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NASA NTRS2001

Gear Damage Detection Using Oil Debris Analysis

The purpose of this paper was to verify, when using an oil debris sensor, that accumulated mass predicts gear pitting damage and to identify a method to set threshold limits for damaged gears. Oil debris data was collected from 8 experiments with no damage and 8 with pitting damage in the NASA Glenn Spur Gear Fatigue Rig. Oil debris feature analysis was performed on this data. Video images of damage progression were also collected from 6 of the experiments with pitting damage. During each test, data from an oil debris sensor was monitored and recorded for the occurrence of pitting damage. The data measured from the oil debris sensor during experiments with damage and with no damage was used to identify membership functions to build a simple fuzzy logic model. Using fuzzy logic techniques and the oil debris data, threshold limits were defined that discriminate between stages of pitting wear. Results indicate accumulated mass combined with fuzzy logic analysis techniques is a good predictor of pitting damage on spur gears.

Dempsey, Paula J.↗

NASA NTRS2006

Dynamics and Adaptive Control for Stability Recovery of Damaged Aircraft

This paper presents a recent study of a damaged generic transport model as part of a NASA research project to investigate adaptive control methods for stability recovery of damaged aircraft operating in off-nominal flight conditions under damage and or failures. Aerodynamic modeling of damage effects is performed using an aerodynamic code to assess changes in the stability and control derivatives of a generic transport aircraft. Certain types of damage such as damage to one of the wings or horizontal stabilizers can cause the aircraft to become asymmetric, thus resulting in a coupling between the longitudinal and lateral motions. Flight dynamics for a general asymmetric aircraft is derived to account for changes in the center of gravity that can compromise the stability of the damaged aircraft. An iterative trim analysis for the translational motion is developed to refine the trim procedure by accounting for the effects of the control surface deflection. A hybrid direct-indirect neural network, adaptive flight control is proposed as an adaptive law for stabilizing the rotational motion of the damaged aircraft. The indirect adaptation is designed to estimate the plant dynamics of the damaged aircraft in conjunction with the direct adaptation that computes the control augmentation. Two approaches are presented 1) an adaptive law derived from the Lyapunov stability theory to ensure that the signals are bounded, and 2) a recursive least-square method for parameter identification. A hardware-in-the-loop simulation is conducted and demonstrates the effectiveness of the direct neural network adaptive flight control in the stability recovery of the damaged aircraft. A preliminary simulation of the hybrid adaptive flight control has been performed and initial data have shown the effectiveness of the proposed hybrid approach. Future work will include further investigations and high-fidelity simulations of the proposed hybrid adaptive Bight control approach.

Nguyen, Nhan↗

NASA NTRS2011

Coupling Between Doppler Radar Signatures and Tornado Damage Tracks

On April 27, 2011, the southeastern United States was raked with several episodes of severe weather. Numerous tornadoes caused extensive damage, and tragically, the deaths of over 300 people. In Alabama alone, there were 61 confirmed tornados, 4 of them produced EF5 damage, and several were on the ground an hour or more with continuous damage tracks exceeding 80km. The use of Doppler radars covering the region provided reflectivity and velocity signatures that allowed forecasters to monitors the severe storms from beginning to end issuing hundreds of severe weather warnings throughout the day. Meteorologists from the the NWS performed extensive surveys to assess the intensity, duration, and ground track of tornadoes reported during the event. Survey activities included site visits to the affected locations, analysis of radar and satellite data, aerial surveys, and interviews with eyewitnesses. Satellite data from NASA's MODIS and ASTER instruments played a helpful role in determining the location of tornado damage paths and in the assessment. High resolution multispectral and temporal composites helped forecasters corroborate their damage assessments, determine starting and ending points for tornado touchdowns, and helped to provide forecasters with a better big-picture view of the damage region. The imagery also helped to separate damage from the April 27th tornados from severe weather that occurred earlier that month. In a post analysis of the outbreak, tornado damage path signatures observed in the NASA satellite data have been correlated to "debris ball" signatures in the NWS Doppler radars and a special ARMOR dual-polarization radar operated by the University of Alabama Huntsville during the event. The Doppler radar data indicates a circular enhanced reflectivity signal and rotational couplet in the radial velocity likely associated with the tornado that is spatially correlated with the damage tracks in the observed satellite data. An algorithm to detect and isolate the "debris ball" from precipitation signatures in the dual polarization radar data has been developed and verified using the NASA damage track data.

