Autofrettage Crack Growth in COPV liner Material
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Jonas Merrell↗
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Unconservatism of ANSI AIAA S081B for Damage Tolerance Life Analysis of COPVs
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D. S. Dawicke↗
Development of a Numerical Model of Hypervelocity Impact into a Pressurized Composite Overwrapped Pressure Vessel
As the outlook for space exploration becomes more ambitious and spacecraft travel deeper into space than ever before, it is increasingly important that propulsion systems perform reliably within the space environment. The increased reliability compels designers to increase design margin at the expense of system mass, which contrasts with the need to limit vehicle mass to maximize payload. Such are the factors that motivate the integration of high specific strength composite materials in the construction of pressure vessels commonly referred to as composite overwrapped pressure vessels (COPV). The COPV consists of a metallic liner for the inner shell of the COPV that is stiff, negates fluid permeation and serves as the anchor for composite laminates or filaments, but the liner itself cannot contain the stresses from the pressurant it contains. The compo-site-fiber reinforced polymer (CFRP) is wound around the liner using a combination of hoop (circumferential) and helical orientations. Careful consideration of wrap orientation allows the composite to evenly bear structural loading and creates the COPV's characteristic high strength to weight ratio. As the CFRP overwrap carries most of the stresses induced by pressurization, damage to the overwrap can affect mission duration, mission success and potentially cause loss-of-vehicle/loss-of-crew. For this reason, it is critical to establish a fundamental understanding of the mechanisms involved in the failure of a stressed composite such as that of the COPV. One of the greatest external threats to the integrity of a spacecraft's COPV is an impact from the meteoroid and orbital debris environments (MMOD). These impacts, even from submillimeter particles, generate extremely high stress states in the CFRP that can damage numerous fibers. As a result of this possibility, initial assumptions in survivability analysis for some human-rated NASA space-craft have assumed that any alteration of the vessel due to impact is considered a catastrophic failure. This assumption is conservative and made due to lack of knowledge on the level of allow-able damage to the composite overwrap that can be sustained and still allow successful completion of the mission. To quantify the allowable damage level to the composite overwrap involves assessing stress redistribution following damage as well as evaluating possible time-dependent mechanisms involved in the COPV response to an impact event. Limited published work in this subject has shown that COPV can withstand at least some level of damage due to high energy impacts. These observations have been confirmed and expanded upon in recent experimental research performed by NASA. This research has demonstrated that there is not only robustness in a COPV to compensate for CFRP damage, but has also identified two significant failure modes for pressurized COPV. The lowest threshold failure mode involves the perforation of the vessel, and the highest threshold failure mode is the catastrophic rupture. While both of these failure modes mean a loss of the COPV, system robustness affords some tolerance to the venting as opposed to the more catastrophic rupture. As a consequence, it is necessary to understand the conditions that result in the transition between these failure modes. The aforementioned experimental research has been performed in both the unpressurized and pressurized condition to identify the damage level that triggered the failure thresh-old. This COPV test program was sponsored by the NASA Engineering and Safety Center (NESC), and tests were performed at NASA White Sands Test Facility (WSTF). Planning and coordination were provided by NASA JSC Hypervelocity Impact Technology (HVIT) group, and the COPVs were provided by the ISS Program. Unpressurized testing has been conducted at the pressure of the vacuum test chamber, while, the pressurized testing has been conducted at 290 +/- 10 bar (4,200 100 psi) using nitrogen as the pressurizing gas, which corresponds to the design pressure for the target COPV. In this research, spherical aluminum projectiles with varying diameter has been chosen as the impactor. For the unpressurized COPV, the dependence of penetration up to the dependence of hole size in the liner has been obtained as a function of impact conditions. For the pressurized research, the dependence of penetration up to rupture has been obtained as a function of im-pact conditions. Two representative post-test photographs of the failed COPV's from a nor-mal impact into the COPV surface are shown in Fig. 1. These images display the dramatic difference between failure modes, venting (Fig. 1a) and rupture (Fig. 1b). For venting, liner perforation, severed composite fibers/tows and ply delamination are commonly observed damage characteristics of this COPV failure mode. In the case of rupture, the COPV typically experienced a separation of its domed regions and severe break-up of the cylindrical region. Fully understanding the transition from venting to rupture experimentally is costly and potentially unachievable for conditions that cannot be generated in the laboratory. These shortcomings have motivated the performance of three-dimensional numerical simulations to expand the existing experimental database. These simulations have been carried out with the nonlinear-structural-dynamics, analysis-tool, CTH. A typical pressure contour plot from an impact simulation of an entire COPV is shown in Fig. 2. To generate the COPV stress state without initiating a shock wave, the pressure in the simulated COPV is ramped up to the final pressure over a millisecond prior to impact of the projectile with nitrogen gas. Figure 2a shows the system in this initial condition. After one millisecond, a projectile is initiated into the simulation and impacts the COPV. Figure 2b shows the system after this impact. In the figure, the onset of venting is represented as the change in pressure (μbar), red to green, at the perforation site. Also seen in the figure is the eroded projectile that had passed into the COPV vessel with the generated shock wave in the pressurant propagating just ahead of the material. In this paper, pertinent experimental details and the development of the material constitutive models necessary for this work along with the efforts to validate their use are dis-cussed. The simulation results are presented and compared with the NASA experimental observations. While work is on-going from this effort, early observations pertinent to the failure threshold are presented.
