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At least 703 records · Page 39

A Selection of Composites Simulation Practices at NASA Langley Research Center

One of the major areas of study at NASA Langley Research Center is the development of technologies that support the use of advanced composite materials in aerospace applications. Amongst the supporting technologies are analysis tools used to simulate the behavior of these materials. This presentation will discuss a number of examples of analysis tools and simulation practices conducted at NASA Langley. The presentation will include examples of damage tolerance analyses for both interlaminar and intralaminar failure modes. Tools for modeling interlaminar failure modes include fracture mechanics and cohesive methods, whilst tools for modeling intralaminar failure involve the development of various progressive failure analyses. Other examples of analyses developed at NASA Langley include a thermo-mechanical model of an orthotropic material and the simulation of delamination growth in z-pin reinforced laminates.

Ratcliffe, James G.↗

Design and Analysis of Buckling-Critical Large-Scale Sandwich Composite Cylindrical Test Articles

It has long been established in the literature that the buckling response of thin-shell structures can be very sensitive to the presence of small geometric and loading imperfections. The Shell Buckling Knockdown Factor Project (SBKF) was established by the NASA Engineering and Safety Center (NESC) to develop analysis-based shell buckling design recommendations for stiffened-metallic and composite launch-vehicle shell structures. Large-scale buckling tests were used to validate the modeling and analysis methods applied in developing these analysis-based recommendations. Herein, the test article design methodology for 8-ft-diameter, honeycomb-core sandwich composite cylinder validation tests is discussed and cylinder designs are presented. In this methodology, first, the sandwich composite design space was defined using several nondimensional parameters, and the desired test article design space was determined by examining the designs of launch-vehicle cylinder structures. Essentially all test article designs within certain design parameters were generated and then downselected based on simple closed-form failure calculations and the nondimensional design-space parameters. Four of these designs that spanned a significant portion of the design space of interest and had global buckling as the first predicted failure mode were selected and subjected to higher-fidelity finite element analyses (FEAs): shell-element-based analyses, axisymmetric-element-based analyses, and global-local analyses. The analysis flow discussed in this report supported the design objective. As the analysis flow progressed, designs were downselected so the fidelity of the analysis methods, and consequently their computational cost and accuracy, was increased. The selection of the FEA types created an analysis framework where particular methods complemented each other and reduced the uncertainty of the predicted test article responses. The analysis results are illustrated using several designs when the computationally expeditious closed-form analysis stage is discussed. Once this stage is complete, the higher-fidelity FEA types are illustrated using one selected detailed test article design. Both perfect and imperfect test article geometries were considered.

Buckling↗

A Novel Concentrating Solar Weathering Apparatus for Experimental Validation of Multi-Modal Degradation Models

High-performance coatings for Concentrating Solar Power (CSP) receivers are subjected to remarkable environmental stressors during normal operations. Applied to the receiver tubes, these coatings serve to maximize the solar absorptivity of the receiver, transferring as much heat as possible from the solar collectors into the heat-transfer fluid (HTF). The lifecycle of these coatings is not well-defined, and the harsh operational conditions make them difficult to test. NREL has designed, built, and tested an apparatus to expose these samples to design levels of environmental stress and well beyond, into accelerated and destructive conditions. The chamber is actively cooled, monitored, and has the capability to supply humidification for cycling tests, allowing us to test multi-modal degradation and failure conditions at high temperature, high flux, and high humidity conditions. These conditions can catalyze high-temperature oxidation, mechanical degradation, and other modes of absorptivity loss seen in selective solar receiver coatings. The experimental data can feed lifecycle models for expensive and necessarily resilient materials, offering insights to aid maintenance schedules, technoeconomic analysis, and material industry performance benchmarks. This presentation will demonstrate the apparatus design and performance, as well as initial results for aging on a selective receiver coating.

14 SOLAR ENERGY↗

Analysis of Leakage Flows in Turbomachinery

Navier-Stokes calculations predict leakage flow in high-pressure fuel pump. Accurate calculation of internal turbomachinery flow dynamics helps spot possible failure modes and establishes coupling between cyclic loading and structural dynamics. Approach also useful in analyzing two-and quasi-three-dimensional leakage flows in other turbomachinery components.

Sindir, M. M.↗

Preloaded joint analysis methodology for space flight systems

This report contains a compilation of some of the most basic equations governing simple preloaded joint systems and discusses the more common modes of failure associated with such hardware. It is intended to provide the mechanical designer with the tools necessary for designing a basic bolted joint. Although the information presented is intended to aid in the engineering of space flight structures, the fundamentals are equally applicable to other forms of mechanical design.