Jedlovec, Gary J.↗

NASA NTRS2014

Open Circuit Resonant (SansEC) Sensor Technology for Lightning Mitigation and Damage Detection and Diagnosis for Composite Aircraft Applications

Traditional methods to protect composite aircraft from lightning strike damage rely on a conductive layer embedded on or within the surface of the aircraft composite skin. This method is effective at preventing major direct effect damage and minimizes indirect effects to aircraft systems from lightning strike attachment, but provides no additional benefit for the added parasitic weight from the conductive layer. When a known lightning strike occurs, the points of attachment and detachment on the aircraft surface are visually inspected and checked for damage by maintenance personnel to ensure continued safe flight operations. A new multi-functional lightning strike protection (LSP) method has been developed to provide aircraft lightning strike protection, damage detection and diagnosis for composite aircraft surfaces. The method incorporates a SansEC sensor array on the aircraft exterior surfaces forming a "Smart skin" surface for aircraft lightning zones certified to withstand strikes up to 100 kiloamperes peak current. SansEC sensors are open-circuit devices comprised of conductive trace spiral patterns sans (without) electrical connections. The SansEC sensor is an electromagnetic resonator having specific resonant parameters (frequency, amplitude, bandwidth & phase) which when electromagnetically coupled with a composite substrate will indicate the electrical impedance of the composite through a change in its resonant response. Any measureable shift in the resonant characteristics can be an indication of damage to the composite caused by a lightning strike or from other means. The SansEC sensor method is intended to diagnose damage for both in-situ health monitoring or ground inspections. In this paper, the theoretical mathematical framework is established for the use of open circuit sensors to perform damage detection and diagnosis on carbon fiber composites. Both computational and experimental analyses were conducted to validate this new method and system for aircraft composite damage detection and diagnosis. Experimental test results on seeded fault damage coupons and computational modeling simulation results are presented. This paper also presents the shielding effectiveness along with the lightning direct effect test results from several different SansEC LSP and baseline protected and unprotected carbon fiber reinforced polymer (CFRP) test panels struck at 40 and 100 kiloamperes following a universal common practice test procedure to enable damage comparisons between SansEC LSP configurations and common practice copper mesh LSP approaches. The SansEC test panels were mounted in a LSP test bed during the lightning test. Electrical, mechanical and thermal parameters were measured during lightning attachment and are presented with post test nondestructive inspection comparisons. The paper provides correlational results between the SansEC sensors computed electric field distribution and the location of the lightning attachment on the sensor trace and visual observations showing the SansEC sensor's affinity for dispersing the lightning attachment.

Szatkowski, George N.↗

NASA NTRS2015

Dissemination of Earth Remote Sensing Data for Use in the NOAA/NWS Damage Assessment Toolkit

The National Weather Service has developed the Damage Assessment Toolkit (DAT), an application for smartphones and tablets that allows for the collection, geolocation, and aggregation of various damage indicators that are collected during storm surveys. The DAT supports the often labor‐intensive process where meteorologists venture into the storm‐affected area, allowing them to acquire geotagged photos of the observed damage while also assigning estimated EF‐scale categories based upon their observations. Once the data are collected, the DAT infrastructure aggregates the observations into a server that allows other meteorologists to perform quality control and other analysis steps before completing their survey and making the resulting data available to the public. In addition to in‐person observations, Earth remote sensing from operational, polar-orbiting satellites can support the damage assessment process by identifying portions of damage tracks that may be missed due to road limitations, access to private property, or time constraints. Products resulting from change detection techniques can identify damage to vegetation and the land surface, aiding in the survey process. In addition, higher resolution commercial imagery can corroborate ground‐based surveys by examining higher‐resolution commercial imagery. As part of an ongoing collaboration, NASA and NOAA are working to integrate near real‐time Earth remote sensing observations into the NOAA/NWS Damage Assessment Toolkit. This presentation will highlight recent developments in a streamlined approach for disseminating Earth remote sensing data via web mapping services and a new menu interface that has been integrated within the DAT. A review of current and future products will be provided, including products derived from MODIS and VIIRS for preliminary track identification, along with conduits for higher‐resolution Landsat, ASTER, and commercial imagery as they become available. In addition to tornado damage assessments, the team is also investigating the use of near real‐time imagery for identifying hail damage to vegetation, which also results in large swaths of damage, particularly in the central United States during the peak growing season months of June, July, and August. This presentation will present an overview of recent activities, challenges and successes, best practices, and opportunities for future work and collaboration

