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NASA NTRS2010

Modeling of Failure for Analysis of Triaxial Braided Carbon Fiber Composites

In the development of advanced aircraft-engine fan cases and containment systems, composite materials are beginning to be used due to their low weight and high strength. The design of these structures must include the capability of withstanding impact loads from a released fan blade. Relatively complex triaxially braided fiber architectures have been found to yield the best performance for the fan cases. To properly work with and design these structures, robust analytical tools are required that can be used in the design process. A new analytical approach models triaxially braided carbon fiber composite materials within the environment of a transient dynamic finite-element code, specifically the commercially available transient dynamic finite-element code LS-DYNA. The geometry of the braided composites is approximated by a series of parallel laminated composites. The composite is modeled by using shell finite elements. The material property data are computed by examining test data from static tests on braided composites, where optical strain measurement techniques are used to examine the local strain variations within the material. These local strain data from the braided composite tests are used along with a judicious application of composite micromechanics- based methods to compute the stiffness properties of an equivalent unidirectional laminated composite required for the shell elements. The local strain data from the braided composite tests are also applied to back out strength and failure properties of the equivalent unidirectional composite. The properties utilized are geared towards the application of a continuum damage mechanics-based composite constitutive model available within LS-DYNA. The developed model can be applied to conduct impact simulations of structures composed of triaxially braided composites. The advantage of this technology is that it facilitates the analysis of the deformation and damage response of a triaxially braided polymer matrix composite within the environment of a transient dynamic finite-element code such as LS-DYNA in a manner which accounts for the local physical mechanisms but is still computationally efficient. This methodology is tightly coupled to experimental tests on the braided composite, which ensures that the material properties have physical significance. Aerospace or automotive companies interested in using triaxially braided composites in their structures, particularly for impact or crash applications, would find the technology useful. By the development of improved design tools, the amount of very expensive impact testing that will need to be performed can be significantly reduced.

Goldberg, Robert K.↗

NASA NTRS2008

The Effects of Heat Treatment and Microstructure Variations on Disk Superalloy Properties at High Temperature

The effects of heat treatment and resulting microstructure variations on high temperature mechanical properties were assessed for a powder metallurgy disk superalloy LSHR. Blanks were consistently supersolvus solution heat treated and quenched at two cooling rates, than aged at varying temperatures and times. Tensile, creep, and dwell fatigue crack growth tests were then performed at 704 C. Gamma' precipitate microstructures were quantified. Relationships between heat treatment-microstructure, heat treatment-mechanical properties, and microstructure-mechanical properties were assessed.

Gabb, Timothy P.↗

NASA NTRS2003

Versatile Turbine Disk Alloy Designed and Processed for Higher Temperature Applications

Advanced turbine engine configurations using higher temperature combustor and airfoil concepts require compressor and turbine disks that can withstand temperatures higher than the 650 C typical of current engines. This requires disk alloy and processing improvements. A versatile disk alloy was needed that could be given either fine grain heat treatments for high strength and fatigue and creep resistance up to 704 C or given coarse grain heat treatments for high strength and creep and dwell crack-growth resistance at higher temperatures. This alloy could produce disks with uniform microstructures and properties, as well as with varied, optimized microstructures at disk bore and rim sections. A series of experimental disk alloys were designed and processed to give subscale disks about 13 cm in diameter and 4 cm thick. These alloys had varying levels of key elements to affect mechanical properties and change the "solvus" solution heat-treatment temperature necessary to produce coarse grain microstructures. Disks were given coarse grain heat treatments followed by rapid oil quenching and slower fan air quenching. These heat treatments were intended to simulate the cooling paths of rapidly cooled full-scale disks at the outermost rim and interior bore locations, respectively. Preliminary quench tests of tensile specimens and coin-size minidisks had indicated that alloys having high solvus temperatures were more prone to cracking during rapid quenching from coarse grain heat treatments. These findings were confirmed in the subscale disks, where such alloys did form undesirable quench cracks. Mechanical tests were performed on specimens from subscale disks given these coarse grain heat treatments, as well as on specimens given a fine grain heat treatment. Tensile, creep, and crack growth tests were performed at 704 C and higher temperatures. A versatile alloy was identified that had a low solvus temperature for resistance to quench cracking as well as an optimal combination of high levels of strengthening refractory elements that produced balanced high mechanical properties for both fine grain and coarse grain microstructures. This low-solvus, high-refractory (LSHR) alloy has been scaled-up to produce prototype full-scale turbine disks typical of regional jet turbofan engines. Disks were successfully heat treated to give uniform coarse grain and uniform fine grain microstructures. Additional disks were given a NASA dual microstructure heat treatment (DMHT) that intentionally varied the solution heat-treatment temperatures between the disk rim and bore (re f. 1). The disk rim was heated to a high enough temperature to produce a coarse grain microstructure, while the bore was maintained at a lower temperature to produce a fine grain microstructure (see the figure). This DMHT can produce optimal high strength, fatigue, and creep resistance up to 704 C in the cooler running disk bore, and high strength, creep resistance, and dwell crack growth resistance at higher temperatures for the hotter disk rim. Extensive mechanical testing is being initiated to compare the mechanical properties of the uniform and DMHT disks.

