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At least 91 records · Page 5
All sourcesNASA NTRSDOE OSTI
NASA NTRSDate not supplied

Stiffness and Fatigue Life Estimator for Polymer Composite Laminates Using Machine Learning

Machine learning (ML) models are increasingly being used in many engineering fields due to the advancements in ML algorithms and availability of high-speed computing power. One of the most popular ML class of models is artificial neural networks (ANN). ML is increasingly being used in the design and analysis of composite materials and structures, specifically in the constitutive modeling of composite materials with the focus on greatly accelerating multiscale analyses of composite materials and structures through development of surrogate models. Towards that end, Python-based neural nets have been developed to predict initial stiffness and fatigue life of an eight-ply symmetric polymer matrix composite laminate. Two types of neural networks, a Multilayer Perceptron (MLP) and a Recurrent Neural Network (RNN), have been established. Results show that both neural net type algorithms can provide an excellent estimate of initial laminate stiffness as well as fatigue life of eight-ply symmetric polymer matrix composite laminates (PMCs). RNNs are better able to capture the shape of the fatigue curve of a laminate. The resulting tool and GUI can be very useful for system level studies to obtain an estimate of desired properties and life of PMC composite laminates. Further, the associated surrogate models can also be used in composite multiscale analyses to replace the actual physics-based calculations at lower scales and thereby significantly increase the computational efficiency of such analyses and thus make micromechanics-based multiscale analyses a viable industrial tool for large scale structural problems.

multiscale analysis↗
NASA NTRS2023

Stiffness and Fatigue Life Estimator for Polymer Composite Laminates Using Machine Learning

Machine learning (ML) models are increasingly being used in many engineering fields due to the advancements in ML algorithms and availability of high-speed computing power. One of the most popular ML class of models is artificial neural networks (ANN). ML is increasingly being used in the design and analysis of composite materials and structures, specifically in the constitutive modeling of composite materials with the focus on greatly accelerating multiscale analyses of composite materials and structures through development of surrogate models. Towards that end, Python-based neural nets have been developed to predict initial stiffness and fatigue life of an eight-ply symmetric polymer matrix composite laminate. Two types of neural networks, a Multilayer Perceptron (MLP) and a Recurrent Neural Network (RNN), have been established. Results show that both neural net type algorithms can provide an excellent estimate of initial laminate stiffness as well as fatigue life of eight-ply symmetric polymer matrix composite laminates (PMCs). RNNs are better able to capture the shape of the fatigue curve of a laminate. The resulting tool and GUI can be very useful for system level studies to obtain an estimate of desired properties and life of PMC composite laminates. Further, the associated surrogate models can also be used in composite multiscale analyses to replace the actual physics-based calculations at lower scales and thereby significantly increase the computational efficiency of such analyses and thus make micromechanics-based multiscale analyses a viable industrial tool for large scale structural problems.

multiscale analysis↗
NASA NTRS2012

Characterization and Analysis of Triaxially Braided Polymer Composites under Static and Impact Loads

In order to design impact resistant aerospace components made of triaxially-braided polymer matrix composite materials, a need exists to have reliable impact simulation methods and a detailed understanding of the material behavior. Traditional test methods and specimen designs have yielded unrealistic material property data due to material mechanisms such as edge damage. To overcome these deficiencies, various alternative testing geometries such as notched flat coupons have been examined to alleviate difficulties observed with standard test methods. The results from the coupon level tests have been used to characterize and validate a macro level finite element-based model which can be used to simulate the mechanical and impact response of the braided composites. In the analytical model, the triaxial braid unit cell is approximated by using four parallel laminated composites, each with a different fiber layup, which roughly simulates the braid architecture. In the analysis, each of these laminated composites is modeled as a shell element. Currently, each shell element is considered to be a smeared homogeneous material. Simplified micromechanics techniques and lamination theory are used to determine the equivalent stiffness properties of each shell element, and results from the coupon level tests on the braided composite are used to back out the strength properties of each shell element. Recent improvements to the model include the incorporation of strain rate effects into the model. Simulations of ballistic impact tests have been carried out to investigate and verify the analysis approach.