Molthan, Andrew↗

NASA NTRS2016

Characterization of Aircraft Structural Damage Using Guided Wave Based Finite Element Analysis for In-Flight Structural Health Management

The development of multidisciplinary Integrated Vehicle Health Management (IVHM) tools will enable accurate detection, diagnosis and prognosis of damage under normal and adverse conditions during flight. The adverse conditions include loss of control caused by environmental factors, actuator and sensor faults or failures, and structural damage conditions. A major concern is the growth of undetected damage/cracks due to fatigue and low velocity foreign object impact that can reach a critical size during flight, resulting in loss of control of the aircraft. To avoid unstable catastrophic propagation of damage during a flight, load levels must be maintained that are below the load-carrying capacity for damaged aircraft structures. Hence, a capability is needed for accurate real-time predictions of safe load carrying capacity for aircraft structures with complex damage configurations. In the present work, a procedure is developed that uses guided wave responses to interrogate damage. As the guided wave interacts with damage, the signal attenuates in some directions and reflects in others. This results in a difference in signal magnitude as well as phase shifts between signal responses for damaged and undamaged structures. Accurate estimation of damage size and location is made by evaluating the cumulative signal responses at various pre-selected sensor locations using a genetic algorithm (GA) based optimization procedure. The damage size and location is obtained by minimizing the difference between the reference responses and the responses obtained by wave propagation finite element analysis of different representative cracks, geometries and sizes.

Seshadri, Banavara R.↗

NASA NTRS2016

Incorporation of Damage and Failure into an Orthotropic Elasto-Plastic Three-Dimensional Model with Tabulated Input Suitable for Use in Composite Impact Problems

A material model which incorporates several key capabilities which have been identified by the aerospace community as lacking in the composite impact models currently available in LS-DYNA(Registered Trademark) is under development. In particular, the material model, which is being implemented as MAT 213 into a tailored version of LS-DYNA being jointly developed by the FAA and NASA, incorporates both plasticity and damage within the material model, utilizes experimentally based tabulated input to define the evolution of plasticity and damage as opposed to specifying discrete input parameters (such as modulus and strength), and is able to analyze the response of composites composed with a variety of fiber architectures. The plasticity portion of the orthotropic, three-dimensional, macroscopic composite constitutive model is based on an extension of the Tsai-Wu composite failure model into a generalized yield function with a non-associative flow rule. The capability to account for the rate and temperature dependent deformation response of composites has also been incorporated into the material model. For the damage model, a strain equivalent formulation is utilized to allow for the uncoupling of the deformation and damage analyses. In the damage model, a diagonal damage tensor is defined to account for the directionally dependent variation of damage. However, in composites it has been found that loading in one direction can lead to damage in multiple coordinate directions. To account for this phenomena, the terms in the damage matrix are semi-coupled such that the damage in a particular coordinate direction is a function of the stresses and plastic strains in all of the coordinate directions. The onset of material failure, and thus element deletion, is being developed to be a function of the stresses and plastic strains in the various coordinate directions. Systematic procedures are being developed to generate the required input parameters based on the results of experimental tests.

Finite Element Method↗

NASA NTRS2016

Analysis and Characterization of Damage and Failure Utilizing a Generalized Composite Material Model Suitable for Use in Impact Problems

A material model which incorporates several key capabilities which have been identified by the aerospace community as lacking in state-of-the art composite impact models is under development. In particular, a next generation composite impact material model, jointly developed by the FAA and NASA, is being implemented into the commercial transient dynamic finite element code LS-DYNA. The material model, which incorporates plasticity, damage, and failure, utilizes experimentally based tabulated input to define the evolution of plasticity and damage and the initiation of failure as opposed to specifying discrete input parameters (such as modulus and strength). The plasticity portion of the orthotropic, three-dimensional, macroscopic composite constitutive model is based on an extension of the Tsai-Wu composite failure model into a generalized yield function with a non-associative flow rule. For the damage model, a strain equivalent formulation is utilized to allow for the uncoupling of the deformation and damage analyses. In the damage model, a semi-coupled approach is employed where the overall damage in a particular coordinate direction is assumed to be a multiplicative combination of the damage in that direction resulting from the applied loads in the various coordinate directions. Due to the fact that the plasticity and damage models are uncoupled, test procedures and methods to both characterize the damage model and to covert the material stress-strain curves from the true (damaged) stress space to the effective (undamaged) stress space have been developed. A methodology has been developed to input the experimentally determined composite failure surface in a tabulated manner. An analytical approach is then utilized to track how close the current stress state is to the failure surface.