Chambers, Jeffrey A.↗

Bearing-bypass loading in composite joints - Testing and stress analysis

A combined experimental and analytical study of bearing and bypass loading on single-fastener specimens of a 16-ply, quasi-isotropic T300/5208 graphite/epoxy laminate with a centrally located hole is reported. The specimens were loaded in either tension or compression, and onset damage, ultimate strengths, and corresponding failure modes were determined. The tension data showed the expected linear interaction for combined bearing-bypass loading with damage developing in the net-section tension mode. However, the bearing-onset strengths showed an unexpected interaction of the bearing and compressive bypass loads in which the latter reduced the bearing-onset strength. A linear finite element analysis showed that bearing-bypass loading had a marked influence on the bolt-hole contact which in turn had a significant effect on local stresses.

Crews, John H., Jr.↗

Transmission and Distribution Real-Time Analysis Software for Monitoring and Control: Design and Simulation Testing

The US electric grid is facing operational, stability, and security challenges. Transmission system operators need some measure of visibility into distribution system renewable generation. Distribution system generation needs to support transmission system voltage. The grid is experiencing an expansion in measurement systems. How to take full advantage of this expansion and defend against attacks, both cyber and physical, poses additional challenges. This paper introduces software designed to meet these challenges. At the center of the software is an Integrated System Model (ISM) that spans from transmission to secondary distribution. The ISM is employed in real-time abnormality detection, voltage stability forecasting, and multi-mode control. The software architecture along with selected analysis modules is presented. Testing results are presented for: 1—attacks on utility infrastructure; 2—energy savings from optimal control; 3—distribution system control response during a low voltage transmission system event; 4—cyber-attacks on PV inverters, where physical inverters are used in hardware-in-the-simulation-loop studies. Contributions of this work include real-time analysis that spans from three-phase transmission through secondary distribution; an approach for detecting abnormalities that employs measurements from three independent measurement systems; and a multi-mode distribution system control that responds to cyber-attacks, physical attacks, equipment failures, and transmission system needs.

14 SOLAR ENERGY↗

Advanced Concept Studies for Supersonic Commercial Transports Entering Service in the 2018-2020 Period Phase 2

