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NASA NTRS1984

Fatigue and Fracture Branch: A compendium of recently completed and on-going research projects

This compendium of recently completed and ongoing research projects from the Fatigue and Fracture Branch at NASA Langley Research Center provides technical descriptions and key results of all such projects expected to lead to publication of significant findings. The common thread to all these studies is the application of fracture mechanics analyses to engineering problems in metals and composites, with particular emphasis on airframe structural materials. References to recent publications are included where appropriate.

Elber, W.↗

NASA NTRS1984

On gravity from SST, geoid from Seasat, and plate age and fracture zones in the Pacific

Data from an additional 50 satellite-to-satellite tracking (SST) passes were combined with earlier measurements of the high degree and order (n, m, 12) gravity in the central Pacific. A composite map was produced which shows good agreement with conventional GEM models. Data from the Seasat altimeter was reduced and found to agree well with both the SST and the GEM fields. The maps are dominated especially in the east, by a pattern of roughly east-west anomalies with a transverse wavelength of about 2000 km. Further comparison with regional bathymetric data shows a remarkably close correlation with plate age. Each anomaly band is framed by those major fracture zones having large offsets. The regular spacing of these fractures seems to account for the fabric in the gravity fields. Other anomalies are accounted for by hot spots. The source of part of these anomalies is in the lithosphere itself. The possible plume size and ascent velocity necessary to supply deep mantle material to the upper mantle without complete thermal equilibration is considered. Previously announced in STAR as N84-11559

Marsh, B. D.↗

NASA NTRS1984

Simplified composite micromechanics equations for strength, fracture toughness and environmental effects

A unified set of composite micromechanics equations of simple form is summarized and described. This unified set includes composite micromechanics equations for predicting: (1) ply in-plane uniaxial strengths; (2) through-the-thickness strength (interlaminar and flexural); (3) in-plane fracture toughness; (4) in-plane impact resistance; and (5) through-the-thickness (interlaminar and flexural) impact resistance. Equations are also included for predicting the hygrothermal effects on strength, fracture toughness and impact resistance. Several numerical examples are worked out to illustrate the ease of use of the various composite micromechanics equations.

Chamis, C. C.↗

NASA NTRS1984

The effect of extreme temperatures on the elastic properties and fracture behavior of graphite/polyimide composites

The influence of elevated and cryogenic temperatures on the elastic moduli and fracture strengths of several C6000/PMR-15 and C6000/NR-15082 laminates was measured. Tests were conducted at -157 C, 24 C, and 316 C (-250 F, 75 F, and 600 F). Both notched and unnotched laminates were tested. The average stress failure criterion was used to predict the fracture strength of quasi-isotropic notched laminates.

Morris, D. H.↗

NASA NTRS1984

A comparison of several methods of calculating fracture toughness from composite laminate test data

Critical fracture toughness was determined by two different techniques for graphite/epoxy laminates of three stacking sequences and several thicknesses. Critical fracture toughness was determined by a finite element stress analysis of a center-cracked tension specimen which yielded the stress intensity factor as a function of specimen thickness and applied load. As an alternative approach the critical strain energy release rate was determined from the compliance calibration technique. Test results from both procedures are compared and discussed.

Harris, C. E.↗

NASA NTRS1984

Fracture mechanics evaluation of GaAs

A data base of mechanical and fracture properties for GaAs was generated. The data for single crystal GaAs will be used to design reusable GaAs solar modules. Database information includes; (1) physical property characterizations; (2) fracture behavior evaluations; and (3) strength of cells determined as a function of cell processing and material parameters.

Chen, C. P.↗

NASA NTRS1985

An Elastic Analysis of a Plated Bone to Determine Fracture Gap Motion

An elastic analysis to determine fracture gap motions occurring in the osteotomized and plated canine femur was performed using the finite element program NASTRAN. The femur was idealized as a hollow right cylinder, and transverse anisotropy was assumed for the elastic properties of the bone. A 3-D 360 degree model consisting of 224 isoparametric quadrilateral hexahedral and 11 beam elements was created. A range of plate stiffnesses was tested by varying the modulus of elasticity of the plate from 207 GPa to 1 GPA. Moments were applied in the plane of the plate, about the axis of the plate, and in the plane of the screws. Results showed that, for plates of typical geometry and elastic modulus under 10 GPa, the contribution to fracture gap motion occurring due to deformation in the bone was negligible compared to that contribution from deformation in the plate.