Garcia, M. A.↗
Self-Healing Nanocomposites for Reusable Composite Cryotanks
Composite cryotanks, or composite overwrapped pressure vessels (COPVs), offer advantages over currently used aluminum-lithium cryotanks, particularly with respect to weight savings. Future NASA missions are expected to use COPVs in spaceflight propellant tanks to store fuels, oxidizers, and other liquids for launch and space exploration vehicles. However, reliability, reparability, and reusability of the COPVs are still being addressed, especially in cryogenic temperature applications; this has limited the adoption of COPVs in reusable vehicle designs. The major problem with composites is the inherent brittleness of the epoxy matrix, which is prone to microcrack formation, either from exposure to cryogenic conditions or from impact from different sources. If not prevented, the microcracks increase gas permeation and leakage. Accordingly, materials innovations are needed to mitigate microcrack damage, and prevent damage in the first place, in composite cryotanks. The self-healing technology being developed is capable of healing the microcracks through the use of a novel engineered nanocomposite, where a uniquely designed nanoparticle additive is incorporated into the epoxy matrix. In particular, this results in an enhancement in the burst pressure after cryogenic cycling of the nanocomposite COPVs, relative to the control COPVs. Incorporating a novel, self-healing, epoxy-based resin into the manufacture of COPVs allows repeatable self-healing of microcracks to be performed through the simple application of a low-temperature heat source. This permits COPVs to be reparable and reusable with a high degree of reliability, as microcracks will be remediated. The unique phase-separated morphology that was imparted during COPV manufacture allows for multiple self-healing cycles. Unlike single-target approaches where one material property is often improved at the expense of another, robustness has been introduced to a COPV by a combination of a modified resin and nanoparticle additives. Unique nanoparticles were used that have been surface-functionalized to be compatible with the resin. Both organic and inorganic components toughen the matrix and result in a more impact-resistant COPV. In one resin system containing an inorganic nanomaterial additive, a significant improvement in burst performance was observed after the COPV was cryo-impact-damaged and then self-healed, with a greater than 10% improvement in burst pressure after the self-healing process was performed. Initial cross-sectional analysis via microscopy showed good resin infiltration of the carbon fibers and without voids. To further enhance the capability between the nanomaterial additives and the resin, a surface modification was successfully performed. A second specialty epoxy resin was prepared using a surface modified nanomaterial additive, and COPVs were fabricated. Steps were taken to improve the mechanical properties of the COPVs by using a low-viscosity resin system that contained a different curing agent. This lower viscosity improves the processing of the COPV, and preliminary results show that the burst pressure of these new vessels is 20 to 25% higher than that of the original. The self-healing concept demonstrated in this research and development effort represents a platform technology, and the self-healing property is neither restricted to the particular epoxy system used here, nor to the COPV application. Self-healing is a direct result of a unique phase separated morphology created via the resin and is aided by the nanoparticles. The self-healing function can be introduced to other customer-specific resin systems in coating, bulk, or composite applications provided that the unique phase separated morphology can be enabled in those systems.
