ALBERT

Description: An analytic procedure has been developed to determine the transient response of simply supported, retangular laminated composite plates subjected to impact loads from airgun-propelled or drop-weight impactors. A first-order shear deformation theory has been included in the analysis to represent properly any local short-wavelength transient bending response. The impact force has been modeled as a locally distributed load with cosine-cosine distribution. A double Fourier series expansion and the Timoshenko small increment method have been used to determine the contact force, out-of-plane deflections, and in-plane strains and stresses at any plate location due to an impact force at any plate location. The results of experimental and analytical studies are compared for quasi-isotropic laminates. The results indicate the importance of including transverse shear deformation effects in the analysis for predicting the response of laminated plates subjected to both airgun-propelled and dropped-weight impactors. The results also indicate that plate boundary conditions influence the axial strains more significantly than the contact force for a dropped-weight impactor. The results of parametric studies identify a scaling approach based on impactor momentum that may account for the differences in the responses of plates impacted by airgun-propelled or dropped-weight impactors.

Description: A significant percentage of time spent in a typical finite element analysis is taken up in the modeling and assignment of loads and constraints. This process not only requires the analyst to be well-versed in the art of finite element modeling, but also demands familiarity with some sort of preprocessing software in order to complete the task expediently. COMGEN (COmposite Model GENerator) is an interactive FORTRAN program which can be used to create a wide variety of finite element models of continuous fiber composite materials at the micro level. It quickly generates batch or "session files" to be submitted to the finite element pre- and post-processor program, PATRAN. (PDA Engineering, Costa Mesa, CA.) In modeling a composite material, COMGEN assumes that its constituents can be represented by a "unit cell" of a fiber surrounded by matrix material. Two basic cell types are available. The first is a square packing arrangement where the fiber is positioned in the center of a square matrix cell. The second type, hexagonal packing, has the fiber centered in a hexagonal matrix cell. Different models can be created using combinations of square and hexagonal packing schemes. Variations include two- and three- dimensional cases, models with a fiber-matrix interface, and different constructions of unit cells. User inputs include fiber diameter and percent fiber-volume of the composite to be analyzed. In addition, various mesh densities, boundary conditions, and loads can be assigned to the models within COMGEN. The PATRAN program then uses a COMGEN session file to generate finite element models and their associated loads which can then be translated to virtually any finite element analysis code such as NASTRAN or MARC. COMGEN is written in FORTRAN 77 and has been implemented on DEC VAX series computers under VMS and SGI IRIS series workstations under IRIX. If the user has the PATRAN package available, the output can be graphically displayed. Without PATRAN, the output is tabular. The VAX VMS version is available on a 5.25 inch 360K MS-DOS format diskette (standard distribution media) or a 9-track 1600 BPI DEC VAX FILES-11 format magnetic tape, and it requires about 124K of main memory. The standard distribution media for the IRIS version is a .25 inch streaming magnetic tape cartridge in UNIX tar format. The memory requirement for the IRIS version is 627K. COMGEN was developed in 1990. DEC, VAX and VMS are trademarks of Digital Equipment Corporation. PATRAN is a registered trademark of PDA Engineering. SGI IRIS and IRIX are trademarks of Silicon Graphics, Inc. MS-DOS is a registered trademark of Microsoft Corporation. UNIX is a registered trademark of AT&T.