Goldberg, Robert K.↗
DOE OSTI2024

Vertical z-axis discontinuous carbon fibers for improved lightning strike performance of continuous fiber-reinforced polymer composites

Effective lightning strike protection for critical aerospace and wind applications requires high electrical conductivity to dissipate current efficiently. However, polymer matrix composites face a challenge due to their inherently insulating nature. While conventional carbon fiber-reinforced composites (CFRP) exhibit electrical conductivity in the planar direction, achieving through-thickness conductivity remains an ongoing challenge. In this work, we have undertaken the fabrication of CFRP interleaved with vertically oriented carbon fibers (Z-fiber) to impart higher electrical conductivity along the thickness direction. Two Z-fiber composite variations are prepared: Z-1 with a single layer of Z-fiber and Z-5 with five interleaved layers and compared with no Z-fiber layer (Z-0) composite. The composite panels were subjected to lab-scale lightning strike tests with a current magnitude of 100 kA. To emulate real-world service conditions, an aerospace-grade paint coating was applied to the composite laminates. Comparative analysis shows Z-1 reduces damage diameter to ∼22 mm compared to Z-0 (∼26 mm), while Z-5 exhibits the least damage (∼16.7 mm), confirmed by optical microscopy. Z-5 demonstrates nine times higher through-thickness electrical conductivity than Z-0, reducing electrical anisotropy substantially. Thermal-electric finite element damage modeling predicts surface damage within 6% of experimental values for both Z-0 and Z-5 composites. Flexural tests post-lightning reveal Z-5 retains 66% flexural strength and 86% modulus, significantly better than Z-0, which retains less than 40% for both properties. This study highlights the efficacy of Z-fiber composites in lightning strike protection, offering improved through-thickness conductivity and mechanical property retention.

36 MATERIALS SCIENCE↗
NASA NTRS2017

Aerogel / Polymer Composite Materials

The invention provides new composite materials containing aerogels blended with thermoplastic polymer materials at a weight ratio of aerogel to thermoplastic polymer of less than 20:100. The composite materials have improved thermal insulation ability. The composite materials also have better flexibility and less brittleness at low temperatures than the parent thermoplastic polymer materials.

Williams, Martha K.↗
NASA NTRS2000

Erosion Coatings for High-Temperature Polymer Composites: A Collaborative Project With Allison Advanced Development Company

The advantages of replacing metals in aircraft turbine engines with high-temperature polymer matrix composites (PMC's) include weight savings accompanied by strength improvements, reduced part count, and lower manufacturing costs. Successfully integrating high-temperature PMC's into turbine engines requires several long-term characteristics. Resistance to surface erosion is one rarely reported property of PMC's in engine applications because PMC's are generally softer than metals and their erosion resistance suffers. Airflow rates in stationary turbine engine components typically exceed 2.3 kg/sec at elevated temperatures and pressures. In engine applications, as shown in the following photos, the survivability of PMC components is clearly a concern, especially when engine and component life-cycle requirements become longer. Although very few publications regarding the performance of erosion coatings on PMC's are available particularly in high-temperature applications the use of erosion-resistant coatings to significantly reduce wear on metallic substrates is well documented. In this study initiated by the NASA Glenn Research Center at Lewis Field, a low-cost (less than $140/kg) graphite-fiber-reinforced T650 35/PMR 15 sheet-molding compound was investigated with various coatings. This sheet-molding compound has been compression molded into many structurally complicated components, such as shrouds for gas turbine inlet housings and gearboxes. Erosion coatings developed for PMC s in this study consisted of a two-layered system: a bondcoat sprayed onto a cleaned PMC surface, followed by an erosion-resistant, hard topcoat sprayed onto the bondcoat as shown in following photomicrograph. Six erosion coating systems were evaluated for their ability to withstand harsh thermal cycles, erosion resistance (ASTM G76 83 "Standard Practice for Conducting Erosion Tests by Solid Particle Impingement Using Gas Jets") using Al2O3, and adhesion to the graphite fiber polyimide composite (ASTM D 4541 95 "Pull Off Strength of Coatings"). Glenn and Allison Advanced Development Company collaborated to optimize erosion coatings for gas turbine fan and compressor applications. All the coating systems survived aggressive thermal cycling without spalling. During erosion tests (see the final photo), the most promising coating systems tested had Cr3C2-NiCr and WC-Co as the hard topcoats. In all cases, these coating systems performed significantly better than that with a TiN hard topcoat. When material depth (thickness) loss is considered, the Cr3C2-NiCr and WC-Co coating systems provided, on average, an erosion resistance 8.5 times greater than that for the uncoated PMR 15/T650 35 composite. Similarly, Cr3C2-NiCr and WC-Co coating systems adhered to the PMC substrate during tensile tests significantly better than systems containing a TiN topcoat. Differences in topcoats of Cr3C2-NiCr and WC-Co were determined by considering issues such as cost and environmental impact. The preferred erosion-resistant coating system for PMR 15/T650 35 has WC-Co as the hard topcoat. This system provides the following benefits in comparison to the coating system with Cr3C2-NiCr topcoat: lower powder material cost (15 to 20 percent), environmentally friendly materials (Cr3C2-NiCr is hazardous), and higher deposition yield (10 to 15 percent), which results in less waste.