Cooke, F. W.↗

NASA NTRS1985

Fracture toughness of hot-pressed beryllium

This paper presents the results of an investigation into the fracture toughness, sustained-load flaw growth, and fatigue-crack propagation resistance of S200E hot-pressed beryllium at room temperature. It also reviews the literature pertaining to the influence of various factors on the fracture toughness of hot-pressed beryllium determined using fatigue-cracked specimens.

Lemon, D. D.↗

NASA NTRS1985

The fracture behavior of filament wound cylinders with surface flaws

The behavior of tensile coupons with surface notches of various semielliptical shapes has been evaluated for specimens obtained from a thick filament wound graphite/epoxy cylinder. Specimens with very shallow notches were observed to be notch insensitive and the unnotched strength from these specimens was determined to be 54.97 Ksi with an associated failure strain of 1.328 percent. Specimens with deeper notches were sensitive to notch depth and notch aspect ratio. Isotropic linear elastic fracture mechanics with an estimated fracture toughness of 27.2 Ksi-in.-to the 1/2 correctly predicted the influence of notch depth, aspect ratio and specimen finite width.

Harris, C. E.↗

NASA NTRS1985

Analysis of stress-strain, fracture, and ductility behavior of aluminum maxtrix composites containing discontinuous silicon carbide reinforcement

Mechanical properties and stress-strain behavior were evaluated for several types of commercially fabricated aluminum matrix composites, containing up to 40 vol pct discontinuous SiC whisker, nodule, or particulate reinforcement. The elastic modulus of the composites was found to be isotropic, to be independent of type of reinforcement, and to be controlled solely by the volume percentage of SiC reinforcement present. The yield/tensile strengths and ductility were controlled primarily by the matrix alloy and temper condition. Type and orientation of reinforcement had some effect on the strengths of composites, but only for those in which the whisker reinforcement was highly oriented. Ductility decreased with increasing reinforcement content; however, the fracture strains observed were higher than those reported in the literature for this type of composite. This increase in fracture strain was probably attributable to cleaner matrix powder, better mixing, and increased mechanical working during fabrication. Comparison of properties with conventional aluminum and titanium structural alloys showed that the properties of the low-cost, lightweight composites demonstrated very good potential for application to aerospace structures.

Mcdanels, D. L.↗

NASA NTRS1985

A fracture mechanics study of the turbine wheel in the Space Shuttle auxiliary power unit

The experimental and analytical efforts performed for fracture control of the Space Shuttle auxiliary power unit (APU) wheel are described and a summary of fracture mechanics concepts relevant to safe-life analysis of fatigue loaded parts is given. An environmental crack growth test program is conducted by NASA on candidate wheel materials exposed to decomposed hydrazine which is found to be no more severe in causing crack growth than an environment of high-temperature air. Details of the crack growth testing and the safe-life analysis are presented. The results show that special nondestructive examination is needed for the APU wheel to meet the required mission life for either the maximum design or expected speed-range operations.

Forman, R. G.↗

NASA NTRS1985

On the use of crack-tip-opening displacement to predict the fracture strength of notched graphite/epoxy laminates

Using the center-cracked tension specimen geometry, the fracture strength of notched graphite/epoxy laminates is measured experimentally. Four replicate tests are conducted for a variety of laminate-stacking sequences, thicknesses, and notch lengths. Extensive notch-tip damage prior to fracture is characteristic of most laminates. The values of critical crack-tip-opening displacement (CTOD) are calculated from values of crack-opening displacement measured at the notch center line at failure and are found to be independent of notch size for the laminates studied. A Dugdale (1950) model is used along with the estimated CTOD to predict notched laminate strength.