Description: A significant percentage of time spent in a typical finite element analysis is taken up in the modeling and assignment of loads and constraints. This process not only requires the analyst to be well-versed in the art of finite element modeling, but also demands familiarity with some sort of preprocessing software in order to complete the task expediently. COMGEN (COmposite Model GENerator) is an interactive FORTRAN program which can be used to create a wide variety of finite element models of continuous fiber composite materials at the micro level. It quickly generates batch or "session files" to be submitted to the finite element pre- and post-processor program, PATRAN. (PDA Engineering, Costa Mesa, CA.) In modeling a composite material, COMGEN assumes that its constituents can be represented by a "unit cell" of a fiber surrounded by matrix material. Two basic cell types are available. The first is a square packing arrangement where the fiber is positioned in the center of a square matrix cell. The second type, hexagonal packing, has the fiber centered in a hexagonal matrix cell. Different models can be created using combinations of square and hexagonal packing schemes. Variations include two- and three- dimensional cases, models with a fiber-matrix interface, and different constructions of unit cells. User inputs include fiber diameter and percent fiber-volume of the composite to be analyzed. In addition, various mesh densities, boundary conditions, and loads can be assigned to the models within COMGEN. The PATRAN program then uses a COMGEN session file to generate finite element models and their associated loads which can then be translated to virtually any finite element analysis code such as NASTRAN or MARC. COMGEN is written in FORTRAN 77 and has been implemented on DEC VAX series computers under VMS and SGI IRIS series workstations under IRIX. If the user has the PATRAN package available, the output can be graphically displayed. Without PATRAN, the output is tabular. The VAX VMS version is available on a 5.25 inch 360K MS-DOS format diskette (standard distribution media) or a 9-track 1600 BPI DEC VAX FILES-11 format magnetic tape, and it requires about 124K of main memory. The standard distribution media for the IRIS version is a .25 inch streaming magnetic tape cartridge in UNIX tar format. The memory requirement for the IRIS version is 627K. COMGEN was developed in 1990. DEC, VAX and VMS are trademarks of Digital Equipment Corporation. PATRAN is a registered trademark of PDA Engineering. SGI IRIS and IRIX are trademarks of Silicon Graphics, Inc. MS-DOS is a registered trademark of Microsoft Corporation. UNIX is a registered trademark of AT&T.

Description: The Integrated Composite Analyzer (ICAN) is a computer program designed to carry out a comprehensive linear analysis of multilayered fiber composites. The analysis contains the essential features required to effectively design structural components made from fiber composites. ICAN includes the micromechanical design features of the Intraply Hybrid Composite Design (INHYD) program to predict ply level hygral, thermal, and mechanical properties. The laminate analysis features of the Multilayered Filamentary Composite Analysis (MFCA) program are included to account for interply layer effects. ICAN integrates these and additional features to provide a comprehensive analysis capability for composite structures. Additional features unique to ICAN include the following: 1) ply stress-strain influence coefficients, 2) microstresses and microstrain influence coefficients, 3) concentration factors around a circular hole, 4) calculation of probable delamination locations around a circular hole, 5) Poisson's ratio mismatch details near a straight edge, 6) free-edge stresses, 7) material card input for finite element analysis using NASTRAN (available separately from COSMIC) or MARC, 8) failure loads based on maximum stress criterion, and laminate failure stresses based on first-ply failures and fiber breakage criteria, 9) transverse shear stresses, normal and interlaminar stresses, and 10) durability/fatigue type analyses for thermal as well as mechanical cyclic loads. The code can currently assess degradation due to mechanical and thermal cyclic loads with or without a defect. ICAN includes a dedicated data bank of constituent material properties, and allows the user to build a database of material properties of commonly used fibers and matrices so the user need only specify code names for constituents. Input to ICAN includes constituent material properties (or code names), factors reflecting the fabrication process, and composite geometry. ICAN performs micromechanics, macromechanics, and laminate analysis including the hygrothermal response of fiber composites. ICAN output includes the various ply and composite properties, composite structural response, and composite stress analysis results with details of failure. Output can be tailored to specific needs by choosing the appropriate options. Two machine versions of ICAN are available. The IBM 370 series version (LEW-14468) is written in FORTRAN IV for the IBM 370 series computers running OS/TSS. The IBM PC version (LEW-15592) is written in FORTRAN 77 for use on the IBM PC series computers running MS-DOS and Microsoft FORTRAN 5.1. The IBM 370 version requires 3.5Mb of memory for execution. No sample executable is provided. For the IBM PC version, a sample executable, along with sample input and output data, is included on the distribution medium. Although the included executable requires a math coprocessor, the ICAN source can be recompiled into an executable which does not require a math coprocessor. The standard distribution medium for the IBM 370 version of ICAN is a 9-track 1600 BPI magnetic tape in EBCDIC CARD IMAGE format. The standard distribution medium for the IBM PC version is one 5.25 inch 360K MS-DOS format diskette. The contents of the diskette are compressed using the PKWARE archiving tools. The utility to unarchive the files, PKUNZIP.EXE, is included. ICAN was developed in 1986 and the IBM PC version was released in 1992.