Finite Element Method↗

NASA NTRSDate not supplied

Progressive Damage Failure Analysis of Post-Buckled Composite Single-Stringer Panel with Teflon Inserts

The high strength-to-weight and stiffness-to-weight ratio materials, such as laminated composites, are advantageous for modern aircraft. Laminated composites with initial flaws are susceptible to delamination under buckling loads. PDA tools help enhance the industry’s understanding of the mechanisms for damage initiation and growth in composite structures while assisting in the design, analysis, and sustainment methods of these composite structures. The global-local modeling approach for the single-stringer post-buckled panel was evaluated through this effort, using Teflon inserts to simulate the defect of damage during manufacturing. This understanding is essential for designing the post-buckled structure, reducing weight while predicting damage initiation location, and addressing a potential design review for future aircraft repairs. In this work, the initial damage was captured with Teflon inserts as the starting configuration; and any reference to the damage initiation refers to any damage beyond the “initial unbonded region.” The effort aims to develop, evaluate, and enhance methods to predict damage initiation and progression and the failure of post-buckled hat-stiffened panels using multiple Abaqus FEA Virtual Crack Closure Technique (VCCT) definitions. Validation of the PDA using the VCCT material model was performed on a large single-stringer panel subjected to compressive loading. The compressive loading of the panel caused the skin to buckle before any damage began to occur locally. In addition, comparisons are made for critical aspects of the damage morphology, such as a growth pattern that included delamination from the skin-stiffener interface to the skin and ply interfaces. When compared against the experimental data produced through the NASA Advanced Composites Project (ACP), the present model captured damage migration from one surface to another, and model validations were within 4% of the experimental data.

PDA↗

NASA NTRSDate not supplied

Airburst & Blast Damage Modeling Sensitivities for Asteroid Impact Risk Assessment

Blast overpressure from a high-energy airburst or surface impact is the primary source of damage from potentially hazardous asteroid strikes. There are many sources of uncertainty in evaluating these potential damage risks, both in the approaches used to model the entry, breakup, and airburst behaviors of diverse asteroid properties, and in the blast modeling approaches used to estimate the ground damage from these very large-scale, high-energy events. In this study, we use NASA’s Probabilistic Asteroid Impact Risk (PAIR) model to investigate trends and sensitivities in asteroid airburst altitudes and the resulting blast damage estimates across a range of asteroid sizes. In particular, we show how uncertainties in asteroid breakup behavior and effective airburst altitudes combine with height-of-burst (HOB) blast damage models to produce key sensitivities and trends in the amount of damage expected from different asteroid sizes and airburst altitudes. We show airburst altitude ranges and probabilities stemming from asteroid entry and breakup modeling uncertainties, compare differences between traditional nuclear-based HOB blast models and simulation-based HOB models for larger asteroid energies, and show how the resulting interplay between likely burst altitudes and optimal burst heights affects blast damage trends across different asteroid sizes. Finally, we combine the relative likelihoods of asteroid sizes, airburst altitudes, and resulting blast damage severity to evaluate what airburst regimes pose the highest overall level of risk (when considering both the relative likelihood and scale of potential damage) for a mid-sized asteroid threat scenario. Results show what asteroid size regimes are most sensitive to airburst and blast modeling uncertainties, provide insight into nonintuitive trends in the size and severity of blast damage expected from different airburst events, and highlight where additional blast modeling studies or refinements may help improve future impact risk estimates

ATAP↗

NASA NTRS2024

Piezoelectric impedance-based high-accuracy damage identification using sparsity conscious multi-objective optimization inverse analysis

