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The failure mechanisms in the fatigue of composite materials are analyzed in terms of the requirements for designing fatigue-critical composite structures. Fiber reinforced polymers, fiber reinforced metals, fatigue of composite structures, and composite design considerations are discussed. It is concluded that composite materials offer the engineer the opportunity for tailoring stiffness in different directions for designing dynamic components.
Composites were exposed in circulating and static air environments up to 600 F for a maximum of 1000 hours. Composites of HT-S, HM-S, Thornel 50S, and Fortafil 5-Y fiber and a new addition type polyimide resin were laminated in a matched-die mold. Flexural strength, flexural modulus, and interlaminar shear strengths were determined at 75, 500 and 600 F after various durations of exposure. Composite and fiber weight loss characteristics were determined by isothermal gravimetric analysis in air. Properties of composites exposed and tested at the environment temperatures are compared with those determined under short-term exposure. A new short beam interlaminar shear fixture is described. Environmental effects of long-term (up to one year) ambient temperature exposure on the elevated temperature mechanical properties of graphite/polyimide composites are presented.
Composite micromechanics and macromechanics and the miniature Izod impact test are used to investigate the impact resistance of unidirectional composites. Several composite systems are examined both theoretically and experimentally. The composites are classified theoretically with respect to their impact resistance for longitudinal, transverse, and shear modes. Experimental results are reported only for Izod impact with the fibers either parallel or transverse to the cantilever longitudinal axis. Impact resistance design criteria which evolved during this investigation are used to design hybrid composites with improved impact resistance. The results show that in situ fiber and matrix elongation to fracture, matrix modulus, fabrication process, fiber and void volume ratios, and microresidual stresses are variables which affect the impact resistance.
Journal bearings with self-alining spherical elements of graphite-fiber-reinforced-polyimide composites were tested from 24 to 340 C (75 to 650 F) at unit loads up to 3.5 times 10 to the 7th power N/sq m (5000 psi). The journal oscillated in the cylindrical bore of the composite element + or - 15 deg at 1 hertz. Outer races and journals were metal hardened of Rockwell C-32 and finished to 10 to the minus 7th power m. A 45 wt. percent graphite-fiber composite gave low friction (0.08 to 0.13), low wear, and almost no plastic deformation under any of the test conditions. Composites with 15 and 25 wt. percent graphite fiber failed by plastic deformation at 315 C (600 F) and 3.5 times 10 to the 7th power N/sq m (5000 psi). A composite with 60 wt. percent graphite fiber failed by brittle fracture under the same conditions, but had very low friction coefficients (0.05 to 0.10) and may be a good bearing material at lighter loads.
Strain compatibility equations are used to evaluate the thermal stresses existing when unidirectional graphite composites are bonded to aluminum structures. Based on thermal stresses and optimum placement of the composite, skin-stringer aluminum panels are optimized for minimum weight compression panels with selective composite reinforcement. Composite reinforced skin-stringer panels are thermal cycled to determine the effect of thermal fatigue on structural integrity. Both cycled and uncycled panels are tested in compression and tension. Test results are correlated with predicted loads. Use of filamentary graphite composites is an efficient method of reinforcing metal structures, but care must be taken to minimize thermal stresses.
Significant results were obtained in fabrication studies of the role of metallic additives of Zr, Ti, Ni, Fe and Cr on the densification of ZrB2. All elemental additions lower the processing temperatures required to effect full densification of ZrB2. Each addition effects enhanced densification by a clearly distinguishable and different mechanism and the resulting fabricated materials are different. A significant improvement in strength and fracture toughness was obtained for the ZrB2/Ti composition. Mechanical characterization studies for the ZrB2/SiC/C composites and the new ZrB2/Metal materials produced data relevant to the effect of impacting load on measured impact energies, a specimen configuration for which controlled fracture could occur in a suitably hard testing apparatus, and fracture strength data. Controlled fracture--indicative of measurable fracture toughness--was obtained for the ZrB2-SiC-C composite, and a ZrB2/Ti composite fabricated from ZrB2 with an addition of 30 weight per cent Ti. The increased strength and toughness of the ZrB2/Ti composite is consistent with the presence of a significantly large amount of a fine grained acicular phase formed by reaction of Ti with ZrB2 during processing.
