Failure mechanisms at metal-dielectric interfaces
Failure mechanisms at metal-dielectric interfaces
DIELECTRIC MATERIAL↗
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An assessment of test specimens and test techniques useful to the evaluation of structural reinforced plastic materials at cryogenic temperatures.
Physical and thermal properties of structural reinforced plastic materials at cryogenic temperatures
REINFORCED PLASTIC↗
Strength criteria for composite materials (a literature survey)
Literature concerning strength (failure) criteria for composite materials is reviewed with emphasis on phenomenological failure criteria. These criteria are primarily intended to give a good estimation of the safety margin with respect to failure for arbitrary multiaxial stress states. The failure criteria do not indicate the types of fracture that will occur in the material. The collection of failure criteria is evaluated for applicability for the glass reinforced plastics used in mine detectors. Material tests necessary to determine the parameters in the failure criteria are discussed.
Roode, F.↗
Probabilistic and Possibilistic Analyses of the Strength of a Bonded Joint
The effects of uncertainties on the predicted strength of a single lap shear joint are examined. Probabilistic and possibilistic methods are used to account for uncertainties. A total of ten variables are assumed to be random, with normal distributions. Both Monte Carlo Simulation and the First Order Reliability Method are used to determine the probability of failure. Triangular membership functions with upper and lower bounds located at plus or minus three standard deviations are used to model uncertainty in the possibilistic analysis. The alpha cut (or vertex) method is used to evaluate the possibility of failure. Linear and geometrically nonlinear finite element analyses are used calculate the response of the joint; fracture in the adhesive and material strength failure in the strap are used to evaluate its strength. Although probabilistic and possibilistic analyses provide significantly more information than do conventional deterministic analyses, they are computationally expensive. A novel scaling approach is developed and used to substantially reduce the computational cost of the probabilistic and possibilistic analyses. The possibilistic approach for treating uncertainties appears to be viable during the conceptual and preliminary design stages when limited data are available and high accuracies are not needed. However, this viability is mixed with several cautions that are discussed herein.
Stroud, W. Jefferson↗
The Role of Molecular Weight and Temperature on the Elastic and Viscoelastic Properties of a Glassy Thermoplastic Polyimide
Mechanical testing of the elastic and viscoelastic response of an advanced thermoplastic polyimide (LaRC-SI) with known variations in molecular weight was performed over a range of temperatures below the glass transition temperature. The notched tensile strength was shown to be a strong function of both molecular weight and temperature, whereas stiffness was only a strong function of temperature. A critical molecular weight was observed to occur at a weight average molecular weight of M, approx. 22,000 g/mol below which, the notched tensile strength decreases rapidly. This critical molecular weight transition is temperature-independent. Low, molecular weight materials tended to fail in a brittle manner, whereas high molecular weight materials exhibited ductile failure. Furthermore, low molecular weight materials have increased creep compliance and creep compliance rate, and are more sensitive to temperature than the high molecular weight materials. At long timescales (less than 1100 hours) physical aging serves to significantly decrease the creep compliance and creep rate of all the materials tested. Low molecular weight materials are less influenced by the effects of physical aging.
Nicholson, Lee M.↗
Stress Corrosion Cracking of Metals in Propellants
Stress corrosion cracking (SCC) of a fracture critical metallic material can cause a premature failure if the material is susceptible in the unique service environment. Material fluid compatibility is an area of interest for the current NASA programs leading the human exploration path to Mars. White Sands Test Facility, the agency's lead on hypergolic propellant testing, identifies a lack in stress corrosion cracking susceptibility data for metallic materials in hypergolic propellants. The development of a stress corrosion cracking screening method is necessary to bridge the knowledge gap and enable the community to more confidently select materials for the use in systems containing corrosive fluids.
Alcantara, Ilse↗
An Experimental Investigation of Silicone-to-Metal Bond Strength in Composite Space Docking System Seals
The National Aeronautics and Space Administration (NASA) is currently developing a new universal docking mechanism for future space exploration missions called the Low Impact Docking System (LIDS). A candidate LIDS main interface seal design is a composite assembly of silicone elastomer seals vacuum molded into grooves in an electroless nickel plated aluminum retainer. The strength of the silicone-tometal bond is a critical consideration for the new system, especially due to the presence of small areas of disbond created during the molding process. In the work presented herein, seal-to-retainer bonds of subscale seal specimens with different sizes of intentional disbond were destructively tensile tested. Nominal specimens without intentional disbonds were also tested. Tension was applied either uniformly on the entire seal circumference or locally in one short circumferential length. Bond failure due to uniform tension produced a wide scatter of observable failure modes and measured load-displacement behaviors. Although the preferable failure mode for the seal-to-retainer bond is cohesive failure of the elastomer material, the dominant observed failure mode under the uniform loading condition was found to be the less desirable adhesive failure of the bond in question. The uniform tension case results did not show a correlation between disbond size and bond strength. Localized tension was found to produce failure either as immediate tearing of the elastomer material outside the bond region or as complete peel-out of the seal in one piece. The obtained results represent a valuable benchmark for comparison in the future between adhesion loads under various separation conditions and composite seal bond strength.