Two elements are essential in structural health monitoring utilizing dynamic responses: response measurement with high-frequency contents, i.e., small characteristic wavelengths, that can adequately reflect damage features, and effective inverse identification analysis that is however oftentimes under-determined. The advancement of smart structure integration has led to active interrogation through frequency-sweeping piezoelectric impedance measurement at high frequency range. In this research we develop a multi-objective optimization formulation for the identification of damage location and severity utilizing piezoelectric impedance. While one optimization objective is to match the response measurement with finite element model prediction in the damage parametric space, the other is the number of locations of damage, i.e., the sparsity of damage index as the solution vector, since damage usually occurs within a small number of locations. This multi-objective formulation fits well the under-determined nature of damage identification, as it naturally provides multiple solutions as basis for further elucidation. The challenge remaining is how to find a small solution set that can include the actual damage scenario. Here we develop a novel inverse identification framework utilizing the intelligent swarm optimizer which possesses flexibility for enhancement. We first embed a sparsity enforcement process into the population generation of the optimizer, which yields a solution repository intrinsically possessing sparsity. We then apply reinforcement learning so the agents can adaptively opt for local strategies with the aim of enriching the searching patterns to diversify the solutions. Through the incorporation of a Q-table, searching toward more promising directions will be rewarded. Our case analyses employing experimental data indicate that this sparsity-conscious multi-objective particle swarm optimization technique can lead to a small solution set which generally encompasses the true damage scenario. This effectively solves the structural damage identification problem with piezoelectric impedance measurement.

Yang Zhang↗

NASA NTRS2020

Analysis of Open Hole Compression Specimens Using the CompDam Continuum Damage Mechanics Model

This report documents a validation study on the standard Open Hole Compression (OHC) laminate test specimen conducted as part of the NASA Advanced Composites Project (ACP). Tests were conducted on OHC specimens with hard, quasi-isotropic, and soft layups using digital image correlation and X-Ray computed tomography to capture the structural response and damage evolution. Progressive damage models were constructed for use with the CompDam continuum damage mechanics code following the best practices established during the ACP. Detailed interrogation of the analysis results and comparison with experimental measurements provide a basis for assessing the capability of the modeling approach for OHC. The structural response is found to be captured well, with strengths predicted within 3\% of the experimental values for hard and quasi-isotropic laminates. In the soft laminate, the model predicts failure to be more brittle than the nonlinear, ductile response that was measured. Damage states extracted from the models at the same load level as test measurements are overlaid to show directly the similarities and differences between test and analysis results. Studying the damage evolution predicted by the analysis reveals that the failure process is a competition between fiber damage and delamination/sub-laminate buckling, with fiber damage dominating the collapse in the hard laminate and sub-laminate buckling governing in the soft laminate. Finally, a series of parametric studies varying numerical solution parameters (mesh size, mass scaling) and physical properties (fiber direction compressive strength and toughness) reveal sensitivities and deficiencies of the model. To the authors' knowledge, this study is the first for OHC specimens to include detailed evaluation of damage mode interactions, direct overlay of predicted and measured damage states, and sensitivity of the predicted results to difficult-to-measure fiber direction material properties.

Continuum damage mechanics↗

NASA NTRS2001

Response of thyroid follicular cells to gamma irradiation compared to proton irradiation. I. Initial characterization of DNA damage, micronucleus formation, apoptosis, cell survival, and cell cycle phase redistribution

The RBE of protons has been assumed to be equivalent to that of photons. The objective of this study was to determine whether radiation-induced DNA and chromosome damage, apoptosis, cell killing and cell cycling in organized epithelial cells was influenced by radiation quality. Thyroid-stimulating hormone-dependent Fischer rat thyroid cells, established as follicles, were exposed to gamma rays or proton beams delivered acutely over a range of physical doses. Gamma-irradiated cells were able to repair DNA damage relatively rapidly so that by 1 h postirradiation they had approximately 20% fewer exposed 3' ends than their counterparts that had been irradiated with proton beams. The persistence of free ends of DNA in the samples irradiated with the proton beam implies that either more initial breaks or a quantitatively different type of damage had occurred. These results were further supported by an increased frequency of chromosomal damage as measured by the presence of micronuclei. Proton-beam irradiation induced micronuclei at a rate of 2.4% per gray, which at 12 Gy translated to 40% more micronuclei than in comparable gamma-irradiated cultures. The higher rate of micronucleus formation and the presence of larger micronuclei in proton-irradiated cells was further evidence that a qualitatively more severe class of damage had been induced than was induced by gamma rays. Differences in the type of damage produced were detected in the apoptosis assay, wherein a significant lag in the induction of apoptosis occurred after gamma irradiation that did not occur with protons. The more immediate expression of apoptotic cells in the cultures irradiated with the proton beam suggests that the damage inflicted was more severe. Alternatively, the cell cycle checkpoint mechanisms required for recovery from such damage might not have been invoked. Differences based on radiation quality were also evident in the alpha components of cell survival curves (0.05 Gy(-1) for gamma rays, 0.12 Gy(-1) for protons), which suggests that the higher level of survival of gamma-irradiated cells could be attributed to the persistence of nonlethally irradiated thyrocytes and/or the capacity to repair damage more effectively than cells exposed to equal physical doses of protons. The final assessment in this study was radiation-induced cell cycle phase redistribution. Gamma rays and protons produced a similar dose-dependent redistribution toward a predominantly G(2)-phase population. From our cumulative results, it seems likely that a majority of the proton-irradiated cells would not continue to divide. In conclusion, these findings suggest that there are quantitative and qualitative differences in the biological effects of proton beams and gamma rays. These differences could be due to structured energy deposition from the tracks of primary protons and the associated high-LET secondary particles produced in the targets. The results suggest that a simple dose-equivalent approach to dosimetry may be inadequate to compare the biological responses of cells to photons and protons.