Sutter, James K.↗
NASA NTRS1990

Rate dependent constitutive models for fiber reinforced polymer composites

A literature survey was conducted to assess the state-of-the-art in rate dependent constitutive models for continuous fiber reinforced polymer matrix composite (PMC) materials. Several recent models which include formulations for describing plasticity, viscoelasticity, viscoplasticity, and rate-dependent phenomenon such as creep and stress relaxation are outlined and compared. When appropriate, these comparisons include brief descriptions of the mathematical formulations, the test procedures required for generating material constants, and details of available data comparing test results to analytical predictions.

Gates, Thomas S.↗
NASA NTRS2010

Investigation of a Macromechanical Approach to Analyzing Triaxially-Braided Polymer Composites

A macro level finite element-based model has been developed to simulate the mechanical and impact response of triaxially-braided polymer matrix composites. In the analytical model, the triaxial braid architecture is simulated by using four parallel shell elements, each of which is modeled as a laminated composite. The commercial transient dynamic finite element code LS-DYNA is used to conduct the simulations, and a continuum damage mechanics model internal to LS-DYNA is used as the material constitutive model. The material stiffness and strength values required for the constitutive model are determined based on coupon level tests on the braided composite. Simulations of quasi-static coupon tests of a representative braided composite are conducted. Varying the strength values that are input to the material model is found to have a significant influence on the effective material response predicted by the finite element analysis, sometimes in ways that at first glance appear non-intuitive. A parametric study involving the input strength parameters provides guidance on how the analysis model can be improved.

Goldberg, Robert K.↗
NASA NTRS2002

Molecular modeling of polymer composite interactions with analytes in electronic nose sensors for environmental monitoring in International Space Station

We report a molecular modeling study to investigate the polymer-carbon black (CB) composite-analyte interactions in resistive sensors. These sensors comprise the JPL Electronic Nose (ENose) sensing array developed for monitoring breathing air in human habitats. The polymer in the composite is modeled based on its stereisomerism and sequence isomerism, while the CB is modeled as uncharged naphthalene rings (with no hydrogens). The Dreiding 2.21 force field is used for the polymer and solvent molecules and graphite parameters are assigned to the carbon black atoms. A combination of molecular mechanics (MM) and molecular dynamics (NPT-MD and NVT-MD) techniques are used to obtain the equilibrium composite structure by inserting naphthalene rings in the polymer matrix. Polymers considered for this work include poly(4- vinylphenol), polyethylene oxide, and ethyl cellulose. Analytes studied are representative of both inorganic (ammonia) and organic (methanol, toluene, hydrazine) compounds. The results are analyzed for the composite microstructure by calculating the radial distribution profiles as well as for the sensor response by predicting the interaction energies of the analytes with the composites.