Description: Advanced composite materials have gained use in the aerospace industry over the last 20 years because of their high specific strength and stiffness, and low coefficient of thermal expansion. Design of composite structures requires the analysis of composite material behavior. The Finite Element Composite Analysis Program, FECAP, is a special purpose finite element analysis program for analyzing composite material behavior with a microcomputer. Composite materials, in regard to this program, are defined as the combination of at least two distinct materials to form one nonhomogeneous anisotropic material. FECAP assumes a state of generalized plane strain exists in a material consisting of two or more orthotropic phases, subjected to mechanical and/or thermal loading. The finite element formulation used in FECAP is displacement based and requires the minimization of the total potential energy for each element with respect to the unknown variables. This procedure leads to a set of linear simultaneous equations relating the unknown nodal displacements to the applied loads. The equations for each element are assembled into a global system, the boundary conditions are applied, and the system is solved for the nodal displacements. The analysis may be performed using either 4-mode linear or 8-mode quadratic isoparametric elements. Output includes the nodal displacements, and the element stresses and strains. FECAP was written for a Hewlett Packard HP9000 Series 200 Microcomputer with the HP Basic operating system. It was written in HP BASIC 3.0 and requires approximately 0.5 Mbytes of RAM in addition to what is required for the operating system. A math coprocessor card is highly recommended. FECAP was developed in 1988.

Description: In the field of fracture mechanics, stress-intensity factors are important parameters for predicting fracture strengths and fatigue lives. BOFFO performs stress analysis of two-dimensional linear elastic orthotropic or composite bodies with or without cracks using the Boundary Force Method. The Boundary Force Method is versatile since complex geometries, crack configurations, and load distributions can be analyzed with ease. The BOFFO program is easy to use because only the boundaries of the region of interest are modeled using a built-in mesh generator. Stresses can be computed at any specified point in the body. Stress-intensity factor solutions and strain-energy release rates are computed for both mode I and mixed mode fracture problems. The Boundary Force Method is a numerical technique that uses the fundamental solutions for concentrated forces and moments in an infinite sheet to obtain the solution to the boundary value problem of interest. These fundamental solutions are used in the BOFFO program to exactly satisfy the stress-free conditions on the crack faces. The other boundary conditions are approximately satisfied by applying the appropriate sets of concentrated horizontal and vertical forces and moments along the boundary. The problem configuration is defined using two sets of axes. The global X- and Y-axes define the specimen boundaries, loads, and material properties. The local axes define the crack length and orientation. The user can specify four types of symmetry conditions: symmetry about the X-axis, symmetry about the Y-axis, symmetry about the X- and Y-axes, or no symmetry. The lines of symmetry are not modeled as boundaries. The accuracy of the solution depends on how well the boundary conditions are approximated, which in turn depends on the refinement of the boundary mesh. BOFFO uses the radial-line method for element mesh generation. BOFFO is written in FORTRAN V for execution on CDC CYBER 170 Series computers running NOS. The execution time and memory required depend on the number of boundary elements in the mesh. With twelve elements, the main memory requirement is 26K Cyber words. Input and output are tabular. BOFFO is available on a 9-track 1600 BPI ASCII Card Image format magnetic tape. This program was developed in 1990. CDC CYBER and NOS are trademarks of Control Data Corporation.