Eberly, Daniel↗
Testing of Full Scale Flight Qualified Kevlar Composite Overwrapped Pressure Vessels
Many decades ago NASA identified a need for low-mass pressure vessels for carrying various fluids aboard rockets, spacecraft, and satellites. A pressure vessel design known as the composite overwrapped pressure vessel (COPV) was identified to provide a weight savings over traditional single-material pressure vessels typically made of metal and this technology has been in use for space flight applications since the 1970's. A typical vessel design consisted of a thin liner material, typically a metal, overwrapped with a continuous fiber yarn impregnated with epoxy. Most designs were such that the overwrapped fiber would carry a majority of load at normal operating pressures. The weight advantage for a COPV versus a traditional singlematerial pressure vessel contributed to widespread use of COPVs by NASA, the military, and industry. This technology is currently used for personal breathing supply storage, fuel storage for auto and mass transport vehicles and for various space flight and aircraft applications. The NASA Engineering and Safety Center (NESC) was recently asked to review the operation of Kevlar 2 and carbon COPVs to ensure they are safely operated on NASA space flight vehicles. A request was made to evaluate the life remaining on the Kevlar COPVs used on the Space Shuttle for helium and nitrogen storage. This paper provides a review of Kevlar COPV testing relevant to the NESC assessment. Also discussed are some key findings, observations, and recommendations that may be applicable to the COPV user community. Questions raised during the investigations have revealed the need for testing to better understand the stress rupture life and age life of COPVs. The focus of this paper is to describe burst testing of Kevlar COPVs that has been completed as a part of an the effort to evaluate the effects of ageing and shelf life on full scale COPVs. The test articles evaluated in this discussion had a diameter of 22 inches for S/N 014 and 40 inches for S/N 011. The time between manufacture and burst was 28 and 22 years. Visual inspection, shearography, heat soak thermography and borescope inspection were performed on vessel S/N 011 and all but shearography was performed on S/N 014 before they were tested and details of this work can be found in a companion paper titled, "Nondestructive Methods and Special Test Instrumentation Supporting NASA Composite Overwrapped Pressure Vessel Assessments." The vessels were instrumented so that measurements could be made to aid in the understanding of vessel response. Measurements made on the test articles included girth, boss displacement, internal volume, multiple point strain, full field strain, eddy current, acoustic emission (AE) pressure and temperature. The test article before and during burst is shown with the pattern used for digital image correlation full field strain measurement blurring as the vessel fails.
Greene, Nathanael↗
Material Issues in Space Shuttle Composite Overwrapped Pressure Vessels
Composite Overwrapped Pressure Vessels (COPV) store gases used in four subsystems for NASA's Space Shuttle Fleet. While there are 24 COPV on each Orbiter ranging in size from 19-40", stress rupture failure of a pressurized Orbiter COPV on the ground or in flight is a catastrophic hazard and would likely lead to significant damage/loss of vehicle and/or life and is categorized as a Crit 1 failure. These vessels were manufactured during the late 1970's and into the early 1980's using Titanium liners, Kevlar 49 fiber, epoxy matrix resin, and polyurethane coating. The COPVs are pressurized periodically to 3-5ksi and therefore experience significant strain in the composite overwrap. Similar composite vessels were developed in a variety of DOE Programs (primarily at Lawrence Livermore National Laboratories or LLNL), as well as for NASA Space Shuttle Fleet Leader COPV program. The NASA Engineering Safety Center (NESC) formed an Independent Technical Assessment (ITA) team whose primary focus was to investigate whether or not enough composite life remained in the Shuttle COPV in order to provide a strategic rationale for continued COPV use aboard the Space Shuttle Fleet with the existing 25-year-old vessels. Several material science issues were examined and will be discussed in this presentation including morphological changes to Kevlar 49 fiber under stress, manufacturing changes in Kevlar 49 and their effect on morphology and tensile strength, epoxy resin strain, composite creep, degradation of polyurethane coatings, and Titanium yield characteristics.