Gaier, James R.↗
Progressive Failure Analysis Methodology for Laminated Composite Structures
A progressive failure analysis method has been developed for predicting the failure of laminated composite structures under geometrically nonlinear deformations. The progressive failure analysis uses C(exp 1) shell elements based on classical lamination theory to calculate the in-plane stresses. Several failure criteria, including the maximum strain criterion, Hashin's criterion, and Christensen's criterion, are used to predict the failure mechanisms and several options are available to degrade the material properties after failures. The progressive failure analysis method is implemented in the COMET finite element analysis code and can predict the damage and response of laminated composite structures from initial loading to final failure. The different failure criteria and material degradation methods are compared and assessed by performing analyses of several laminated composite structures. Results from the progressive failure method indicate good correlation with the existing test data except in structural applications where interlaminar stresses are important which may cause failure mechanisms such as debonding or delaminations.
Sleight, David W.↗
Materials investigation of STS-3 parachute failure
Main parachute, No. 2 of SRB A-12 on STS-3, sustained damage during deployment or initial inflation that resulted in its collapse and failure to sustain load. During an investigation of the materials from this parachute, optical and scanning electron microscope analyses were conducted. This examination identified stains and abrasions on vent lines that appear to have been a result of friction contact with its flotation bag lanyard. Mechanical testing of the vent band indicated a reduction in strength of 37 percent obviously due to structural overload, heat, and ocean water exposure. It is concluded from this and other available data that entanglement of parachutes No. 1 and No. 2 during deployment caused adequate structural damage to main parachute No. 2 to render it unable to carry load.
Nichols, R. L.↗
The effect of resin toughness and modulus on compressive failure modes of quasi-isotropic graphite/epoxy laminates
Compressive failure mechanisms in quasi-isotropic graphite/epoxy laminates were characterized for both unnotched and notched specimens and also following damage by impact. Two types of fibers (Thornel 300 and 700) and four resin systems (Narmco 5208, American Cyanamid BP907, and Union Carbide 4901/MDA and 4901/mPDA) were studied. For all material combinations, failure of unnotched specimens was initiated by kinking of fibers in the 0-degree plies. A major difference was observed, however, in the mode of failure propagation after the 0-degree ply failure. The strength of quasi-isotropic laminates in general increased with increasing resin tensile modulus. The laminates made with Thornel 700 fibers exhibited slightly lower compressive strengths than did the laminates made with Thornel 300 fibers. The notch sensitivity as measured by the hole strength was lowest for the BP907 resin and highest for the 5208 resin. For the materials studied, however, the type of fiber had no effect on the notch sensitivity.
Sohi, M. M.↗
The effect of resin toughness and modulus on compressive failure modes of quasi-isotropic graphite/epoxy laminates
Compressive failure mechanisms in quasi-isotropic graphite/epoxy laminates were characterized for both unnotched and notched specimens and also following damage by impact. Two types of fibers (Thornel 300 and 700) and four resin systems (Narmco 5208, American Cyanamid BP907, and Union Carbide 4901/MDA and 4901/mPDA) were studied. For all material combinations, failure of unnotched specimens was initiated by kinking of fibers in the 0-degree plies. A major difference was observed, however, in the mode of failure propagation after the 0-degree ply failure. The strength of quasi-isotropic laminates in general increased with increasing resin tensile modulus. The laminates made with Thornel 700 fibers exhibited slightly lower compressive strengths than did the laminates made with Thornel 300 fibers. The notch sensitivity as measured by the hole strength was lowest for the BP907 resin and highest for the 5208 resin. For the materials studied, however, the type of fiber had no effect on the notch sensitivity.
Hahn, H. Thomas↗
Local crippling of thin-walled graphite-epoxy stiffeners
Results from an experimental and analytical study of the local buckling, postbuckling, and crippling (failure) behavior of channel, zee, and I- and J-section stiffeners made of AS4/3502 graphite-epoxy unidirectional tape are presented. Thirty-six specimens were tested in axial compression. Experimental results indicate the existence of a number of damage initiation modes, all of which involve either delamination in some part of the specimen or local material strength failure in a corner of the specimen. The flange width-to-thickness ratio is found to influence the mode of damage initiation. The inner corner radius strongly affects the crippling stress for the I- and J-section specimens, but was not found to have a significant effect on the crippling stress of channels and zees. Geometrically nonlinear analyses of five specimens were performed with the STAGS general purpose computer code. Correlation between analytical and experimental results is excellent through buckling, but agreement degrades in postbuckling. The discrepancies in postbuckling are attributed to neglect of transverse shearing deformations in the analysis and development of damage in the specimens. Hashin's compressive fiber mode failure criterion correlates reasonably well with the first major damage event in a first ply failure analysis.