Description: GAMNAS (Geometric and Material Nonlinear Analysis of Structures) is a two-dimensional finite element stress analysis program developed to support fracture mechanics studies of debonding and delamination. GAMNAS options include linear, geometric nonlinear, material nonlinear, and combined geometric and material nonlinear analysis. GAMNAS can analyze plastic deformations of isotropic materials. GAMNAS can calculate strain energy release rates using a virtual crack extension technique. The element available to the GAMMNAS user is a four-node isoparametric quadrilateral with full or reduced integration. GAMNAS has been used to investigate debonding and delamination of adhesively bonded composites. GAMNAS is written in FORTRAN 77 for batch execution and has been implemented on a PRIME 700 series computer. As currently dimensioned for a maximum global stiffness matrix of 1300 degrees of freedom and a bandwidth of 70, GAMNAS has a central memory requirement of approximately 603K of 16 bit words. GAMNAS was developed in 1983.

Description: A study is made of the thermomechanical buckling of flat unstiffened composite panels with central circular cutouts. The panels are subjected to combined temperature changes and applied edge loading (or edge displacements). The analysis is based on a first-order shear deformation plate theory. A mixed formulation is used with the fundamental unknowns consisting of the generalized displacements and the stress resultants of the plate. Both the stability boundary and the sensitivity coefficients are evaluated. The sensitivity coefficients measure the sensitivity of the buckling response to variations in the different lamination and material parameters of the panel. Numerical results are presented showing the effects of the variations in the hole diameter, laminate stacking sequence, fiber orientation, and aspect ratio of the panel on the thermomechanical buckling response and its sensitivity coefficients.

Description: To use graphite polyetheretherketone (PEEK) material on highly curved surfaces requires that the material be drapable and easily conformable to the surface. This paper presents the mechanical property characterization and impact resistance results for laminates made from two types of graphite/PEEK materials that will conform to a curved surface. These laminates were made from two different material forms. These forms are: (1) a fabric where each yarn is a co-mingled Celion G30-500 3K graphite fiber and PEEK thermoplastic fiber; and (2) an interleaved material of Celion G30-500 3K graphite fabric interleaved with PEEK thermoplastic film. The experimental results from the fabric laminates are compared with results for laminates made from AS4/PEEK unidirectional tape. The results indicate that the tension and compression moduli for quasi-isotropic and orthotropic laminates made from fabric materials are at least 79 percent of the modulus of equivalent laminates made from tape material. The strength of fabric material laminates is at least 80 percent of laminates made from tape material. The evaluation of fabric material for shear stiffness indicates that a tape material laminate could be replaced by a fabric material laminate and still maintain 89 percent of the shear stiffness of the tape material laminate. The notched quasi-isotropic compression panel failure strength is 42 to 46 percent of the unnotched quasi-isotropic laminate strength. Damage area after impact with 20 ft-lbs of impact energy is larger for the co-mingled panels than for the interleaved panels. The inerleaved panels have less damage than panels made from tape material. Residual compression strength of quasi-isotropic panels after impact of 20 ft-lbs of energy varies between 33 percent of the undamaged quasi-isotropic material strength for the tape material and 38 percent of the undamaged quasi-isotropic material strength for the co-mingled fabric material.