NASA Discipline Radiation Health↗

NASA NTRSDate not supplied

Sensitivity Study of Impact Risk Model Results to Thermal Radiation Damage Model for Large Objects

NASA’s Probabilistic Asteroid Impact Risk (PAIR) assessment model assesses the likelihood of potential damage for asteroid impact scenarios. Fast-running models are used to capture the effects of different hazards. This paper looks specifically at local ground damage hazards, including blast overpressure and thermal radiation damage, for large object impact scenarios. A sensitivity study is conducted to determine which parameters, and over what ranges, cause impact risks to become sensitive to thermal damage. Two additional thermal models with different approaches are used for comparison. The study determined the current thermal model is most sensitive to the luminous efficiency parameter that reflects the model’s uncertainty in the amount of energy contributing to the thermal radiation damage. This sensitivity was most apparent for the highest severity damage levels. Comparisons of the three models showed that in addition to sensitivities within the models, the impact risks are also sensitive to the choice of thermal model. The study results were applied to the 2023 PDC hypothetical asteroid impact scenario and parameter ranges of interest determined. At the serious damage level, luminous efficiencies above 0.006 showed a small chance of thermal playing an important role, while luminous efficiencies above 0.0008 led to thermal playing a significant role at the unsurvivable damage severity level. Study results are used to identify key areas where additional model refinement and better knowledge of asteroid properties may be important for improving damage estimates.

SMD↗

NASA NTRS2024

Sensitivity Study of Impact Risk Model Results to Thermal Radiation Damage Model for Large Objects

NASA’s Probabilistic Asteroid Impact Risk (PAIR) assessment model assesses the likelihood of potential damage for asteroid impact scenarios. Fast-running models are used to capture the effects of different hazards. This paper looks specifically at local ground damage hazards, including blast overpressure and thermal radiation damage, for large object impact scenarios. A sensitivity study is conducted to determine which parameters, and over what ranges, cause impact risks to become sensitive to thermal damage. Two additional thermal models with different approaches are used for comparison. The study determined the current thermal model is most sensitive to the luminous efficiency parameter that reflects the model’s uncertainty in the amount of energy contributing to the thermal radiation damage. This sensitivity was most apparent for the highest severity damage levels. Comparisons of the three models showed that in addition to sensitivities within the models, the impact risks are also sensitive to the choice of thermal model. The study results were applied to the 2023 Planetary Defense Conference hypothetical asteroid impact scenario and parameter ranges of interest determined. At the serious damage level, luminous efficiencies above 0.006 showed a small chance of thermal playing an important role, while luminous efficiencies above 0.0008 led to thermal playing a significant role at the unsurvivable damage severity level. Study results are used to identify key areas where additional model refinement and better knowledge of asteroid properties may be important for improving damage estimates.