Harris, C. E.↗

NASA NTRS1985

Design of stiffened composite panels with a fracture constraint

An automated procedure for designing minimum-weight composite panels subject to a local damage constraint under tensile loading was developed. A finite element program based on linear elastic fracture mechanics for calculating stress intensity factors (SIF) was incorporated in the design cycle. Panel fracture toughness was obtained by using a strain based criterion. A general purpose mathematical optimization algorithm was used for the weight minimization. Analytical sensitivity derivatives of the SIF employing the adjoint variable technique was used to enhance the computational efficiency of the procedure. Design results for both unstiffened and stiffened plates are presented.

Gurdal, Z.↗

NASA NTRS1985

Fracture morphology of 2-D carbon-carbon composition

Out-of-plane tensile tests of a woven fabric carbon-carbon composite were performed in a scanning electron microscope equipped with a tensile stage and a videotape recording system. The composite was prepared from T-300 8-harness satin graphite fabric and a phenolic resin. The (0/90/0/90/0 sub 1/2) sub 2 laminate, with a Theta describing the orientation of the warp fibers of the fabric, was cured at 160 C and pyrolized at 871 C. This was followed by four cycles of resin impregnation, curing, and pyrolysis. A micrograph of the cross section of the composite is presented. Inspection of the specimen fracture surface revealed that the filaments had no residual matrix bonded to them. Further inspection revealed that the fracture was interlaminar in nature. Failure occurred where filaments of adjacent plies had the same orientation. Thus it is postulated that improvement in transverse tensile strength of 2-D carbon-carbon depends on the improvement of the filament-matrix bond strength.

Avery, W. B.↗

NASA NTRS1986

Criterion for mixed mode fracture in composite bonded joints

A study was undertaken to characterize the debond growth mechanism of adhesively bonded composite joints under mode I, mixed mode I-II, and mode II static loadings. The bonded system consisted of graphite-epoxy composite adherends bonded with a toughened epoxy adhesive. The mode I, mode II and mixed mode I-II fracture energies of the tested adhesives were found to be equal to each other. The criterion for mixed mode fracture in composite bonded joints was found.

Mall, S.↗

NASA NTRS1985

Effects of strain rate on delamination fracture toughness of graphite/epoxy

The objective of this paper is to evaluate various experimental techniques and analysis methods for the characterization of interlaminar fracture toughness, and to determine the effects of strain rate on that property for a graphite/epoxy composite. Mode I interlaminar fracture was investigated by means of a double-cantilever beam (DCB) specimen for AS-4/3501-6 graphite/epoxy. Hinged tabs were used to insure unrestrained rotation at the free ends. Specimens were loaded at quasi-static deflection rates of up to 8.5 mm/s corresponding to crack extension rates of over 51 mm/s. Crack extension was monitored by means of strain gages mounted on the surface of the specimen, or a conductive-paint circuit attached to the edge of the DCB specimen. Continuous records were obtained of load, deflection, and crack extension for determination of the strain energy release rate. The latter was expressed as a power law of the crack extension velocity. Results indicate that the strain energy release rate increases with crack velocity by up to 28 percent for the range of rates considered.

Daniel, I. M.↗

NASA NTRS1985

Interlaminar fracture of composites

Fracture mechanics has been found to be a useful tool for understanding composite delamination. Analyses for calculating strain energy release rates associated with delamination growth have been developed. These analyses successfully characterized delamination onset and growth for particular sources of delamination. Low velocity impact has been found to be the most severe source of composite delamination. A variety of test methods for measuring interlaminar fracture toughness are being developed to identify new composite materials with enhanced delamination resistance.

Obrien, T. K.↗

NASA NTRS1986

Fracture toughness tests on plasma-sprayed coatings

Fracture toughness measurements have been performed on plasma-sprayed coatings. The intrinsic fracture toughness of plasma-sprayed coatings may be ascertained by means of a double cantilever beam (DCB) test. Emphasis is placed on calibration of the specimen geometry. Representative values for alumina coatings are presented.

Berndt, C. C.↗