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NASA NTRS1988

A sintering model for SiC(sub)w/Si3N4 composites

Presented is a model which suggests that it should be possible to pressureless sinter a SiC(sub w)/ Si3N4 composite to theoretical density. Prior failure to achieve complete densification by sintering is attributed to the use of compositions which result in a glass deficit. There is one basic premise for this model. The ratio of glass amount to surface area of nonglass constituents must be the same for both composite and sinterable monolithic Si3N4. This model suggests that whisker and grain sizes and whisker loading influence the glass amount necessary for successful sintering of composites. According to the model, a large glass amount will be necessary for successful sintering of these composites. However, grain boundary thicknesses in the composite will be less than those in the analogous monolithic materials. This suggests that good high temperature strength may still be attained. A recent report supports the predictions of the model.

Freedman, Marc R.↗

NASA NTRS1989

Composite blade structural analyzer (COBSTRAN) user's manual

The installation and use of a computer code, COBSTRAN (COmposite Blade STRuctrual ANalyzer), developed for the design and analysis of composite turbofan and turboprop blades and also for composite wind turbine blades was described. This code combines composite mechanics and laminate theory with an internal data base of fiber and matrix properties. Inputs to the code are constituent fiber and matrix material properties, factors reflecting the fabrication process, composite geometry and blade geometry. COBSTRAN performs the micromechanics, macromechanics and laminate analyses of these fiber composites. COBSTRAN generates a NASTRAN model with equivalent anisotropic homogeneous material properties. Stress output from NASTRAN is used to calculate individual ply stresses, strains, interply stresses, thru-the-thickness stresses and failure margins. Curved panel structures may be modeled providing the curvature of a cross-section is defined by a single value function. COBSTRAN is written in FORTRAN 77.

Aiello, Robert A.↗

NASA NTRS1988

Evaluation of a thermoplastic polyimide (422) for bonding GR/PI composite

A hot-melt processable copolyimide previously studied and characterized as an adhesive for bonding Ti-6Al-4V was used to bond Celion 6000/LARC-160 composite. Comparisons are made for the two adherend systems. A bonding cycle was determined for the composite bonding and lap shear specimens were prepared which were thermally exposed in a forced-air oven for up to 5000 h at 204 C. The lap shear strengths (LSSs) were determined at RT, 177, and 204 C. After thermal exposure at RT, 177, and 204 C the LSS decreased significantly; however, a slight increase was noted for the 204 C tests. Initially the LSS values are higher for the bonded Ti-6Al-4V than for the bonded composite, however, the LSS decreases dramatically between 5000 and 10,000 h of 204 C thermal exposure. Longer periods of thermal exposure up to 20,000 h results in further decreases in the LSSs. Although the bonded composite retained useful strengths for exposures up to 5000 h, based on the por results of the bonded Ti-6Al-4V beyond 5000 h, the 422 adhesive bonded composites would most likely also produce poor strengths beyond 5000 h exposure. Adhesive bonded composite lap shear specimens exposed to boiling water for 72 h exhibited greatly reduced strengths at all test temperatures. The percent retained after water boil for each test temperature was essentially the same for both systems.

Progar, Donald J.↗

NASA NTRS1989

Mechanical properties characterization of composite sandwich materials intended for space antenna applications

The composite materials proposed for use in the Advanced Communications Technology Satellite (ACTS) program contains a new, high modulus graphite fiber as the reinforcement. A study was conducted to measure certain mechanical properties of the new fiber-reinforced material as well as of a composite-faced aluminum honeycomb sandwich structure. Properties were measured at -157, 22, and 121 C. Complete characterization of this material was not intended. Longitudinal tensile, picture-frame shear, short-beam shear, and flexural tests were performed on specimens of the composite face-sheet materials. Unidirectional, cross-plied, and quasi-isotropic fiber composite ply layup designs were fabricated and tested. These designs had been studied by using NASA's Integrated Composite Analyzer (ICAN) computer program. Flexural tests were conducted on (+/- 60/0 deg) sub s composite-faced sandwich structure material. Resistance strain gages were used to measure strains in the tensile, picture-frame, and sandwich flexural tests. The sandwich flexural strength was limited by the core strength at 157 and 22 c. The adhesive bond strength was the limiting factor at 121 C. Adhesive mechanical properties are reflected in sandwich structure flexural properties when the span-to-depth ratio is great enough to allow a significant shear effect on the load-deflection behavior of the sandwich beam. Most measured properties agreed satisfactorily with the properties predicted by ICAN.