Description: The Integrated Composite Analyzer (ICAN) is a computer program designed to carry out a comprehensive linear analysis of multilayered fiber composites. The analysis contains the essential features required to effectively design structural components made from fiber composites. ICAN includes the micromechanical design features of the Intraply Hybrid Composite Design (INHYD) program to predict ply level hygral, thermal, and mechanical properties. The laminate analysis features of the Multilayered Filamentary Composite Analysis (MFCA) program are included to account for interply layer effects. ICAN integrates these and additional features to provide a comprehensive analysis capability for composite structures. Additional features unique to ICAN include the following: 1) ply stress-strain influence coefficients, 2) microstresses and microstrain influence coefficients, 3) concentration factors around a circular hole, 4) calculation of probable delamination locations around a circular hole, 5) Poisson's ratio mismatch details near a straight edge, 6) free-edge stresses, 7) material card input for finite element analysis using NASTRAN (available separately from COSMIC) or MARC, 8) failure loads based on maximum stress criterion, and laminate failure stresses based on first-ply failures and fiber breakage criteria, 9) transverse shear stresses, normal and interlaminar stresses, and 10) durability/fatigue type analyses for thermal as well as mechanical cyclic loads. The code can currently assess degradation due to mechanical and thermal cyclic loads with or without a defect. ICAN includes a dedicated data bank of constituent material properties, and allows the user to build a database of material properties of commonly used fibers and matrices so the user need only specify code names for constituents. Input to ICAN includes constituent material properties (or code names), factors reflecting the fabrication process, and composite geometry. ICAN performs micromechanics, macromechanics, and laminate analysis including the hygrothermal response of fiber composites. ICAN output includes the various ply and composite properties, composite structural response, and composite stress analysis results with details of failure. Output can be tailored to specific needs by choosing the appropriate options. Two machine versions of ICAN are available. The IBM 370 series version (LEW-14468) is written in FORTRAN IV for the IBM 370 series computers running OS/TSS. The IBM PC version (LEW-15592) is written in FORTRAN 77 for use on the IBM PC series computers running MS-DOS and Microsoft FORTRAN 5.1. The IBM 370 version requires 3.5Mb of memory for execution. No sample executable is provided. For the IBM PC version, a sample executable, along with sample input and output data, is included on the distribution medium. Although the included executable requires a math coprocessor, the ICAN source can be recompiled into an executable which does not require a math coprocessor. The standard distribution medium for the IBM 370 version of ICAN is a 9-track 1600 BPI magnetic tape in EBCDIC CARD IMAGE format. The standard distribution medium for the IBM PC version is one 5.25 inch 360K MS-DOS format diskette. The contents of the diskette are compressed using the PKWARE archiving tools. The utility to unarchive the files, PKUNZIP.EXE, is included. ICAN was developed in 1986 and the IBM PC version was released in 1992.

Description: The energy absorption response and crushing characteristics of geometrically scaled graphite-Kevlar epoxy composite plates were investigated. Two different trigger mechanisms including notch, and steeple geometries were incorporated into the plate specimens to initiate crushing. Sustained crushing was achieved with a new test fixture which provided lateral support to prevent global buckling. Values of specific sustained crushing stress (SSCS) were obtained which were lower than values reported for tube specimens from previously published data. Two sizes of hybrid plates were fabricated; a baseline or model plate, and a full-scale plate with inplane dimensions scaled by a factor of two. The thickness dimension of the full-scale plates was increased using two different techniques: the ply-level method in which each ply orientation in the baseline laminate stacking sequence is doubled, and the sublaminate technique in which the baseline laminate stacking sequence is repeated as a group. Results indicated that the SSCS has a small dependence on trigger mechanism geometry. However, a reduction in the SSCS of 10-25% was observed for the full-scale plates as compared with the baseline specimens, indicating a scaling effect in the crushing response.

Description: This report discusses a methodology that can be used to assess the effect of foreign body impacts on composite structural integrity. The described effort focuses on modeling the effect of a central impact on a 5 3/4 inch filament wound test article. The discussion will commence with details of the material modeling that was used to establish the input properties for the analytical model. This discussion is followed by an overview of the impact assessment methodology. The progress on this effort to date is reviewed along with a discussion of tasks that have yet to be completed.

