave layup with an RS-3 pre-preg binder. Test coupons were fabricated and exposed to electrons ranging from 10 keV to 100 keV, at 1 nA/cm2, while being held at cryogenic temperatures. While under electron bombardment, electrical discharges were observed and recorded with the majority of discharges occurring with electron energies of 25 keV. A decrease in temperature to liquid nitrogen temperatures showed a marked increase in the magnitude of these discharges. The results indicate that dielectric discharges are primarily produced due to the presence of large regions of the non-conductive pre-preg on the surface of the carbon sheets. The frequency and magnitude of discharges decreased when layers of the pre-preg material were removed from the composite surface. These tests indicate that solar array panels may be used in the Jovian environment, but that electrostatic discharges can be expected on the carbon composite solar arrays.

Jupiter↗
NASA NTRS2017

Method and Apparatus for Non-Destructive Evaluation of Materials

Methods and apparatus for characterizing composite materials for manufacturing quality assurance (QA), periodic inspection during the useful life, or for forensic analysis/material testing. System are provided that relate eddy-current sensor responses to the fiber layup of a composite structure, the presence of impact damage on a composite structure with or without a metal liner, volumetric stress within the composite, fiber tow density, and other NDE inspection requirements. Also provided are systems that determine electromagnetic material properties and material dimensions of composite materials from capacitive sensor inspection measurements. These properties are related to the presence of buried defects in non-conductive composite materials, moisture ingress, aging of the material due to service or environmental/thermal exposure, or changes in manufacturing quality.

Goldfine, Neil J.↗
NASA NTRS2017

The Effects of Fiber Orientation and Adhesives on Tensile Properties of Carbon Fiber Reinforced Polymer Matrix Composite with Embedded Nickel-Titanium Shape Memory Alloys

Nickel-titanium (NiTi) shape memory alloy (SMA) sections were embedded within carbon fiber reinforced polymer matrix composite (CFRPPMC) laminates and their tensile properties were evaluated with simultaneous monitoring of modal acoustic emissions. The test specimens were fabricated in three different layup configurations and two different thin film adhesives were applied to bond the SMA with the PMC. A trio of acoustic sensors were attached to the specimens during tensile testing to monitor the modal acoustic emission (AE) as the materials experienced mechanical failure. The values of ultimate tensile strengths, strains, and moduli were obtained. Cumulative AE energy of events and specimen failure location were determined. In conjunction, optical and scanning electron microscopy techniques were used to examine the break areas of the specimens. The analysis of AE data revealed failure locations within the specimens which were validated from the microscopic images. The placement of 90 deg plies in the outer ply gave the strongest acoustic signals during break as well as the cleanest break of the samples tested. Overlapping 0 deg ply layers surrounding the SMA was found to be the best scenario to prevent failure of the specimen itself.

shape memory alloy↗
NASA NTRS2018

Determination of Ballistic Limit for IM7/8552 Using Peridynamics

Significant testing is required to design and certify primary aircraft structure subject to High Energy Dynamic Impact (HEDI) events; current work under the NASA Advanced Composites Consortium (ACC) HEDI Project seeks to determine the state-of-the-art of dynamic fracture simulations for composite structures in these events. This paper discusses one of four Progressive Damage Analysis (PDA) methods selected for this project: peridynamics, through EMU implementation. A brief discussion of peridynamic theory is provided, followed by an outline of ballistic impact testing performed for model development and assessment. Detailed modeling approach and test-analysis correlation for a single open test case are presented, followed by the results of a series of blind predictions made prior to testing and test-analysis correlation performed with measured NASA test results. Specifically, we present simulation results for the ballistic limit (V50) of IM7/8552 composite panels ballistically tested with an impactor representative of a high-velocity fan-blade-out condition. In particular, force and displacement history and the damage state determined analytically are compared to measured results. Ultimately, peridynamics has the ability to predict damage patterns, impact force and deflections during a high energy dynamic impact event on composite panels of different layups using two different types of impactors. Blind predictions were promising and increased confidence in the model for impact simulation. There are open questions regarding the fidelity of the test fixture idealization in regards to stiffness and damping which will need to be addressed in future work.