electronic noise environmental monitoring polymer ↗
NASA NTRSDate not supplied

Polymer Composite Material Screening for a Cryotank Application

Composite cryotanks will play a key role in enabling the next generation of efficient aircraft. Carbon fiber reinforced polymer (CFRP) composites have the benefits of reduced weight and potentially higher structural strength compared to traditional metallic fuel tanks. A material screening study was conducted to inform material selection for liquid hydrogen (LH2) fuel storage. Three composite materials were considered because of their aerospace grade toughness, strength, and existing data to compare against. These materials were a thermoplastic low-melt polyaryletherketone (LM-PAEK)/carbon fiber (CF), thermoset/CF, and hybrid thermoset/thermoplastic polyurethane (TPU) veil/CF composite. Mechanical screening tests included tension, compression, in-plane shear (IPS), and tensile-tensile fatigue (TTF). Each material was tested at both a baseline (no liquid nitrogen/LN2 cycling) and 100 LN2-cycled conditions to determine the knockdown factor, if any, of each material when exposed to environmental loading effects in a cryotank. Results show minimal effects of the LN2-cycling compared against baseline values. The three materials behaved similarly in tension; however, the thermoplastic/CF had the highest IPS toughness. The hybrid thermoset/TPU/CF composite had the lowest IPS strength, compressive strength, and toughness. LN2-cycling had minimal effects on tensile-tensile fatigue performance of the thermoplastic/CF material. Mechanical data was captured to guide material down selection for future commercially viable hydrogen aircraft design.

Composites↗
NASA NTRS2026

Polymer Composite Material Testing for a Cryotank Application

Composite cryotanks will play a key role in enabling the next generation of efficient aircraft. Carbon fiber reinforced polymer (CFRP) composites have the benefits of reduced weight and potentially higher structural strength compared to traditional metallic fuel tanks. A material screening study was conducted to inform material selection for liquid hydrogen (LH2) fuel storage. Three composite materials were considered because of their aerospace grade toughness, strength, and existing data to compare against. These materials were a thermoplastic low-melt polyaryletherketone (LM-PAEK)/carbon fiber (CF), thermoset/CF, and hybrid thermoset/thermoplastic polyurethane (TPU) veil/CF composite. Mechanical screening tests included tension, compression, in-plane shear (IPS), and tensile-tensile fatigue (TTF). Each material was tested at both a baseline (no liquid nitrogen/LN2 cycling) and 100 LN2-cycled conditions to determine the knockdown factor, if any, of each material when exposed to environmental loading effects in a cryotank. Results show minimal effects of the LN2-cycling compared against baseline values. The three materials behaved similarly in tension; however, the thermoplastic/CF had the highest IPS toughness. The hybrid thermoset/TPU/CF composite had the lowest IPS strength, compressive strength, and toughness. LN2-cycling had minimal effects on tensile-tensile fatigue performance of the thermoplastic/CF material. Mechanical data was captured to guide material down selection for future commercially viable hydrogen aircraft design. In its current state, there does not exist a consolidated, publicly available database for CFRP composite material performance data at cryogenic temperatures. The next step in this work is to test the thermoplastic and thermoset CFRP composites, as well as the neat resins, at LH2 relevant temperature (20 K) to capture this crucial material property data. These results are essential to inform cryotank design and modeling efforts. The process to start this next round of testing has begun. Planned mechanical tests include toughness (single-edge notched beam), tension (unidirectional and quasi-isotropic), thermal expansion, and thermal conductivity. Some tests will also be conducted at an intermediate temperature of 111 K relevant to liquid natural gas (LNG), another attractive fuel choice. The ultimate goal is to manufacture a sub-scale cryotank part that can pass relevant burst, fatigue, permeation, and thermal cycling tests. This work is a part of NASA’s Commercially viable Hydrogen Aircraft for Robust Growth in Efficiency (CHARGE) Project under the larger NASA Subsonic Vehicle Technologies and Tools (SVTT) Project.

composites↗
NASA NTRS1983

N-Butyl acrylate polymer composition for solar cell encapsulation and method

A polymer syrup for encapsulating solar cell assemblies. The syrup includes uncrosslinked poly(n-butyl)acrylate dissolved in n-butyl acrylate monomer. Preparation of the poly(n-butyl)acrylate and preparation of the polymer syrup is disclosed. Methods for applying the polymer syrup to solar cell assemblies as an encapsulating pottant are described. Also included is a method for solar cell construction utilizing the polymer syrup as a dual purpose adhesive and encapsulating material.

Gupta, Amitava↗
NASA NTRS2011

Methods of Making and Using Shape Memory Polymer Composite Patches

A method of repairing a composite component having a damaged area including: laying a composite patch over the damaged area: activating the shape memory polymer resin to easily and quickly mold said patch to said damaged area; deactivating said shape memory polymer so that said composite patch retains the molded shape; and bonding said composite patch to said damaged part.

Hood, Patrick J.↗