Description: For many years the metalworking industry has cleaned metal and composite substrates with chlorinated solvents. Recently, however, health and disposal related environmental concerns have increased regarding chlorinated solvents, including 1,1,1-trichloroethane, trichloroethylene, methylene chloride, or Freon'. World leaders have instituted a production ban of certain ozone depleting chlorofluorocarbons (CFC's) by 1996. The Occupational Safety and Health Administration (OSHA) has instituted worker vapor exposure limitations for virtually all of the solvents used in solvent-based cleaners. In addition, the United States Environmental Protection Agency (EPA) has defined nearly all solvent-based cleaners as 'hazardous'. Cradle to grave waste responsibility is another reason manufacturers are trying to replace chlorinated solvents in their cleaning processes. Because of these factors, there now is a world wide effort to reduce and/or eliminate the use of chlorinated solvents for industrial cleaning. Waterbased cleaners are among the alternatives being offered to the industry. New technology alkaline cleaners are now available that can be used instead of chlorinated solvents in many cleaning processes. These waterbased cleaners reduce the release of volatile organic compounds (VOC's) by as much as 99 percent. (The definition and method of calculation of VOC's now varies from region to region.) Hazardous waste generation can also be significantly reduced or eliminated with new aqueous technology. This in turn can ease worker exposure restrictions and positively impact the environment. This paper compares the chemical and physical properties of this aqueous cleaners versus chlorinated solvents.

Description: A significant increase in the use of composite materials has occurred during the past 20 years. Associated with this increased use is the potential for employees to be exposed to offgassing components from composite systems. Various components in composite systems, particularly residual solvents, offgas under various conditions. The potential for offgassing to occur increases as a composite material is heated either during cure or during lay-up operations. Various techniques can be employed to evaluate the offgassing characteristics of a composite system. A joint effort between AIA and SACMA resulted in the drafting of a proposed test method for evaluating the offgassing potential of composite materials. The purpose of testing composite materials for offgassing is to provide the industrial hygienist with information which can be used to assess the safety of the workplace. This paper outlines the proposed test method and presents round robin testing data associated with the test method. Also in this presentation is a discussion of classes of compounds which require specialized sampling techniques.

Description: Although advanced aerospace materials and advanced composites provide outstanding performance, they also present several unique post-mishap environmental, safety, and health concerns. The purpose of this paper is to provide information on some of the unique hazards and concerns associated with these materials when damaged by fire, explosion, or high-energy impact. Additionally, recommended procedures and precautions are addressed as they pertain to all phases of a composite aircraft mishap response, including fire-fighting, investigation, recovery, clean-up, and guidelines are general in nature and not application-specific. The goal of this project is to provide factual and realistic information which can be used to develop consistent and effective procedures and policies to minimize the potential environmental, safety, and health impacts of a composite aircraft mishap response effort.

Description: In an effort to gain a better understanding of effective safety and health work practice controls for composite manufacturing operations, the Aerospace Industries Association (AIA) Occupational Safety and Health Committee established a Composites Task Group. The group's task was to provide AIA members with recommendations for minimizing occupational exposure risk and to determine research needs and information gaps. The strategy included a review of toxicological information on composites, a review of member company experience and control methods, and interaction with other professional organizations who share an interest in composite work practices.

Description: The health, safety and environmental requirements for the production of composite materials are discussed. The areas covered include: (1) chemical identification for each chemical; (2) toxicology; (3) industrial hygiene; (4) fire and safety; (5) environmental aspects; and (6) medical concerns.

Description: The definition and purpose of Product Stewardship is discussed. Its' impact in the composites industry is stated. The report also outlines 12 ways that Product Stewardship can be utilized by consumers.

Description: An outline of the Occupational Safety and Health Agency's concerns of skin exposure to hazardous chemicals is presented, followed by the corresponding slide narrations. Specifically, dermatitis and skin absorption as compared to lung absorption are addressed. Lung versus skin exposure is examined for glycol ethers and acrylamide. Examples of skin exposure include PBC's in transformers, toluene and xylene from autobody work, polynuclear aromatics (PNA's) among Coke oven workers, toluene diisocyanate (TDI), and occupational chemical exposures in an academic medical center. Permeation through gloves in the semiconductor industry is addressed as evidence for the need to assess the effectiveness of PPE (Personal Protective Equipment). This leads to the revisions of the PPE standard and the Safety and Health Program standard.