Gabb, TImothy P.↗

NASA NTRS2015

Additive Manufacturing and Characterization of Ultem Polymers and Composites

The objective of this project was to conduct additive manufacturing to produce aircraft engine components by Fused Deposition Modeling (FDM), using commercially available polyetherimides - Ultem 9085 and experimental Ultem 1000 mixed with 10 percent chopped carbon fiber. A property comparison between FDM-printed and injection-molded coupons for Ultem 9085, Ultem 1000 resin and the fiber-filled composite Ultem 1000 was carried out. Furthermore, an acoustic liner was printed from Ultem 9085 simulating conventional honeycomb structured liners and tested in a wind tunnel. Composite compressor inlet guide vanes were also printed using fiber-filled Ultem 1000 filaments and tested in a cascade rig. The fiber-filled Ultem 1000 filaments and composite vanes were characterized by scanning electron microscope (SEM) and acid digestion to determine the porosity of FDM-printed articles which ranged from 25-31 percent. Coupons of Ultem 9085 and experimental Ultem 1000 composites were tested at room temperature and 400 degrees Fahrenheit to evaluate their corresponding mechanical properties.

Polymers↗

NASA NTRS1990

A study of hydrogen environment effects on microstructure property behavior of NASA-23 alloy and related alloy systems

This work is part of the overall advanced main combustion chamber (AMCC) casting characterization program of the Materials and Processes Laboratory of the Marshall Space Flight Center. The influence of hydrogen on the tensile properties and ductility behavior of NASA-23 alloy were analyzed. NASA-23 and other referenced alloys in cast and hipped conditions were solution treated and aged under selected conditions and characterized using optical metallography, scanning electron microscopy, and electron microprobe analysis techniques. The yield strength of NASA-23 is not affected much by hydrogen under tensile tests carried at 5000 psig conditions; however, the ultimate strength and ductility properties are degraded. This implies that the physical mechanisms operating would be related to the plastic deformation process. The fracture surfaces characteristics of NASA-23 specimens tensile tested in hydrogen, helium, and air were also analyzed. These revealed surface cracks around specimen periphery with the fracture surface showing a combination of intergranular and transgranular modes of fracture. It is seen that the specimens charged in hydrogen seem to favor a more brittle fracture mode in comparison to air and helium charged specimens. The AMCC casting characterization program is to be analyzed for their hydrogen behavior. As a result of this program, the basic microstructural factors and fracture characteristics in some cases were analyzed.

Diwan, Ravinder M.↗

NASA NTRS1971

Long-term aging of elastomers: Chemical stress relaxation of fluorosilicone rubber and other studies

Aerospace applications of elastomers are considered, including: propellant binders, bladder materials for liquid propellant expulsion systems, and fuel tank sealants for high-speed aircraft. A comprehensive molecular theory for mechanical properties of these materials has been developed but has only been tested experimentally in cases where chemical degradation processes are excluded. Hence, a study is being conducted to ascertain the nature, extent, and rate of chemical changes that take place in some elastomers of interest. Chemical changes that may take place in the fluorosilicone elastomer, LS 420, which is regarded as a fuel and high-temperature-resistant rubber are investigated. The kinetic analysis of the chemical stress relaxation and gel permeation chromatography studies comprise the major portion of the report.