Bowles, Kenneth J.↗

NASA NTRS1989

Composite Blade Structural Analyzer (COBSTRAN) theoretical/programmer's manual

This manual describes the organization and flow of data and analysis in the computer code, COBSTRAN (COmposite Blade STRuctural ANalyzer). This code combines composite mechanics and laminate theory with an internal data base of fiber and matrix properties and was developed for the design and analysis of composite turbofan and turboprop blades and composite wind turbine blades. Inputs to the code are constituent fiber and matrix material properties, factors reflecting the fabrication process, composite geometry and blade geometry. COBSTRAN performs the micromechanics and laminate analyses of these fiber composites and generates a NASTRAN finite element model of the blade. This manual describes the equations formulated and solved in the code and the function of each of the seventy-two subroutines. COBSTRAN is written in FORTRAN 77.

Aiello, Robert A.↗

NASA NTRS1986

Transport composite fuselage technology: Impact dynamics and acoustic transmission

A program was performed to develop and demonstrate the impact dynamics and acoustic transmission technology for a composite fuselage which meets the design requirements of a 1990 large transport aircraft without substantial weight and cost penalties. The program developed the analytical methodology for the prediction of acoustic transmission behavior of advanced composite stiffened shell structures. The methodology predicted that the interior noise level in a composite fuselage due to turbulent boundary layer will be less than in a comparable aluminum fuselage. The verification of these analyses will be performed by NASA Langley Research Center using a composite fuselage shell fabricated by filament winding. The program also developed analytical methodology for the prediction of the impact dynamics behavior of lower fuselage structure constructed with composite materials. Development tests were performed to demonstrate that the composite structure designed to the same operating load requirement can have at least the same energy absorption capability as aluminum structure.

Jackson, A. C.↗

NASA NTRS1988

Prediction of high temperature metal matrix composite ply properties

The application of the finite element method (superelement technique) in conjunction with basic concepts from mechanics of materials theory is demonstrated to predict the thermomechanical behavior of high temperature metal matrix composites (HTMMC). The simulated behavior is used as a basis to establish characteristic properties of a unidirectional composite idealized an as equivalent homogeneous material. The ply properties predicted include: thermal properties (thermal conductivities and thermal expansion coefficients) and mechanical properties (moduli and Poisson's ratio). These properties are compared with those predicted by a simplified, analytical composite micromechanics model. The predictive capabilities of the finite element method and the simplified model are illustrated through the simulation of the thermomechanical behavior of a P100-graphite/copper unidirectional composite at room temperature and near matrix melting temperature. The advantage of the finite element analysis approach is its ability to more precisely represent the composite local geometry and hence capture the subtle effects that are dependent on this. The closed form micromechanics model does a good job at representing the average behavior of the constituents to predict composite behavior.

Caruso, J. J.↗

NASA NTRS1990

Heat treatment study of the SiC/Ti-15-3 composite system

The oxidation and aging behaviors of a continuous fiber SiC/Ti-15V-3Cr-3Sn-3Al composite (SiC/Ti-15-3) were investigated. The aging characteristic of the composite were compared with those of the unreinforced Ti-15-3 matrix material, which was processed in the same manner as the composite. Various age hardened conditions of both the unreinforced matrix and the composite were evaluated by using optical microscopy, hardness measurements, and room temperature tensile tests (unreinforced matrix only). The Ti-15-3 material formed a thick surface oxide at temperature at or above 550 C when heat treated in air. The in situ composite matrix was softer than the unreinforced matrix for equivalent aging conditions. Both materials hardened to a maximum, then softened during overaging. The temperature at which peak aging occurred was approx. 450 C for both the in situ composite matrix and the unreinforced matrix. The room temperature elastic modulus and ultimate tensile strength of the unreinforced matrix varied as a function of aging treatment and paralleled the hardness behavior. The modulus and tensile strength showed little response to aging up to temperatures of 300 C; however, these properties increased after aging at 550 C. Aging at temperatures above 550 C resulted in a decrease in the modulus and tensile strength. The failure strain was a function of the precipitation state and of the amount of oxidation resulting from the heat treatment. Aging in air at the higher temperatures (greater than 550 C) caused the formation of a thick oxide layer and reduced the ductility. Aging in vacuum at these temperatures resulted in significantly higher ductilities. Long term exposures at 700 C caused the formation of a large grain boundary alpha-phase which reduced the ductility, even though the specimens were heat treated in vacuum.