Lockheed Martin Aeronautics Company (LM), working in conjunction with General Electric Global Research (GE GR) and Stanford University, executed a 19 month program responsive to the NASA sponsored "N+2 Supersonic Validation: Advanced Concept Studies for Supersonic Commercial Transports Entering Service in the 2018-2020 Period" contract. The key technical objective of this effort was to validate integrated airframe and propulsion technologies and design methodologies necessary to realize a supersonic vehicle capable of meeting the N+2 environmental and performance goals. The N+2 program is aligned with NASA's Supersonic Project and is focused on providing system level solutions capable of overcoming the efficiency, environmental, and performance barriers to practical supersonic flight. The N+2 environmental and performance goals are outlined in the technical paper, AIAA-2014-2138 (Ref. 1) along with the validated N+2 Phase 2 results. Our Phase 2 efforts built upon our Phase 1 studies (Ref. 2) and successfully demonstrated the ability to design and test realistic configurations capable of shaped sonic booms over the width of the sonic boom carpet. Developing a shaped boom configuration capable of meeting the N+2 shaped boom targets is a key goal for the N+2 program. During the LM Phase 1 effort, LM successfully designed and tested a shaped boom trijet configuration (1021) capable of achieving 85 PLdB under track (forward and aft shock) and up to 28 deg off-track at Mach 1.6. In Phase 2 we developed a refined configuration (1044-2) that extended the under 85 PLdB sonic boom level over the entire carpet of 52 deg off-track at a cruise Mach number of 1.7. Further, the loudness level of the configuration throughout operational conditions calculates to an average of 79 PLdB. These calculations rely on propagation employing Burger's (sBOOM) rounding methodology, and there are indications that the configuration average loudness would actually be 75 PLdB. We also added significant fidelity to the design of the configuration in this phase by performing a low speed wind tunnel test at our LTWT facility in Palmdale, by more complete modelling of propulsion effects in our sonic boom analysis, and by refining our configuration packaging and performance assessments. Working with General Electric, LM performed an assessment of the impact of inlet and nozzle effects on the sonic boom signature of the LM N+2 configurations. Our results indicate that inlet/exhaust streamtube boundary conditions are adequate for conceptual design studies, but realistic propulsion modeling at similar stream-tube conditions does have a small but measurable impact on the sonic boom signature. Previous supersonic transport studies have identified aeroelastic effects as one of the major challenges associated with the long, slender vehicles particularly common with shaped boom aircraft (Ref. 3). Under the Phase 2 effort, we have developed a detailed structural analysis model to evaluate the impact of flexibility and structural considerations on the feasibility of future quiet supersonic transports. We looked in particular at dynamic structural modes and flutter as a failure that must be avoided. We found that for our N+2 design in particular, adequate flutter margin existed. Our flutter margin is large enough to cover uncertainties like large increases in engine weight and the margin is relatively easy to increase with additional stiffening mass. The lack of major aeroelastic problems probably derives somewhat from an early design bias. While shaped boom aircraft require long length, they are not required to be thin. We intentionally developed our structural depths to avoid major flexibility problems. So at the end of Phase 2, we have validated that aeroelastic problems are not necessarily endemic to shaped boom designs. Experimental validation of sonic boom design and analysis techniques was the primary objective of the N+2 Supersonic Validations contract; and in this Phase, LM participated in four high speed wind tunnel tests. The first so-called Parametric Test in the Ames 9x7 tunnel did an exhaustive look at variation effects of the parameters: humidity, total pressure, sample time, spatial averaging distance and number of measurement locations, and more. From the results we learned to obtain data faster and more accurately, and made test condition tolerances easy to meet (eliminating earlier 60 percent wasted time when condition tolerances could not be held). The next two tests used different tunnels. The Ames 11 ft tunnel was used to test lower Mach numbers of 1.2 and 1.4. There were several difficulties using this tunnel for the first time for sonic boom including having to shift the measurement Mach numbers to 1.15 and 1.3 to avoid flow problems. It is believed that the 11 ft could be used successfully to measure sonic boom but there are likely to be a number of test condition restrictions. The Glenn 8x6 ft tunnel was used next and the tunnel has a number of desirable features for sonic boom measurement. While the Ames 9x7 can only test Mach 1.55 to 2.55 and the 11 ft can only test Mach 1.3 and lower, the Glenn 8x6 can test continuously from Mach 0.3 to 2.0. Unfortunately test measurement accuracy was compromised by a reference pressure drift. Post-test analysis revealed that the drift occurred when Mach number drifted slightly. Test measurements indicated that if Mach number drift is eliminated, results from the 8x6 would be more accurate, especially at longer distances, than results from the 9x7. The fourth test in the 9x7, called LM4, used everything we learned to comprehensively and accurately measure our new 1044-02 configuration with a full-carpet shaped signature design. Productivity was 8 times greater than our Phase 1 LM3 test. Measurement accuracy and repeatability was excellent out to 42 in. However, measurements at greater distances require the rail in the aft position and become substantially less accurate. Further signature processing or measurement improvements are needed for beyond near-field signature validation.

Morgenstern, John↗

Optimal Geometry for Focused Ion Beam-Milled Samples for Direct-Pull Micro-Tensile Testing Performed In Situ in a Scanning Electron Microscope

A thorough procedure was developed to efficiently manufacture dogbone samples using focused ion beam (FIB) milling for micro-tensile testing. A Bruker PI 89 PicoIndenter, Billerica, MA, USA, was used as a case study, although the analysis and results are applicable to other micro-mechanical testing systems capable of mounting a standard, Ø12.7 mm × Ø3.2 mm pin, scanning electron microscopy (SEM) pin stub (Ted Pella, Redding, CA, USA). Nine dogbones were made from an Fe-45Cu alloy additively manufactured using powder-fed laser-directed energy deposition (DED-LB). Testing showed that fracture was confined to the gauge section for all dogbones and that the fracture mode, ductile vs. brittle, was entirely dependent on the grain orientation relative to the loading direction. The analysis showed that the measured plastic strain to failure can vary from >11% (optimal geometry) to <1% (non-optimal geometry) in micro-tensile testing of high-tensile-strength (>1 GPa) metallic materials. Subsequently, a finite element analysis (FEA) was conducted to identify the improved dogbone geometries. A total of ten thousand dogbone geometries were tested, and their dimensions were defined by a set of four adjustable parameters (corner radius, load surface angle, load surface length, and dogbone head length). The gauge width and gauge length were fixed to 4 µm and 10 µm, respectively. Three-dimensional surface plots of the stress concentration as a function of two parameters were used to identify the optimal ranges of parameter values. The addition of maximum width and length constraints, measuring 25 µm and 30 µm, respectively, allowed us to identify an optimal geometry at load surface angles of 30° and 45°. Their respective dimensions (corner radius, load surface length, and dogbone head length) are, in µm, 12, 6, and 7 and 10, 7, and 7. Testing these two optimal geometries with a range of gauge lengths from 4 to 20 µm showed that smaller gauge lengths only slightly reduced the detrimental stress concentration outside the gauge section. However, smaller gauge lengths will notably improve the FIB surface polishing step as tapering is reduced with smaller dogbone lengths.