An intumescent composition and the foamed product prepared by heating are discussed wherein the composition comprises the reaction product of para-benzoquinone dioxime and a concentrated mineral acid such as sulfuric acid, phosphoric acid, and polyphosphoric acid. The composition is useful as an intumescent agent either by itself or when combined with other materials. A fire-resistant and heat-insulating composition is provided by heating the intumescent composition above its intumescent temperature.
A review of the field of stress waves in composite materials is presented covering the period up to December 1972. The major properties of waves in composites are discussed and a summary is made of the major experimental results in this field. Various theoretical models for analysis of wave propagation in laminated, fiber and particle reinforced composites are surveyed. The anisotropic, dispersive and dissipative properties of stress pulses and shock waves in such materials are reviewed. A review of the behavior of composites under impact loading is presented along with the application of wave propagation concepts to the determination of impact stresses in composite plates.
The results of a study of the use of composite materials in the wing of a tilt rotor aircraft are presented. An all-metal tilt rotor aircraft was first defined to provide a basis for comparing composite with metal structure. A configuration study was then done in which the wing of the metal aircraft was replaced with composite wings of varying chord and thickness ratio. The results of this study defined the design and performance benefits obtainable with composite materials. Based on these results the aircraft was resized with a composite wing to extend the weight savings to other parts of the aircraft. A wing design was then selected for detailed structural analysis. A development plan including costs and schedules to develop this wing and incorporate it into a proposed flight research tilt rotor vehicle has been devised.
The flow characteristics of lunar compositions 14310 and 14259 have been determined over a wide range of viscosity. The temperature ranges covered by the measurements are 1270 to 1440 C and 700 to 825 C for the 14310 composition and 1154 to 1431 C and 700 to 820 C for the 14259 composition. Reliable data could not be obtained over the intermediate ranges of temperature because of the occurrence of crystallization. The apparent activation energies for viscous flow in the high-temperature and low-temperature regions are respectively about 60 and 160 kcal/gm at for the 14310 composition and 60 and 170 kcal/gm at for the 14259 composition.
Estimates of the magnitudes of elastic stresses and elastoplastic stresses and strains were made for tungsten fiber-reinforced 80Ni + 20Cr matrix composites. Heating or cooling between 80 and 2000 F was assumed. The calculated elastic stresses exceeded representative or estimated strengths of constituents. For composites with less than 0.65 volume fraction of fiber, plastic flow was considered possible, and elastoplastic solutions indicated that stresses would be reduced but with the concomitant occurrence of sufficiently large strain ranges, particularly in the matrix, to pose a possible thermal fatigue problem. Limited experimental studies on tungsten fiber-copper matrix composites heated and cooled a number of times between 80 and 1600 F in a conventional furnace and then heated from 80 to 1652 F in a hot-stage microscope resulted in matrix microfracture for a 70 volume fraction fiber composite and substantial matrix strain for a 40 volue fraction fiber composite.
Glass compositions in the Luna 20 soil indicate a minor contribution of mare rocks and a major contribution of highly feldspathic highland material. Glasses with the composition of highland basalt (anorthositic gabbro or norite) predominate in a range of highly aluminous glasses. The analyses of minerals in the soil show that the highland rocks have a unique assemblage of minerals that can readily be distinguished from the mineral assemblages of either mare or KREEP basalts. The soils are characterized by abundant anorthitic, low-Fe plagioclase. Highly magnesian orthopyroxenes, pigeonites, and augites are the most prominent pyroxenes. Unlike mare basalt pyroxenes, clinopyroxenes with intermediate Ca values are not abundant, but extreme iron enrichment toward pyroxferroite does occur. Olivines are more abundant than at other sites and are Mg-rich, low in Ca and Cr. Spinels with compositions approaching MgAl2O4 predominate over pleonastes and chromites. Ilmenite and metal are present but not abundant. The mineral compositions are consistent with derivation from a suite of highly feldspathic rocks in which highland basalt compositions predominate.