Sutter, James K.↗
Damage Control Plan for International Space Station Recharge Tank Assembly Composite Overwrapped Pressure Vessel
As NASA has retired the Space Shuttle Program, a new method of transporting compressed gaseous nitrogen and oxygen needed to be created for delivery of these crucial life support resources to the International Space Station (ISS). One of the methods selected by NASA includes the use of highly pressurized, unprotected Recharge Tank Assemblies (RTAs) utilizing Composite Overwrapped Pressure Vessels (COPVs). A COPV consists of a thin liner wrapped with a fiber composite and resin or epoxy. It is typically lighter weight than an all metal pressure vessel of similar volume and therefore provides a higher-efficiency means for gas storage. However COPVs are known to be susceptible to damage resulting from handling, tool drop impacts, or impacts from other objects. As a result, a comprehensive Damage Control Plan has been established to mitigate damage to the RTA COPV throughout its life cycle. The DCP is intended to evaluate and mitigate defined threats during manufacturing, shipping and handling, test, assembly level integration, shipment while pressurized, launch vehicle integration and mission operations by defining credible threats and methods for preventing potential damage while still maintaining the primary goal of resupplying ISS gas resources. A comprehensive threat assessment is performed to identify all threats posed to the COPV during the different phases of its lifecycle. The threat assessment is then used as the basis for creating a series of general inspection, surveillance and reporting requirements which apply across all phases of the COPV's life, targeted requirements only applicable to specific work phases and a series of training courses for both ground personnel and crew aboard the ISS. A particularly important area of emphasis deals with creating DCP requirements for a highly pressurized, large and unprotected RTA COPV for use during Inter Vehicular Activities (IVA) operations in the micro gravity environment while supplying pressurized gas to the ISS for crew life support.
Cook, Anthony J.↗
Continued Development of Meandering Winding Magnetometer (MWM (Register Trademark)) Eddy Current Sensors for the Health Monitoring, Modeling and Damage Detection of Composite Overwrapped Pressure Vessels
Composite Overwrapped Pressure Vessels (COPVs) are used in essentially all NASA spacecraft, launch. vehicles and payloads to contain high-pressure fluids for propulsion, life support systems and science experiments. Failure of any COPV either in flight or during ground processing would result in catastrophic damage to the spacecraft or payload, and could lead to loss of life. Therefore, NASA continues to investigate new methods to non-destructively inspect (NDE) COPVs for structural anomalies and to provide a means for in-situ structural health monitoring (SHM) during operational service. Partnering with JENTEK Sensors, engineers at NASA, Kennedy Space Center have successfully conducted a proof-of-concept study to develop Meandering Winding Magnetometer (MWM) eddy current sensors designed to make direct measurements of the stresses of the internal layers of a carbon fiber composite wrapped COPV. During this study three different MWM sensors were tested at three orientations to demonstrate the ability of the technology to measure stresses at various fiber orientations and depths. These results showed good correlation with actual surface strain gage measurements. MWM-Array technology for scanning COPVs can reliably be used to image and detect mechanical damage. To validate this conclusion, several COPVs were scanned to obtain a baseline, and then each COPV was impacted at varying energy levels and then rescanned. The baseline subtracted images were used to demonstrate damage detection. These scans were performed with two different MWM-Arrays. with different geometries for near-surface and deeper penetration imaging at multiple frequencies and in multiple orientations of the linear MWM drive. This presentation will include a review of micromechanical models that relate measured sensor responses to composite material constituent properties, validated by the proof of concept study, as the basis for SHM and NDE data analysis as well as potential improvements including design changes to miniaturize and make the sensors durable in the vacuum of space
Russell, Richard↗
Comparison of Side-on Peak Overpressure Predictions and Measurements for Type IV Composite Overwrapped Pressure Vessel Catastrophic Failure
This development of empirical data to support realistic and science-based input to safety regulations and transportation standards is a critical need for the hazardous material (HM) transportation industry. Current regulations and standards are based on the TNT equivalency model. However, real world experience indicates that use of the TNT equivalency model to predict composite overwrapped pressure vessel (COPV) potential energy release is unrealistically conservative. The purpose of this report is to characterize and quantify rupture events involving damaged COPV’s of the type used in HM transportation regulated by the Department of Transportation (DOT). This was accomplished using a series of five tests; 2 COPV tests for compressed natural gas (CNG), 2 COPV tests for hydrogen, and 1 COPV test for nitrogen. Measured overpressures from these tests were compared to predicted overpressures from a TNT equivalence model and blast curves. Comparison between the measurements and predictions shows that the predictions are generally conservative, and that the extent of conservatism is dominated by predictions of the chemical contribution to overpressure from fuel within the COPVs.