Description: The high speed civil transport is a commercial aircraft that is expected to carry 300 passengers at Mach 2.4 over a range of more than 6000 nautical miles. With the existing commercial structural material technology (i.e., aluminum) the performance characteristics of the high speed civil transport would not be realized. Therefore there has been a concerted effort in the development of light weight materials capable of withstanding elevated temperatures for long duration. Thermoplastic composite materials are such candidate materials and the understanding of how these materials perform over the long term under harsh environments is essential to safe and effective design. The matrix dominated properties of thermoplastic composites are most affected by both time and temperature. There is currently an effort to perform short term testing to predict long term behavior of in-plane mechanical properties E22 (transverse modulus of elasticity) and G12 (shear modulus). Out-of-plane properties such as E33, G13, and G23 are inherently more difficult to characterize. This is especially true for the out-of-plane shear modulus G23 and hence there is no existing acceptable standard test method. Since G23 is the most matrix dominated property, it is essential that a test method be developed. A shear test methodology is developed to do just that. The test method, called the double notched specimen, along with the previously developed shear gage was tested at room temperature. Mechanical testing confirmed the attributes of the methodology. A finite element parametric study was conducted for specimen optimization. Moire interferometry, a high sensitivity laser optical method, was used for full-field analysis of the specimen. From this work, material parameters will be determined and thus enable the prediction of long term material behavior of laminates subjected to general loading states.

Description: Composites have been increasingly used in the construction of spacecraft. However, unlike metals, composites must be used with particular discretion in space applications because of their outgassing properties. For example, the outgas materials may cause serious contamination problems and affect the performance of delicate instruments. This paper presents an overview of the testing procedure and acceptance criteria for outgassing selection of spacecraft materials. Since composites can contain and absorb moisture which will outgas in space as water vapor, the test results of moisture absorption and desorption of a composite material are discussed also.

Description: Military ground vehicles fires are a significant cause of system loss, equipment damage, and crew injury in both combat and non-combat situations. During combat, the ability to successfully fight an internal fire, without losing fighting and mobility capabilities, is often the key to crew survival and mission success. In addition to enemy hits in combat, vehicle fires are initiated by electrical system failures, fuel line leaks, munitions mishaps and improper personnel actions. If not controlled, such fires can spread to other areas of the vehicle, causing extensive damage and the potential for personnel injury and death. The inherent fire safety characteristics (i.e. ignitability, compartments of these vehicles play a major roll in determining rather a newly started fire becomes a fizzle or a catastrophe. This paper addresses a systems approach to assuring optimum vehicle fire safety during the design phase of complex vehicle systems utilizing extensive uses of composites, plastic and related materials. It provides practical means for defining the potential fire hazard risks during a conceptual design phase, and criteria for the selection of composite materials based on its fire safety characteristics.

Description: There have been many changes over the last several years in the ways that we're required to label, handle, and dispose of the products of our manufacturing processes...and we all know there will be more, not fewer, environmental regulations to deal with in the years to come. It is important to be aware of how a chemical is listed by federal or state regulations or recommending bodies. For example, if a chemical has been listed by OSHA, IARC (International Agency for Research on Cancer), or NTP (the National Toxicology Program) as a carcinogen, this listing will trigger hazard communication requirements. It may cause restrictions on the levels of a chemical that you may release into the air or water as well as how you manage your plant wastes. Understanding how a chemical is listed is the first critical step in overall compliance. Once a chemical makes one of these lists as a hazardous material or a carcinogen, your emissions, labelling, or MSD sheets may need to be changed in order to comply with federal or state regulations. Being fully aware of how the chemicals you use are listed by all pertinent bodies is the essential compass that you must have to follow the regulatory road map.