Chemistry↗

Life-test methodology for mechanical components

System is based on examining and testing each part of item under evaluation to determine whether aging processes, wear, or other inherent failure modes are likely to limit life to less than that required. Procedure may be applied to many long-life devices where statistical reliability analysis would be impractical.

Dufrane, K. F.↗

Polymer matrix and graphite fiber interface study

Hercules AS4 graphite fiber, unsized, or with EPON 828, PVA, or polysulfone sizing, was combined with three different polymer matrices. These included Hercules 3501-6 epoxy, Hercules 4001 bismaleimide, and Hexcel F155 rubber toughened epoxy. Unidirectional composites in all twelve combinations were fabricated and tested in transverse tension and axial compression. Quasi-isotropic laminates were tested in axial tension and compression, flexure, interlaminar shear, and tensile impact. All tests were conducted at both room temperature, dry and elevated temperature, and wet conditions. Single fiber pullout testing was also performed. Extensive scanning electron microphotographs of fracture surfaces are included, along with photographs of single fiber pullout failures. Analytical/experimental correlations are presented, based on the results of a finite element micromechanics analysis. Correlations between matrix type, fiber sizing, hygrothermal environment, and loading mode are presented. Results indicate that the various composite properties were only moderately influenced by the fiber sizings utilized.

Adams, D. F.↗

A Modeling Technique and Representation of Failure in the Analysis of Triaxial Braided Carbon Fiber Composites

Quasi-static tests have been performed on triaxially braided carbon fiber composite materials with large unit cell sizes. The effects of different fibers and matrix materials on the failure mode were investigated. Simulations of the tests have been performed using the transient dynamic finite element code, LS-DYNA. However, the wide range of failure modes observed for the triaxial braided carbon fiber composites during tests could not be simulated using composite material models currently available within LS-DYNA. A macroscopic approach has been developed that provides better simulation of the material response in these materials. This approach uses full-field optical measurement techniques to measure local failures during quasi-static testing. Information from these experiments is then used along with the current material models available in LS-DYNA to simulate the influence of the braided architecture on the failure process. This method uses two-dimensional shell elements with integration points through the thickness of the elements to represent the different layers of braid along with a new analytical method for the import of material stiffness and failure data directly. The present method is being used to examine the effect of material properties on the failure process. The experimental approaches used to obtain the required data will be described, and preliminary results of the numerical analysis will be presented.

Littell, Justin D.↗

A Modeling Technique and Representation of Failure in the Analysis of Triaxial Braided Carbon Fiber Composites

Quasi-static tests have been performed on triaxially braided carbon fiber composite materials with large unit cell sizes. The effects of different fibers and matrix materials on the failure mode were investigated. Simulations of the tests have been performed using the transient dynamic finite element code, LS-DYNA. However, the wide range of failure modes observed for the triaxial braided carbon fiber composites during tests could not be simulated using composite material models currently available within LS-DYNA. A macroscopic approach has been developed that provides better simulation of the material response in these materials. This approach uses full-field optical measurement techniques to measure local failures during quasi-static testing. Information from these experiments is then used along with the current material models available in LS-DYNA to simulate the influence of the braided architecture on the failure process. This method uses two-dimensional shell elements with integration points through the thickness of the elements to represent the different layers of braid along with a new analytical method for the import of material stiffness and failure data directly. The present method is being used to examine the effect of material properties on the failure process. The experimental approaches used to obtain the required data will be described, and preliminary results of the numerical analysis will be presented.

Littell, Justin D.↗

Signature analysis of acoustic emission from graphite/epoxy composites

Acoustic emissions were monitored for crack extension across and parallel to the fibers in a single ply and multiply laminates of graphite epoxy composites. Spectrum analysis was performed on the transient signal to ascertain if the fracture mode can be characterized by a particular spectral pattern. The specimens were loaded to failure quasistatically in a tensile machine. Visual observations were made via either an optical microscope or a television camera. The results indicate that several types of characteristics in the time and frequency domain correspond to different types of failure.