37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
Composite Overwrapped Pressure Vessels, A Primer
Due to the extensive amount of detailed information that has been published on composite overwrapped pressure vessels (COPVs), this document has been written to serve as a primer for those who desire an elementary knowledge of COPVs and the factors affecting composite safety. In this application, the word "composite" simply refers to a matrix of continuous fibers contained within a resin and wrapped over a pressure barrier to form a vessel for gas or liquid containment. COPVs are currently used at NASA to contain high pressure fluids in propulsion, science experiments, and life support applications. They have a significant weight advantage over all metal vessels but require unique design, manufacturing, and test requirements. COPVs also involve a much more complex mechanical understanding due to the interplay between the composite overwrap and the inner liner. A metallic liner is typically used in a COPV as a fluid permeation barrier. The liner design concepts and requirements have been borrowed from all-metal vessels. However, application of metallic vessel design standards to a very thin liner is not straightforward. Different failure modes exist for COPVs than for all-metal vessels, and understanding of these failure modes is at a much more rudimentary level than for metal vessels.
McLaughlan, Pat B.↗
In-Situ Nondestructive Evaluation of Kevlar(Registered Trademark)and Carbon Fiber Reinforced Composite Micromechanics for Improved Composite Overwrapped Pressure Vessel Health Monitoring
NASA has been faced with recertification and life extension issues for epoxy-impregnated Kevlar 49 (K/Ep) and carbon (C/Ep) composite overwrapped pressure vessels (COPVs) used in various systems on the Space Shuttle and International Space Station, respectively. Each COPV has varying criticality, damage and repair histories, time at pressure, and pressure cycles. COPVs are of particular concern due to the insidious and catastrophic burst-before-leak failure mode caused by stress rupture (SR) of the composite overwrap. SR life has been defined [1] as the minimum time during which the composite maintains structural integrity considering the combined effects of stress level(s), time at stress level(s), and associated environment. SR has none of the features of predictability associated with metal pressure vessels, such as crack geometry, growth rate and size, or other features that lend themselves to nondestructive evaluation (NDE). In essence, the variability or surprise factor associated with SR cannot be eliminated. C/Ep COPVs are also susceptible to impact damage that can lead to reduced burst pressure even when the amount of damage to the COPV is below the visual detection threshold [2], thus necessitating implementation of a mechanical damage control plan [1]. Last, COPVs can also fail prematurely due to material or design noncompliance. In each case (SR, impact or noncompliance), out-of-family behavior is expected leading to a higher probability of failure at a given stress, hence, greater uncertainty in performance. For these reasons, NASA has been actively engaged in research to develop NDE methods that can be used during post-manufacture qualification, in-service inspection, and in-situ structural health monitoring. Acoustic emission (AE) is one of the more promising NDE techniques for detecting and monitoring, in real-time, the strain energy release and corresponding stress-wave propagation produced by actively growing flaws and defects in composite materials [3,4,5,6,7,8]. To gain further insight into the mechanisms responsible for composite rupture, broadband modal acoustic emission analysis was used. Also, since AE data reduction proved to be very time consuming, specialized data reduction software was written to automate the process.
Waller, Jess↗
Overview of NASA White Sands Test Facility Composite Overwrapped Pressure Vessel Testing
This viewgraph presentation examines the White Sands Test Facility testing of Composite overwrapped pressure vessel (COPV). A COPV is typically a metallic liner overwrapped with a fiber epoxy matrix. There is a weight advantage over the traditional all metal design. The presentation shows pictures of the facilities at White Sands, and then examines some of the testing performed. The tests include fluids compatibility, and Kevlar COPV. Data for the Kevlar tests are given, and an analysis is reviewed. There is also a comparison between Carbon COPVs and the Kevlar COPVs.