Lerch, Bradley A.↗

NASA NTRS1989

Fatigue crack growth in a unidirectional SCS-6/Ti-15-3 composite

An investigation was conducted to characterize and model the fatigue crack growth (FCG) behavior of a SCS-6/Ti-15-3 metal matrix composite. Part of the study was conducted using a fatigue loading stage mounted inside a scanning electron microscope (SEM). This unique facility allowed high magnification viewing of the composite fatigue processes and measurement of the near crack tip displacements. The unidirectional composite was tested in the (0)8 (i.e., longitudinal) and (90)8 (i.e., transverse) orientations. For comparison purposes unreinforced matrix material produced by the identical process as the reinforced material was also tested. The results of the study reveal that the fatigue crack growth behavior of the composite is a function of specimen geometry, fiber orientation and the interaction of local stress fields with the highly anisotropic composite. In the case of (0)8 oriented single edge notch (SEN) specimens and (90)8 oriented compact tension (CT) specimens, the crack growth was normal to the loading direction. However, for the (0)8 CT specimens the crack grew mostly parallel to the loading and the fiber direction. The unusual fatigue behavior of the (0)8 CT specimens was attributed to the specimen geometry and the associated high tensile bending stresses perpendicular to the fiber direction. These stresses resulted in preferential cracking in the weak interface region perpendicular to the fiber direction. The interface region, and in particular the carbon coating surrounding the fiber proved to be the composites weakest link. In the (0)8 SEN the crack growth was confined to the matrix leaving behind unbroken fibers which bridged the cracked surfaces. As the crack grew longer, more fibers bridged the crack resulting in a progressive decrease in the crack growth rates and eventual crack arrest. The actual near crack tip displacement measurements were used in a proposed formulation for a bridging-corrected effective crack driving force, delta K(sub eff). This parameter was able to account for most of the experienced bridging and correlated the (0)8 SEN fatigue crack growth data reasonably well.

Kantzos, Peter↗

NASA NTRS1990

The assessment of metal fiber reinforced polymeric composites

Because of their low cost, excellent electrical conductivity, high specific strength (strength/density), and high specific modulus (modulus/density) short metal fiber reinforced composites have enjoyed a widespread use in many critical applications such as automotive industry, aircraft manufacturing, national defense, and space technology. However, little data has been found in the study of short metal fibrous composites. Optimum fiber concentration in a resin matrix and fiber aspect ratio (length-to-diameter ratio) are often not available to a user. Stress concentration at short fiber ends is the other concern when the composite is applied to a load-bearing application. Fracture in such composites where the damage will be initiated or accumulated is usually difficult to be determined. An experimental investigation is therefore carefully designed and undertaken to systematically evaluate the mechanical properties as well as electrical properties. Inconel 601 (nickel based) metal fiber with a diameter of eight microns is used to reinforce commercially available thermoset polyester resin. Mechanical testing such as tensile, impact, and flexure tests along with electrical conductivity measurements is conducted to study the feasibility of using such composites. The advantages and limitations of applying chopped metal fiber reinforced polymeric composites are also discussed.

Chung, Wenchiang R.↗

NASA NTRS1990

Composites boost 21st-century aircraft engines

Research and development in light-weight, high-temperature composite materials for ultrahigh-bypass engines to be used in high-speed civil transport/rotocraft is presented. It is noted that the expected benefits to be attained by this R&D include weight reduction, lowered fuel consumption, and lower direct operating costs. A major effort underway in this area is the Advanced High Temperature Engine Materials Technology Program (HITEMP) of NASA, which focuses on providing revolutionary high-temperature composite materials: to 425 C (800 F) for polymer-matrix composites (PMCs), to 1250 C (2280 F) for metal-matrix/intermetallic-matrix composites (MMCs/IMCs), and to as high as 1650 C (3000 F) for ceramic-matrix composites (CMCs). Analytical modeling is being used to investigate the structural behavior of these advanced materials in six distinct areas: micromechanics, deformation and damage, fatigue, fracture, trade-off studies, and load definition. It is concluded that the development of advanced materials such as high-temperature composites is highly dependent on the availability of high-temperature fibers. The wide range of fiber characteristics needed will require the development of more than one fiber. In general, a candidate fiber should have low density, high strength, high stiffness, a CTE matching the matrix, chemical compatibility with the matrix, environmental stability and appropriate fiber diameter.