Kalfayan, S. H.↗

NASA NTRS1972

Flight-and ground-test evaluation of pyrrone foams

Two Pyrrone materials, pure Pyrrone foam with a density of 481 kg/cu m and hollow glass microsphere-Pyrrone composite with a density of 962 kg/cu m, were tested in the Langley 20-inch hypersonic arc heated tunnel at pressure levels from 0.06 to 0.27 atm and heating rates from 1.14 to 11.4 MW/sq m. The 481-kg/cu m Pyrrone foam was also flight tested as an experiment aboard a Pacemaker test vehicle. The results of the ground tests indicated that the thermal effectiveness of the 481-kg/cu m Pyrrone foam was superior to the 962-kg/cu m glass sphere-Pyrrone composite. The 481-kg/cu m Pyrrone foam had approximately one-half the thermal effectiveness of low density phenolic nylon. The 481-kg/cu m Pyrrone foam experienced random mechanical char removal over the entire range of test conditions. Char thermal property inputs for an ablation computer program were developed from the ground test data of the 481-kg/cu m Pyrrone foam. The computer program using these developed char thermal properties, as well as the measured uncharred material properties, adequately predicted the in-depth temperature histories measured during the Pacemaker flight.

Mclain, A. G.↗

NASA NTRS1972

Experimental Investigation of the Mechanical Behavior of a Filled Elastomer at Pressures Below 10 to the -6th Power Torr

The mechanical behavior of a filled elastomer was studied with emphasis on understanding the vacuum-material interactions occurring, and to develop analytical techniques for predicting the vacuum behavior. The test results indicate that two separate mechanisms are involved in the observed property changes: the first controls the time response to applied stress; the second determines the initial internal state of the materials as the result of stresses. It is concluded that the mechanical property changes are attributable to changes in the relaxation processes occurring in the material. These changes are brought about by outgassing of water. Recommendations for future investigations are included.

Gregory, G. L.↗

NASA NTRS1974

Evaluation of a metal fuselage panel selectively reinforced with filamentary composites for space shuttle application

The use of high strength and modulus of advanced filamentary composites to reduce the structural weight of aerospace vehicles was investigated. Application of the technology to space shuttle components was the primary consideration. The mechanical properties for the boron/epoxy, graphite/epoxy, and polyimide data are presented. Structural testing of two compression panel components was conducted in a simulated space shuttle thermal environment. Results of the tests are analyzed.

Wennhold, W. F.↗

NASA NTRS1974

The effect of microstructure and strength on the fracture toughness of an 18 ni, 300 grade maraging steel

Methods for increasing the strength of maraging steels are discussed. An investigation was conducted to systematically vary the strength of 18 weight percent nickel, 300 grade maraging steel, to isolate any attending microstructural changes, and to study the effects of these changes on the fracture toughness of the alloy. A study aimed at determining the aging behavior of the program alloy was carried out to provide data by which to estimate yield strength. The effects of various alloying materials on the strength of the maraging steel are examined. The mechanical properties of the 300 grade maraging steel were determined by tension tests, fatigue precracked Charpy impact tests, and plane strain fracture toughness tests.

Psioda, J. A.↗

NASA NTRS1980

Solar cell array design handbook - The principles and technology of photovoltaic energy conversion

Photovoltaic solar cell array design and technology for ground-based and space applications are discussed from the user's point of view. Solar array systems are described, with attention given to array concepts, historical development, applications and performance, and the analysis of array characteristics, circuits, components, performance and reliability is examined. Aspects of solar cell array design considered include the design process, photovoltaic system and detailed array design, and the design of array thermal, radiation shielding and electromagnetic components. Attention is then given to the characteristics and design of the separate components of solar arrays, including the solar cells, optical elements and mechanical elements, and the fabrication, testing, environmental conditions and effects and material properties of arrays and their components are discussed.

Rauschenbach, H. S.↗

NASA NTRS1981

Comparative thermal fatigue resistance of several oxide dispersion strengthened alloys

The thermal fatigue resistance of several oxide dispersion strengthened (ODS) alloys has been evaluated through cyclic exposure in fluidized beds. The ODS nickel-base alloy MA 754 and ODS iron-base alloy MA 956 as well as four experimental ODS Ni-16Cr-4.5Al base alloys with and without Ta additions were examined. Both bare and coated alloys were subjected to up to 6000 cycles where each cycle consisted of a 3 minute immersion in a fluidized bed at 1130 C followed by a 3 minute immersion in a bed at 357 C. Testing revealed that the thermal fatigue resistance of the ODS nickel-base alloys was excellent and about equal to that of directionally solidified superalloys. However, the thermal fatigue resistance of MA 956 was found to be poor. Metallographic examination of tested specimens revealed that, in general, the post-test microstructures can be rationalized on the basis of previous diffusion, mechanical property, and oxidation studies.