Cuenca, Fernando↗
NASA NTRS2019

Automated Fiber Placement Manufactured Composites for Science Applications

Science instruments with large collecting areas that maintain dimensional stability, such as James Webb Space Telescope and Wide Field Space Telescope, help achieve next generation science advancements. Composite materials often used for science applications include high modulus fibers in cyanate ester matrices to result in dimensionally stable structures with low contamination. Hand lay-up fabrication is the most common approach for science instrument structures. Automated Fiber Placement (AFP) using intermediate modulus fibers is commonplace in aircraft production reducing manufacturing time and increasing quality and consistency. AFP manufacturing for future large science instruments can similarly reduce costs and increase reliability. However, high modulus fibers are more prone to damage than intermediate modulus fibers. This study investigates the manufacturing viability of M55J/RS3C (Tencate) slit tape material using AFP processing. Tencate provides slit tape materials. NASA Langley Research Center (LaRC) manufactured hand layup and AFP lay-up laminates under room temperature for initial trials, Marshall Space Flight Center (MSFC) manufactured AFP laminates under room temperature and elevated temperature conditions to evaluate processing affects. Goddard Space Flight Center (GSFC) tests and evaluates tension and Coefficient of Thermal Expansion (CTE) properties by hand lay-up and AFP slit tape automated manufacturing for large science applications. These results show processing material warm reduces process induced fiber fracture; leading to stiffness and CTE properties consistent with hand lay-up, while observing a slight degradation in tensile strength.

Segal, Kenneth N.↗
NASA NTRS2019

Extravehicular Activity Micormeteoroid and Orbital Debris Risk Assessment Methodology

A well-known hazard associated with exposure to the space environment is the risk of vehicle failure due to an impact from an micrometeoroid and orbital debris (MMOD) particle. Among the vehicles of importance to NASA is the extravehicular mobility unit (EMU) “spacesuit” used while performing a US extravehicular activity (EVA). An EMU impact is of great concern as a large leak could prevent an astronaut from safely reaching the airlock in time resulting in a loss of life. For this reason, a risk assessment is provided to the EVA office at the Johnson Space Center (JSC) prior to certification of readiness for each US EVA. To assess the risk of failure, a detailed finite element model (FEM) of the EMU has been created which has regions for the various shielding configurations. Each shielding configuration is based on the layers and materials over the innermost bladder layer that maintains the acceptable atmospheric environment for the astronaut. Ballistic limit equations (BLE) for each shielding configuration have been determined from hypervelocity impact testing of samples of the EMU layup.

Hoffman, K. D.↗
NASA NTRS2018

The Effects of Fiber Orientation and Adhesives on Tensile Properties of Carbon Fiber Reinforced Polymer Matrix Composite with Embedded Nickel-Titanium Shape Memory Alloys

Tensile tests of Nickel-titanium (NiTi) shape memory alloys (SMA) embedded within carbon fiber reinforced polymer matrix composite (CFRP/PMC) laminates were evaluated with simultaneous monitoring of modal acoustic emissions (MAE). Three different layup configurations utilizing two different thin film adhesives were applied to bond the materials. Ultimate tensile strengths, strains, and moduli were obtained along with cumulative AE energy of events and specimen failure location. Scanning electron microscopy was used to examine the break areas of the specimens post-test. Microscopy was used to validate failure locations revealed from MAE analysis. A unique finding within this research showed that 90° plies in the outer ply gave the strongest acoustic signals as well as the cleanest fracture of the specimens tested. Overlapping 0° ply layers surrounding the SMA was found to be the best scenario to prevent failure of the specimen itself.