Stephens, Joseph R.↗

NASA NTRS1990

Nicalon/siliconoxycarbide ceramic composites

A number of polymers of differing molecular structure, viscosity, copolymer composition, and production procedures, screened for production of strong, tough Nicalon/siliconoxycarbide composites, are discussed. Variables during polymer synthesis include pH, water/methoxy ratio and phenyl/methyl ratio. Final processing temperatures of the composites range from 1200 deg to 1400 deg C. The filler is derived from pyrolysis of the 50 phenyl/50 methyl silsesquioxane copolymer pyrolyzed to 650 deg C, then milled to less than 1-micron powder. Composite samples were fractured to evaluate the influence of matrix composition, final fabrication temperature, and use of filler on the composite mode of failure, modulus, strain capability, and strength. Incorporation of filler was found to increase matrix compressive strength and to influence matrix shrinkage and cracking.

Hurwitz, F. I.↗

NASA NTRS1990

Analyses of composite fuselage structure under various loading conditions

With the characteristics of high strength/weight and stiffness/weight ratios in advanced composite materials, composite plate structures have been successfully applied to secondary load-carrying structural components in the aerospace industry for the past two decades. Recently, filament wound composite shells are being considered for design of primary fuselage structures. To implement the design the structural response under various loading conditions needs to be predicted accurately. Therefore, it is essential to establish a rigorous analytical solution in the area of composite laminated shells. A closed form solution is presented that predicts the response of a composite shell subjected to internal pressure, axial tension, bending, and torsion. The material of the shell is assumed to be general cylindrically anisotropic. Based on the theory of cylindrical anisotropic elasticity coupled partial differential governing equations are developed using Lehknitskii's stress function approach. The general expressions for the stresses and displacements in the composite cylinders under these loading conditions is discussed. Three examples (45) off-axis unidirectional, (45/45) unsymmetric, and (45/45)(sub s) symmetric angle-ply fiber-reinforced laminated shells are shown to illustrate the effect of radius-to-thickness ratios, coupling, and stacking sequence.

Yuan, Fuh-Gwo↗

NASA NTRS1991

Effect of fiber reinforcements on thermo-oxidative stability and mechanical properties of polymer matrix composites

A number of studies have investigated the thermo-oxidative behavior of polymer matrix composites. Two significant observations have been made from these research efforts: (1) fiber reinforcement has a significant effect on composite thermal stability; and (2) geometric effects must be considered when evaluating thermal aging data. A compilation of some results from these studies is presented, and this information shows the influence of the reinforcement fibers on the oxidative degradation of various polymer matrix composites. The polyimide PMR-15 was the matrix material that was used in these studies. The control composite material was reinforced with Celion 6000 graphite fiber. T-40R graphite fibers, along with some very stable ceramic fibers were selected as reinforcing fibers because of their high thermal stability. The ceramic fibers were Nicalon (silicon carbide) and Nextel 312 (alumina-silica-boron oxide). The mechanical properties of the two graphite fiber composites were significantly different, probably owing to variations in interfacial bonding between the fibers and the polyimide matrix. The Celion 6000/PMR-15 bond is very tight but the T-40/PMR-15 bond is less tight. Three oxidation mechanisms were observed: (1) the preferential oxidation of the Celion 6000 fiber ends at cut surfaces, leaving a surface of matrix material with holes where the fiber ends were originally situated; (2) preferential oxidation of the composite matrix; and (3) interfacial degradation by oxidation. The latter two mechanisms were also observed on fiber end cut surfaces. The fiber and interface attacks appeared to initiate interfiber cracking along these surfaces.