Glass composition research was conducted to produce a high modulus, high strength beryllium-free glass fiber. This program was built on the previous research for developing high modulus, high strength glass fibers which had a 5 weight percent beryllia content. The fibers resulting from the composition program were then used to produce fiber reinforced-epoxy resin composites which were compared with composites reinforced by commercial high modulus glass fibers, Thornel S graphite fiber, and hybrids where the external quarters were reinforced with Thornel S graphite fiber and the interior half with glass fiber as well as the reverse hybrid. The composites were given tensile strength, compressive strength, short-beam shear strength, creep and fatigue tests. Comments are included on the significance of the test data.
The thermal shock resistance of hafnia based composites containing graphite powder or tungsten fibers was investigated in terms of material properties which include thermal expansion, thermal conductivity, compressive fracture stress, modulus of elasticity, and phase stability in terms of the processing parameters of hot pressing pressure and/or density, degree of stabilization of the hafnia, and composition. All other parameters were held constant or assumed constant. The thermal shock resistance was directly proportional to the compressive fracture stress to modulus of elasticity ratio and was not affected appreciably by the small thermal expansion or thermal conductivity changes. This ratio was found to vary strongly with the composition and density such that the composites containing graphite had relatively poor thermal shock resistance, while the composites containing tungsten had superior thermal shock resistance.
The friction and wear behavior of some fluoride-metal, self-lubricating composites are summarized. Fluoride-infiltrated sintered nickel alloy composites and plasma-sprayed, co-deposited fluoride-nickel alloy composites are described. The importance of proper surface-conditioning of the composites is stressed. Performance of fluoride-metal composites in some machine application evaluation is discussed.
Processing techniques and design data were characterized for a graphite/epoxy composite system that is useful from 75 K to 450 K, and a graphite/polyimide composite system that is useful from 75 K to 589 K. The Monsanto 710 polyimide resin was selected as the resin to be characterized and used with the graphite fiber reinforcement. Material was purchased using the prepreg specification for the design data generation for both the HT-S/710 and HM-S/710 graphite/polyimide composite system. Lamina and laminate properties were determined at 75 K, 297 K, and 589 K. The test results obtained on the skin-stringer components proved that graphite/polyimide composites can be reliably designed and analyzed much like graphite/epoxy composites. The design data generated in the program includes the standard static mechanical properties, biaxial strain data, creep, fatigue, aging, and thick laminate data.
An approximate theoretical study is made to predict the overall transverse elastoplastic properties of a unidirectional fibre reinforced composite. Based on the simplest deformation theory of plasticity, the overall transverse polyaxial elastoplastic constitutive equations for an incompressible composite are obtained. A simple formula is suggested to evaluate the average stress in the fibres. Furthermore, with the prediction of the overall transverse elastic moduli of a compressible composite, the overall transverse uniaxial stress-strain curve for a compressible composite in the entire elastic-plastic range is obtained. A detailed example is given for a Boron-Aluminum composite. Comparison is made with the experimental and theoretical work done by General Dynamics and Adams respectively.
The isotopic composition of alkali and alkaline earth elements in the Luna 16 regolith was investigated by the method of thermionic emission, without chemical separation. The isotopic composition of the lithium in two regolith samples did not differ (within the limits 0.5 percent) from the mean of the terrestrial reference standard. At the same time, the observed difference (1 percent) in the isotopic composition of lithium between the samples requires further investigation and confirmation. The isotopic compositions of K and Rb did not differ within the limits of experimental error from the isotopic composition of the reference standard.