Greene, Nathanael↗
ANSI/AIAA S-081A, Pressure Vessel Standards Implementation Guidelines
The stress rupture specification for Composite Overwrapped Pressure Vessels (COPV) is discussed. The composite shell of the COPV shall be designed to meet the design life considering the time it is under sustained load. A Mechcanical Damage Control Plan (MDCP) shall be created and implemented that assures the COPV will not fail due to mechanical damage due to manufacturing, testing, shipping, installation, or flight. Proven processes and procedures for fabrication and repair shall be used to preclude damage or material degradation during material processing, manufacturing operations, and refurbushment.Selected NDI techniques for the liner and/or boss(es) shall be performed before overwrapping with composite. When visual inspection reveals mechanical damage or defects exceeding manufacturing specification levels (and standard repair procedures), the damaged COPV shall be submitted to a material review board (MRB) for disposition. Every COPV shall be subjected to visual and other non-destructive inspection (NDI), per the inspection plan.
Greene, Nathanael J.↗
Voluntary Consensus Organization Standards for Nondestructive Evaluation of Thin-Walled Metallic Liners and Composite Overwraps in Composite Overwrapped Pressure Vessels
NASA fracture control requirements outlined in NASA-STD-5009 and NASA-STD-5014 are predicated on the availability and use of sensitive nondestructive evaluation (NDE) methods that can detect and monitor defects, thereby providing data that can be used to predict failure or reduce the risk of failure in fracture critical components. However, in the case of composite materials and components, including composite overwrapped pressure vessels (COPVs), the effect of defects is poorly understood, the NDE methods used to evaluate locate and size defects are typically at lower technical readiness level than analogous NDE methods used for metals, and demonstration studies to verify the probability of detection (POD) are generally lacking or unavailable. These factors together make failure prediction of fracture critical composite materials and components based on size, quantity, or orientation of defects nearly impossible. Also, when inspecting metal liners in as-manufactured COPVs, sensitivity is lost and only the inner surface of the liner is accessible. Also, NDE of COPVs as applied during manufacturing varies significantly from manufacturer to manufacturer and has not yet been standardized. Although requirements exist to perform NDE immediately after manufacturing to establish initial integrity of the parts, procedural detail for NDE of composites is still nonexistent or under development. For example, in practice, only a visual inspection of COPVs is performed during manufacturing and service, leaving in question whether defects of concern, for example, bridging, overwrap winding anomalies, impact damage below visible threshold, out-of-family strain growth, and liner buckling have been adequately detected and monitored. To address these shortcomings, in 2005 the NASA Nondestructive Evaluation Working Group (NNWG) began funding work to develop and adopt standards for nondestructive evaluation of aerospace composites in collaboration with the American Society for Testing and Materials (ASTM) Committee E07 on Nondestructive Testing. Similarly, in 2006 the NASA Engineering and Safety Center (NESC) recommended that nondestructive evaluation methods that can predict composite failure in COPVs should be developed and verified, and integrated into the damage control plan for these vessels
Waller, Jess↗
Smart Composite Pressure Vessels (SCPV) with Integrated Health Monitoring
The U.S. Department of Energy (DOE) is promoting and developing more energy efficient and environmentally friendly technologies that will enable America to use less petroleum. Hydrogen fuel cells – which directly convert the chemical energy in hydrogen to electricity with only water and heat as byproducts – are a very attractive solution that can enable this to happen. To date, DOE's efforts have culminated in commercial demonstration of on-board vehicular hydrogen storage systems that can allow for a driving range of greater than 300 miles. This requires storing 5 Kgs of hydrogen onboard a light vehicle. In order to store this quantity of hydrogen, the hydrogen gas needs to be stored in a composite overwrapped pressure vessel (COPV) at a very high internal pressure. The objective of the program was to demonstrate continuous and predictable health-monitoring of composite pressure vessels. A higher confidence in the operational safety of the vessels will lead to reduced burst factor of safety imposed by regulatory standards and hence will help reduce the structural wall thickness that drives the cost of the vessel. Highly optimized Type III (metal lined) and Type IV (polymer lined) COPVs that are manufactured using filament winding process have been designed and qualified for the above mentioned application. However, the main structural component of the COPVs is carbon fiber and the high cost of carbon fiber composite in a pressure vessel is a primary challenge in reducing the cost of gaseous hydrogen storage. Continuous and remote monitoring of structural health of the COPVs as well as optimization of the strength translation of carbon fibers have the potential to allow for reduced factor of safety, thereby reduced amount of carbon and associated cost of the vessel. In the current program, the project team including Steelhead Composites (SHC), University of Tennessee, Knoxville (UTK), Teijin Carbon America, Oak Ridge National Laboratory (ORNL) and LUNA designed, fabricated, and tested smart composite pressure vessels with integrated sensors. Iterative loops of design and testing using coupons, subscale STEB vessels and full size vessels proved that a new generation of high performance carbon fiber can be used for efficient design of Type 3 vessels for H2 storage. Novel analysis techniques were developed to predict the initiation and propagation of interlaminar damage inside the composite shell due to impact damage, a real threat in practical operation. Such an analysis scheme is typically not used in tank design but is an essential tool for health monitoring of composite vessels. Remote sensing of the key signatures of the tank’s operating parameters such as pressure, acceleration and humidity was demonstrated using a unique device that can wirelessly transmit and stream the data to a remote server. Fiber optic sensors were successfully integrated during fabrication of the tanks. These sensors provide a wealth of information regarding the structural health of the vessel when it is subsequently pressurized or subjected to impact damage. Excellent correlation was demonstrated between the fiber optic sensor and mechanical strain gage data, and between the measurements and analytical predictions.