SMD↗

NASA NTRS1976

Effect of Low Velocity Impact Damage on the Compressive Strength of Graphite/Epoxy Hat-Stiffened Panels

Low velocity impact damage on the compressive strength of graphite/epoxy hat stiffened panels is studied. Fourteen panels, representative of minimum-mass designs for two compression load levels were tested. Eight panels were damaged by impact and the effect on compressive strength was evaluated by comparing the results with data for undamaged panels. The impact tests consisted of firing 1.27 cm diameter aluminum projectiles normal to the plane of the panel at a velocity of approximately 55 m/sec to simulate impact from runway debris. The results of this investigation indicate that impact damage in the panels designed for 0.53 MN/m was contained locally and the damaged panels were capable of carrying the design load. The panels designed for 1.58 MN/m failed between 50 and 58 percent of the design load due to impact damage in the high axial stiffness region. The extent of damage in the high axial stiffness region of both panel designs increased with the magnitude of applied axial load. Damage in this region was the most significant factor in reducing panel strength. Limited damage that was not visually detectable reduced ultimate strength as much as extensive visible damage.

Rhodes, M. D.↗

NASA NTRS1992

A procedure for utilization of a damage-dependent constitutive model for laminated composites

Described here is the procedure for utilizing a damage constitutive model to predict progressive damage growth in laminated composites. In this model, the effects of the internal damage are represented by strain-like second order tensorial damage variables and enter the analysis through damage dependent ply level and laminate level constitutive equations. The growth of matrix cracks due to fatigue loading is predicted by an experimentally based damage evolutionary relationship. This model is incorporated into a computer code called FLAMSTR. This code is capable of predicting the constitutive response and matrix crack damage accumulation in fatigue loaded laminated composites. The structure and usage of FLAMSTR are presented along with sample input and output files to assist the code user. As an example problem, an analysis of crossply laminates subjected to two stage fatigue loading was conducted and the resulting damage accumulation and stress redistribution were examined to determine the effect of variations in fatigue load amplitude applied during the first stage of the load history. It was found that the model predicts a significant loading history effect on damage evolution.

Lo, David C.↗

NASA NTRS1993

Micromechanical simulation of damage progression in carbon phenolic composites

Carbon/phenolic composites are used extensively as ablative insulating materials in the nozzle region of solid rocket motors. The current solid rocket motor (RSRM) on the space shuttle is fabricated from woven rayon cloth which is carbonized and then impregnated with the phenolic resin. These plies are layed up in the desired configuration and cured to form the finished part. During firing, the surface of the carbon/phenolic insulation is exposed to 5000 F gases from the rocket exhaust. The resin pyrolizes and the material chars to a depth which progresses with time. The rate of charring and erosion are generally predictable, and the insulation depth is designed to allow adequate safety margins over the firing time of the motor. However, anomalies in the properties and response of the carbon/phenolic materials can lead to severe material damage which may decrease safety margins to unacceptable levels. Three macro damage modes which were observed in fired nozzles are: ply lift, 'wedge out', and pocketing erosion. Ply lift occurs in materials with plies oriented nearly parallel to the surface. The damage occurs in a region below the charred material where material temperatures are relatively low - about 500 F. Wedge out occurs at the intersection of nozzle components whose plies are oriented at about 45 deg. The corner of the block of material breaks off along a ply interface. Pocketing erosion occurs in material with plies oriented normal to the surface. Thermal expansion is restrained in two directions resulting in large tensile strains and material failure normal to the surface. When a large section of material is removed as a result of damage, the insulation thickness is reduced which may lead to failure of the nozzle due to excessive heating of critical components. If these damage events cannot be prevented with certainty, the designer must increase the thickness of the insulator thus adding to both weight and cost. One of the difficulties in developing a full understanding of these macro damage mechanisms is that the loading environment and the material response to that environment are extremely complex. These types of damage are usually only observed in actual motor firings. Therefore, it is difficult and expensive to evaluate the reliability of new materials. Standard material tests which measure mechanical and thermal properties of test specimens can only provide a partial picture of how the material will respond in the service environment. The development of the ANALOG test procedure which can combine high heating rates and mechanical loads on a specimen will improve the understanding of the interactive effects of the various loads on the system. But a mechanistic model of material response which can account for the heterogeneity of the material, the progression of various micromechanical damage mechanisms, and the interaction of mechanical and thermal stresses on the material is required to accurately correlate material tests with response to service environments. A model based on fundamental damage mechanisms which is calibrated and verified under a variety of loading conditions will provide a general tool for predicting the response of rocket nozzles. The development of a micromechanical simulation technique was initiated and demonstrated to be effective for studying across-ply tensile failure of carbon/phenolic composites.

Slattery, Kerry T.↗