Russell, S. S.↗

Airframe life prediction

The required research to develop improved life prediction methods for metallic and composite structures under severe thermomechanical loading must include the development of a verified thermoinelastic fracture criterion. There has been much work in this area with many fracture criteria being proposed. Due to the lack of adequate experimental verification none of them are widely accepted. Research must also be performed to develop and implement improved thermoinelasticity theories that properly model large temperature excursions and high temperature gradient. This research is required to provide confidence in the simpler theories currently used for thermoinelastic analysis. Finally, experimental data is needed to define the behavior of and damage accumulation process in thermoinelastic materials. Special emphasis must be placed on understanding failure mode transitions under thermomechanical loading conditions.

Sendeckyj, G. P.↗

Software Performs Complex Design Analysis

Designers use computational fluid dynamics (CFD) to gain greater understanding of the fluid flow phenomena involved in components being designed. They also use finite element analysis (FEA) as a tool to help gain greater understanding of the structural response of components to loads, stresses and strains, and the prediction of failure modes. Automated CFD and FEA engineering design has centered on shape optimization, which has been hindered by two major problems: 1) inadequate shape parameterization algorithms, and 2) inadequate algorithms for CFD and FEA grid modification. Working with software engineers at Stennis Space Center, a NASA commercial partner, Optimal Solutions Software LLC, was able to utilize its revolutionary, one-of-a-kind arbitrary shape deformation (ASD) capability-a major advancement in solving these two aforementioned problems-to optimize the shapes of complex pipe components that transport highly sensitive fluids. The ASD technology solves the problem of inadequate shape parameterization algorithms by allowing the CFD designers to freely create their own shape parameters, therefore eliminating the restriction of only being able to use the computer-aided design (CAD) parameters. The problem of inadequate algorithms for CFD grid modification is solved by the fact that the new software performs a smooth volumetric deformation. This eliminates the extremely costly process of having to remesh the grid for every shape change desired. The program can perform a design change in a markedly reduced amount of time, a process that would traditionally involve the designer returning to the CAD model to reshape and then remesh the shapes, something that has been known to take hours, days-even weeks or months-depending upon the size of the model.

Source record↗

Design and Characterization of Thin Stainless Steel Burst Disks for Increasing Two-Stage Light Gas Launcher Efficiency

Laser etched 300 series Stainless Steel Burst Disks (SSBD) ranging between 0.178 mm (0.007-in.) and 0.508mm (0.020-in.) thick were designed for use in a 17-caliber two-stage light gas launcher. First, a disk manufacturing method was selected using a combination of wire electrical discharge machining (EDM) to form the blank disks and laser etching to define the pedaling fracture pattern. Second, a replaceable insert was designed to go between the SSDB and the barrel. This insert reduced the stress concentration between the SSBD and the barrel, providing a place for the petals of the SSDB to open, and protecting the rifling on the inside of the barrel. Thereafter, a design of experiments was implemented to test and characterize the burst characteristics of SSBDs. Extensive hydrostatic burst testing of the SSBDs was performed to complete the design of experiments study with one-hundred and seven burst tests. The experiment simultaneously tested the effects of the following: two SSBD material states (full hard, annealed); five SSBD thicknesses 0.178, 0.254, 0.305, 0.381 mm (0.007, 0.010, 0.012, 0.015, 0.020-in.); two grain directions relative); number of times the laser etch pattern was repeated (varies between 5-200 times); two heat sink configurations (with and without heat sink); and, two barrel configurations (with and without insert). These tests resulted in the quantification of the relationship between SSBD thickness, laser etch parameters, and desired burst pressure. Of the factors investigated only thickness and number of laser etches were needed to develop a mathematical relationship predicting hydrostatic burst pressure of disks using the same barrel configuration. The fracture surfaces of two representative SSBD bursts were then investigated with a scanning electron microscope, one burst hydrostatically in a fixture and another dynamically in the launcher. The fracture analysis verified that both burst conditions resulted in a ductile overload failure indicated by transgranular microvoid coalescence, non-fragmenting rupture and mixed tensile and shear failure modes, regardless of the material states tested. More testing is underway to determine the relationship between SSBD burst pressure and projectile velocity.

Tylka, Jonathan M.↗