Derek Quade↗
NASA NTRS2019

Inducing Bistability in Collapsible Tubular Masts Booms with Thin-Ply Composite Shells

Bistable rollable booms are favorable when a low strain energy requirement for the coiled state is imposed and have more controllable deployment when compared to monostable booms. An inextensional analytical model describing the bending deformation mechanics of Collapsible Tubular Mast (CTM) booms was used to determine how design variables induce bistability, or the existence of two strain energy wells in the rolled-up and unrolled states. The effects of varying lamina material, laminate layup, and shell arc geometries between different inner and outer shell segments on the second strain energy well and stiffness properties were determined for boom cross-sections formed by circular segments. The full design space for two-walled composite CTM booms was explored to evaluate the validity of the developed analytical model. Optimized CTM boom designs were experimentally characterized for comparisons against model results. The model under-predicted the stable coiled diameter of the co-cured two-walled booms by up to 8.9% and 23.4% for the individual thin shells wrapped alone.

Andrew J Lee↗
NASA NTRS2019

Preliminary Nonlinear Structural Analysis of Advanced Composite Tow-Steered Shells with Large Geometric Imperfections

The structural performance of two advanced composite tow-steered shells with and without tow overlaps, and with large geometric imperfections, are predicted using linear and geometrically nonlinear finite element analyses. These shells, 35 in. long and approximately 16.3 in. diameter, are fabricated using automated fiber placement from IM7/8552 graphite/epoxy prepreg. The 8-ply,[±45/±Θ]s. shell layup incorporates a steered fiber angle Θ that varies from 10 deg. to 45 deg. periodically over the shell circumference. Shell analysis models are evaluated using geometric imperfections normalized to ±1 shell wall thickness (±0.040 in.), which are then superposed and rotated incrementally around the shell longitudinal axis. Using these nominal imperfections, the shell prebuckling axial stiffnesses and buckling loads predicted with linear and nonlinear analyses are close to reference values from linear analyses with no imperfections. The linear and nonlinear analyses are then repeated for scaled imperfections that are larger by up to a factor of 10. For these larger imperfections, linear analyses predict reductions in axial stiffnesses and buckling loads of up to 5 and 30 percent, respectively, from reference values. The nonlinear analyses predict even larger reductions in axial stiffnesses and buckling loads of up to 10 and 55 percent, respectively.

Dobrin, Calvin P.↗
NASA NTRS2018

Validation of a Mesoscale Fiber Kinking Model Through Test and Analysis of Double Edge Notch Compression Specimens

Tests and analyses were conducted on a series of geometrically-scaled double edge notch compression specimens to validate the capability of the fiber-kinking model in the NASA continuum damage mechanics code for progressive damage analysis, CompDam. The tests and analyses focused on the fiber-kinking damage mechanism, which is of critical importance for predicting accurately longitudinal compression failure in carbon fiber reinforced polymer laminates. The fiber-kinking model in CompDam was augmented with a new capability to represent a hardening response once a kink band has fully formed, enabling prediction of band broadening. Correlation of the test and analysis results showed agreement in stiffness and strength with less than 10% error. The analysis predicts the same sequence of events leading to ultimate failure that was found in the test. The overall excellent correlation in terms of stiffness, strength, and failure process validates the capability of the model for predicting longitudinal compression failure in notched laminates with cross-ply layups.

Bergan, Andrew C.↗
NASA NTRS2018

Bistable Collapsible Tubular Mast Booms

A promising candidate for deployable composite structures is the two-shelled Collapsible Tubular Mast (CTM) boom, which is to be employed on future solar sail and interplanetary small satellite platforms by the National Aeronautics and Space Administration (NASA). This is due to its two omega-shaped shells forming a closed-section which yields large stiffnesses that allowed for high dimensional stability. An inextensional analytical model describing the bending deformation mechanics of CTM booms was used to determine how design variables induce bistability, or the existence of two strain energy wells. Bistable booms were favorable due to low strain energy requirements for the coiled state and had more controllable deployment when compared to monostable booms. The effects of varying lamina material, laminate layup, and shell arc geometries between different inner and outer shell segments on the second strain energy well and stiffness properties were determined for cross-sections formed by circular segments. The full design space for two-shelled composite CTM booms was explored to evaluate the validity of the simple analytical model developed. Optimal CTM boom designs were manufactured and experimentally characterized for comparisons against model results. The model under-predicted the second stable coiled diameter of the complete two-shelled booms by 27-33% and as low as 3-8% for the individual shells wrapped alone.