Bowles, Kenneth J.↗

NASA NTRS1991

Composite flexible insulation for thermal protection of space vehicles

A composite flexible blanket insulation (CFBI) system considered for use as a thermal protection system for space vehicles is described. This flexible composite insulation system consists of an outer layer of silicon carbide fabric, followed by alumina mat insulation, and alternating layers of aluminized polyimide film and aluminoborosilicate scrim fabric. A potential application of this composite insulation would be as a thermal protection system for the aerobrake of the aeroassist space transfer vehicle (ASTV). It would also apply to other space vehicles subject to high convective and radiative heating during atmospheric entry. The thermal performance of this composite insulation as exposed to a simulated atmospheric entry environment in a plasma arc test facility is described. Other thermophysical properties which affect the thermal response of this composite insulation is included. It shows that this composite insulation is effective as a thermal protection system at total heating rates up to 30.6 W/sq cm.

Kourtides, Demetrius A.↗

NASA NTRS1991

Composite load spectra for select space propulsion structural components

The objective of this program is to develop generic load models with multiple levels of progressive sophistication to simulate the composite load spectra that are induced in space propulsion system components, representative of Space Shuttle Main Engines (SSME), such as transfer ducts, turbine blades, and liquid oxygen (LOX) posts and system ducting. These models will be developed using two independent approaches. The first approach consists of using state-of-the-art probabilistic methods to describe the individual loading conditions and combinations of these loading conditions to synthesize the composite load spectra simulation. The methodology required to combine the various individual load simulation models (hot-gas dynamic, vibrations, instantaneous position, centrifugal field, etc.) into composite load spectra simulation models will be developed under this program. A computer code incorporating the various individual and composite load spectra models will be developed to construct the specific load model desired. The second approach, which is covered under the options portion of the contract, will consist of developing coupled models for composite load spectra simulation which combine the (deterministic) models for composite load dynamic, acoustic, high-pressure and high rotational speed, etc., load simulation using statistically varying coefficients. These coefficients will then be determined using advanced probabilistic simulation methods with and without strategically selected experimental data. This report covers the efforts of the third year of the contract. The overall program status is that the turbine blade loads have been completed and implemented. The transfer duct loads are defined and are being implemented. The thermal loads for all components are defined and coding is being developed. A dynamic pressure load model is under development. The parallel work on the probabilistic methodology is essentially completed. The overall effort is being integrated in an expert system code specifically developed for this project.

Newell, J. F.↗

NASA NTRS1992

Structure-to-property relationships in addition cured polymers. 4: Correlations between thermo-oxidative weight losses of norbornenyl cured polyimide resins and their composites

Relationships are identified between the thermo-oxidative stability (TOS) at 316 C of a wide variety of PMR (polymerization of monomeric reactants) addition cured polyimide resins and their corresponding graphite fiber composites. Weight loss results at 316 C confirmed the expected relationship of increasing aliphatic endcap content with decreasing TOS. Moreover, the resin TOS study also showed an unexpected linear correlation of decreasing weight loss to increasing ratio of benzylic diamine to aliphatic endcap in the range of the stoichiometries studied. Only after long term 316 C aging does the dianhydride used with the benzylic diamines become an additional factor in influencing the amount of PMR resin and composite weight losses. Also, the benzylic systems consistently showed much lower resin and composite weight losses at 316 C than the corresponding nonbenzylic norbornenyl resins and composites, except when the nonbenzylic diamine monomer does not contain a connecting group. Instead, this diamine resulted in a 316 C resin and composite weight loss that was only competitive with benzylic type diamines. Results show excellent correlation between TOS of all graphite fiber PMR composites and resins.

Alston, William B.↗

NASA NTRS1991

Optimization of composite sandwich cover panels subjected to compressive loadings

An analysis and design method is presented for the design of composite sandwich cover panels that include the transverse shear effects and damage tolerance considerations. This method is incorporated into a sandwich optimization computer program entitled SANDOP. As a demonstration of its capabilities, SANDOP is used in the present study to design optimized composite sandwich cover panels for for transport aircraft wing applications. The results of this design study indicate that optimized composite sandwich cover panels have approximately the same structural efficiency as stiffened composite cover panels designed to satisfy individual constraints. The results also indicate that inplane stiffness requirements have a large effect on the weight of these composite sandwich cover panels at higher load levels. Increasing the maximum allowable strain and the upper percentage limit of the 0 degree and +/- 45 degree plies can yield significant weight savings. The results show that the structural efficiency of these optimized composite sandwich cover panels is relatively insensitive to changes in core density. Thus, core density should be chosen by criteria other than minimum weight (e.g., damage tolerance, ease of manufacture, etc.).

Cruz, Juan R.↗