Whittenberger, J. D.↗

NASA NTRS1982

Effect of space flight on bone strength

To test the possibility that spaceflight has a deleterious effect on bone mechanical properties, femur breaking strength by torsional loading in rats that had been flown for 19 days aboard Cosmos 936 was determined. The results showed that femurs from flight rats were less stiff than the flight controls, and failed under torsion at a lower torque and energy of absorption. The defect was corrected following space flight and could be prevented during space flight by centrifuging the rats at 1 x g. Altered bone geometry due to inhibition of bone formation at the periosteal surface provides the most likely explanation for the decrease in bone strength during spaceflight.

Spengler, D. M.↗

NASA NTRS1989

Testing Bonds Between Brittle And Ductile Films

Simple uniaxial strain test devised to measure intrinsic shear strength. Brittle film deposited on ductile stubstrate film, and combination stretched until brittle film cracks, then separates from substrate. Dimensions of cracked segments related in known way to tensile strength of brittle film and shear strength of bond between two films. Despite approximations and limitations of technique, tests show it yields semiquantitative measures of bond strengths, independent of mechanical properties of substrates, with results reproducible with plus or minus 6 percent.

Wheeler, Donald R.↗

NASA NTRS1987

Effect of grain size on the high temperature properties of B2 aluminides

Measurements of the slow plastic flow behavior of cobalt, iron and nickel B2 crystal structure aluminides were conducted on materials fabricated by metallurical techniques. Due to this processing, the aluminides invariably had small equiaxed grains, ranging in size from about 3 to 60 microns in diameter. Grain size was dependent on the extrusion temperature used for powder consolidation, and it proved to be remarkably stable at elevated temperatures. Mechanical properties of all three aluminides were determined via constant velocity compression testing in air between 1000 and 1400 K at strain rates ranging from approx. 10 to the minus 3 power to 10 to the minus 7 power s (-1).

Whittenberger, J. Daniel↗

NASA NTRS1990

Thermal modeling of the NASA-Ames Research Center Cryogenic Optical Test Facility and a single-arch, fused-natural-quartz mirror

A thermal model of the dewar and optical system of the Cryogenic Optical Test Facility at NASA-Ames Research Center was developed using the computer codes SINDA and MONTE CARLO. The model was based on the geometry, boundary conditions, and physical properties of the test facility and was developed to investigate heat transfer mechanisms and temperatures in the facility and in test mirrors during cryogenic optical tests. A single-arch, fused-natural-quartz mirror was the first mirror whose thermal loads and temperature distributions were modeled. From the temperature distribution, the thermal gradients in the mirror were obtained. The model predicted that a small gradient should exist for the single arch mirror. This was later verified by the measurement of mirror temperatures. The temperatures, predicted by the model at various locations within the dewar, were in relatively good agreement with the measured temperatures. The model is applicable to both steady-state and transient cooldown operations.

Ng, Y. S.↗

NASA NTRS1994

Flight service evaluation of composite helicopter components

This paper presents the results of a NASA funded contract and Sikorsky research and development programs to evaluate structural composite components in flight service on Sikorsky Model S-76 helicopters. Selected components were removed and tested at prescribed intervals over a nine year time frame. Four horizontal stabilizers and thirteen tail rotor spars were returned from commercial service in West Palm Beach, Florida and in the Gulf Coast region of Louisiana to determine the long term effects of operations in hot and humid climates on component performance. Concurrent with the flight component evaluation, panels of materials used in their fabrication were exposed to the environment in ground racks. Selected panels were tested annually to determine the effects of exposure on physical and mechanical properties. The results of 55,741 component flight hours and 911 months of field exposure are reported and compared with initial Federal Aviation Administration (FAA) certification data. The findings of this program have provided increased confidence in the long term durability of advanced composite materials used in helicopter structural applications.

Mardoian, George H.↗

NASA NTRS1992

Compressive strength of damaged and repaired composite plates

Tests were performed assessing the effectiveness of repair in restoring the mechanical properties of damaged, solid composite plates made of Fiberite T300/976 graphite-epoxy. Some (75%) or all (100%) of the damaged zone was cut out, and the plate was repaired by plugging and patching the hole. The effectiveness of the repair was evaluated by measuring the compressive strengths of undamaged plates, damaged plates with no cutout, damaged plates with a cutout, and plates that had been repaired.

Finn, Scott R.↗