Fernandez, Juan M.↗
NASA NTRS2019

Evaluation of Temperature Gradients During Cure of a Thick Carbon Fiber/Epoxy Composite

The purpose of this study is to evaluate the development of thermal gradients throughout thick (1") carbon fiber composites and determine the effect of internal temperature distribution during cure on the observed mechanical properties in those composites. Composites up to 1.5" thick (56 plies) were fabricated with T700S/TC380 braided prepreg from Tencate following a modified vacuum bag layup procedure to include embedded thermocouples within the plies of the composite. Composite panels were cured in a programmable oven with thermocouple reading embedded throughout the panel thickness. Maximum temperature gradients measured between regions of the composite did not exceed 10 degrees C for any given composite thickness. The most significant temperature variation was measured between the mid-thickness plies and the tool-side surface plies. Although through thickness temperature variation during cure was small, a measureable variation in coupon glass transition temperature was recorded between the tool side plies and the remainder of the part, prior to post cure. Thermal and mechanical behavior of coupons taken from segments through the thickness of the part were comparable following a post-cure cycle.

Miller, Sandi↗
NASA NTRS2019

An Experimental Investigation concerning the Effects of AFP Defects on Progressive Failure of Tensile Coupons

This paper discusses characterization approaches for the evaluation of potential defects that may occur during the automated fiber placement (AFP) process. Two nondestructive evaluation techniques were utilized simultaneously, acoustic emission (AE) and digital image correlation (DIC), to investigate correlations between mechanical properties and damage propagation during tension tests. The layup configuration is designed with the defect running across the width, and the stacking sequence with seven layers is produced: [−45/0/45/̅9̅̅0̅]s. A total of 3 panels were manufactured: one containing a gap defect in the middle layer, another one with an overlap defect, and a pristine panel for baseline comparison. Each panel accommodates six coupons having dimensions of 20” x 2”. The results indicate that defects caused during the manufacturing process affect damage initiation and growth.

Anay, Rafal↗
NASA NTRS2019

Development of a Design for Manufacturing Tool for Automated Fiber Placement Structures

Existing design processes for laminates constructed with automated fiber placement lack significant integration between the various software tools that compose the process. Tools for finite element analysis, computer aided drafting, stress analysis, tool path simulation, and manufacturing defect prediction are all critical parts of the design process. With traditional hand-layup laminates, the analysis performed with each of these tools could be fairly well decoupled from one another. However, for laminates generated by automated fiber placement, the disciplines can become significantly coupled, especially on structures with curvature. This gives rise to a need for integrated “design for manufacturing” software tools that are able to balance the competing objectives from each discipline. This paper describes the preliminary development of such a tool.

Noevere, August T.↗
NASA NTRS2019

Characterization of Prepreg Tack for Composite Manufacturing by Automated Fiber Placement

Automated fiber placement (AFP) has become the industry standard for large-scale production of carbon fiber reinforced plastics (CFRP) to improve rate and reduce defects associated with manual layup. Still, defects generated during AFP processes require manual, painstaking inspection by technicians and rework of the part when substantial defects are found. Prepreg (carbon fiber infused with uncured epoxy resin) tack is one of the primary factors that influences the generation of defects that arise during auto-mated fiber placement (AFP). Tack, as it relates to AFP processes and defect formation, can be understood as a combination of two stages, cohesion and decohesion. During the cohesion phase, two pieces of prepreg are brought into contact under elevated temperature and pressure. Compaction of the resin within the contact area will result in a degree of intimate contact, I, between the mating prepreg surfaces. Defect formation, as a result of decohesion between prepreg surfaces, occurs after the cohesion phase and arises due to stress from events such as fiber placement over an existing defect, on a contoured path, etc. (Figure 1). Tack strength resists the displacement of prepreg on a surface due to stresses developed during deposition.

Wohl, Christopher J↗