08 HYDROGEN↗
Experimental Investigation of the Shuttle Transportation System Composite Overwrapped Pressure Vessels for Stress Rupture Life
A viewgraph presentation describing stress rupture testing on Composite Overwrapped Pressure Vessels (COPV) is shown. The topics include: 1) Purpose for Testing; 2) NASA WSTF COPV Test Program; 3) NASA WSTF Test Facilities; 4) COPV Impact Study; 5) Fluids Compatibility Testing; 6) Stress Rupture Testing; and 7) COPV Lifting.
Greene, Nathanael↗
Designing of a Fleet-Leader Program for Carbon Composite Overwrapped Pressure Vessels
Composite Overwrapped Pressure Vessels (COPVs) are often used for storing pressurant gases on board spacecraft when mass saving is a prime requirement. Substantial weight savings can be achieved compared to all metallic pressure vessels. For example, on the space shuttle, replacement of all metallic pressure vessels with Kevlar COPVs resulted in a weight savings of about 30 percent. Mass critical space applications such as the Ares and Orion vehicles are currently being planned to use as many COPVs as possible in place of all-metallic pressure vessels to minimize the overall mass of the vehicle. Due to the fact that overwraps are subjected to sustained loads during long periods of a mission, stress rupture failure is a major concern. It is, therefore, important to ascertain the reliability of these vessels by analysis, since it is practically impossible to show by experimental testing the reliability of flight quality vessels. Also, it is a common practice to set aside flight quality vessels as "fleet leaders" in a test program where these vessels are subjected to slightly accelerated operating conditions so that they lead the actual flight vessels both in time and load. The intention of fleet leaders is to provide advanced warning if there is a serious design flaw in the vessels so that a major disaster in the flight vessels can be averted with advance warning. On the other hand, the accelerating conditions must be not so severe as to be prone to false alarms. The primary focus of the present paper is to provide an analytical basis for designing a viable fleet leader program for carbon COPVs. The analysis is based on a stress rupture behavior model incorporating Weibull statistics and power-law sensitivity of life to fiber stress level.
Murthy, Pappu L.N.↗
Fiber Breakage Model for Carbon Composite Stress Rupture Phenomenon: Theoretical Development and Applications
Stress rupture failure of Carbon Composite Overwrapped Pressure Vessels (COPVs) is of serious concern to Science Mission and Constellation programs since there are a number of COPVs on board space vehicles with stored gases under high pressure for long durations of time. It has become customary to establish the reliability of these vessels using the so called classic models. The classical models are based on Weibull statistics fitted to observed stress rupture data. These stochastic models cannot account for any additional damage due to the complex pressure-time histories characteristic of COPVs being supplied for NASA missions. In particular, it is suspected that the effects of proof test could significantly reduce the stress rupture lifetime of COPVs. The focus of this paper is to present an analytical appraisal of a model that incorporates damage due to proof test. The model examined in the current paper is based on physical mechanisms such as micromechanics based load sharing concepts coupled with creep rupture and Weibull statistics. For example, the classic model cannot accommodate for damage due to proof testing which every flight vessel undergoes. The paper compares current model to the classic model with a number of examples. In addition, several applications of the model to current ISS and Constellation program issues are also examined.
Murthy, Pappu L. N.↗