Bonanni, David L.↗
Requirements for energy based constitutive modeling in tire mechanics
The history, requirements, and theoretical basis of a new energy based constitutive model for (rubber) material elasticity, hysteresis, and failure are presented. Energy based elasticity is handled by many constitutive models, both in one dimension and in three dimensions. Conversion of mechanical energy to heat can be modeled with viscoelasticity or as structural hysteresis. We are seeking unification of elasticity, hysteresis, and failure mechanisms such as fatigue and wear. An energy state characterization for failure criteria of (rubber) materials may provide this unification and also help explain the interaction of temperature effects with failure mechanisms which are described as creation of growth of internal crack surface. Improved structural modeling of tires with FEM should result from such a unified constitutive theory. The theory will also guide experimental work and should enable better interpretation of the results of computational stress analyses.
Luchini, John R.↗
Toward an In-Depth Material Model for Cermet Nuclear Thermal Rocket Fuel Elements
The development and qualification of nuclear thermal propulsion (NTP) fuel element technologies would be aided by an in-depth model of material response and failure modes at operating conditions. Integrated computational materials engineering techniques have the potential to provide such a model, as demonstrated here through three case studies focused on a tungsten-uranium mononitride cermet fuel. The first case focuses on the erosion of tungsten (W, also named wolfram), a nominal coating/cladding material, in hot hydrogen. Ab initio techniques are used to calculate erosion rates and thermal expansion at NTP operating conditions. The second focuses on the stability of uranium mononitride (UN) fuels at high temperature and in the presence of hydrogen. Phase diagram techniques reveal potential instabilities and decomposition pathways at high hydrogen concentrations. The third focuses on using microstructure information to predict high temperature mechanical response and failure of tungsten, used in refractory cermet materials. Combined finite element and discrete dislocation dynamics techniques provide mechanical properties in agreement with experimental methods. The integration of these techniques for an all-encompassing material model is discussed.
cermet↗
An investigation of the causes of failure of flexible thermal protection materials in an aerodynamic environment
Tests of small panels of advanced flexible reusable surface insulation (AFRSI) were conducted using a small wind tunnel that was designed to simulate Space Shuttle Orbiter entry mean-flow and pulsating aerodynamic loads. The wind tunnel, with a 3 inch wide by 1.75 inch high by 7.5 inch long test section, proved to be capable of continuous flow at dynamic pressures q near 580 psf with fluctuating pressures over 2 psi RMS at an excitation frequency f sub E of 200 Hz. For this investigation, however, the wind tunnel was used to test entry-temperature preconditioned and heat-cleaned AFRSI at q = 280 psf, Prms was nearly equal to 1.2 psi and f sub E = 200 Hz. The objective of these tests was to determine the mechanism of failure of AFRSI at Orbiter entry conditions. Details of the test apparatus and test results are presented.
Coe, Charles F.↗
Through-the-thickness tensile strength of textile composites
A series of tests was run to characterize the through-the-thickness tensile strength for a variety of composites that included 2D and 3D braids, 2D and 3D weaves, and prepreg tapes. A new test method based on a curved beam was evaluated. The through-the-thickness deformations were characterized using moire interferometry. Failures were significantly different between the 2D and 3D materials. The 2D materials delaminated between layers due to out-of-plane tensile stresses. The strength of the 2D textile composites did not increase relative to the tapes. The 3D materials failed due to the formation of radial cracks caused by high circumferential stresses along the inner radius. A circumferential crack similar to the 2D materials produced the final failure. Final failure in the 3D materials occurred at a lower bending moment than in other materials. The early failures were caused by radial crack formation rather than low through-the-thickness strength.
Jackson, Wade C.↗
United States manned spacecraft reliability experience
Attention is given to the reliability controls in manned spacecraft programs, taking into account the project Mercury, the Gemini program, the Apollo program, the Skylab program, and the Apollo-Soyuz test project. Reliability controls used in these programs are related to reliability management, parts and materials control, failure mode and effects analysis, reliability quantitative analysis, problem reporting and corrective action control, test control, limited-life control, and milestone reviews. A summary is presented of the major reliability tasks and innovations being used on the Space Shuttle program. Examples of these innovations include improved management techniques and an early identification of specific certification tests.
Kleinknecht, K. S.↗
Analysis methods for Kevlar shield response to rotor fragments
Several empirical and analytical approaches to rotor burst shield sizing are compared and principal differences in metal and fabric dynamic behavior are discussed. The application of transient structural response computer programs to predict Kevlar containment limits is described. For preliminary shield sizing, present analytical methods are useful if insufficient test data for empirical modeling are available. To provide other information useful for engineering design, analytical methods require further developments in material characterization, failure criteria, loads definition, and post-impact fragment trajectory prediction.
Gerstle, J. H.↗