Description: The use of advanced composite materials (ACM) in the B-2 bomber, composite armored vehicle, and F-22 advanced tactical fighter has rekindled interest concerning the health risk of burned or burning ACM. The objective of this work was to determine smoke production from burning ACM and its toxicity. A commercial version of the UPITT II combustion toxicity method developed at the University of Pittsburgh, and subsequently refined through a US Army-funded basic research project, was used to established controlled combustion conditions which were selected to evaluate real-world exposure scenarios. Production and yield of toxic species varied with the combustion conditions. Previous work with this method showed that the combustion conditions directly influenced the toxicity of the decomposition products from a variety of materials.

Description: At first view, plastics process emissions research may not seem to have much bearing on outgassing considerations relative to advanced composite materials; however, several parallel issues and cross currents are of mutual interest. The following topics are discussed: relevance of plastics industry research to aerospace composites; impact of clean air act amendment requirements; scope of the Society of the Plastics Industry, Inc. activities in thermoplastic process emissions and reinforced plastics/composites process emissions; and utility of SPI research for advanced polymer composites audiences.

Description: The feasibility of biologically degrading prepreg wastes was studied. The work was conducted with the intention of obtaining baseline data that would facilitate the achievement of two long-range goals. These goals are: (1) the biological remediation of the hazardous components in the prepreg wastes, and (2) providing the potential for recycling the prepreg waste fibers. The experiments examined a prepreg that employs an bismaleimide resin system. Initial results demonstrated an obvious deterioration of the prepreg material when incubated with several bacterial strains. The most active cultures were identified as a mixture of 'Bacillus cereus' and 'Pseudomonas sp'. Gas chromatography analyses revealed seven primary compounds in the resin mixture. Biotransformation studies, using the complete prepreg material, demonstrated on obvious loss of all seven organic compounds. Gas chromatography-mass spectrometry analyses resulted in structure assignments for the two primary components of the resin. Both were analogs of Bisphenol A; one being bismaleimide, and the other being Bisphenol A containing a diglycidyl moiety. The 'diglycidyl analog' was purified using thin-layer chromatography and the biotransformation of this compound (at 27 ug/ml bacterial culture) was monitored. After a seven-day incubation, approximately 40% of the organic compound was biotransformed. These results demonstrate the biotransformation of the prepreg resin and indicate that biological remediation of the prepreg wastes is feasible.

Description: Waviness and tow misalignment are often cited as possible causes of data scatter and lower compression stiffness and strength in textile composites. Strength differences of as much as 40 percent have been seen in composites that appear to have the same basic material and structural properties -- i.e., yarn orientation, yarn size, interlacing geometry. Fabric geometry distortion has been suggested as a possible reason for this discrepancy, but little quantitative data or substantial evidence exists. The focus of this research is to contribute to the present understanding of the causes and effects of geometric distortion in textile composites. The initial part of the study was an attempt to gather qualitative information on a variety of textile structures. Existing and new samples confirmed that structures with a significant direction presence would be more susceptible to distortion due to the compaction process. Thus, uniweaves (fiber vol frac: 54-72 percent) biaxial braids (vf: 34-58 percent) demonstrated very little fabric geometry distortion. In stitched panels, only slight buckling of z-direction stitches was observed, primarily near the surface. In contrast, for structures with high compaction ratios -- e.g., large cylindrical yarns (2.5:1) orpowder towpreg (4:1) -- there were visible distortions where previously smooth and periodic undulations were transformed to abrupt changes in direction. A controlled study of the effect of forming pressure on distortion was conducted on type 162 glass plain weave fabrics. Panels (6 x 6 in) were produced via a resin infusion type setup, but with an EPON 815 epoxy resin. Pressures ranging from hand layup to 200 psi were used (vf: 34-54 percent). Photomicrographs indicated that at pressures up to 50 psi, large changes in thickness were due primarily to resin squeeze out. At higher pressures, when intimate contact was made between the layers, there was some tow flattening and in-plane shifting to optimize nesting. However, even at 200 psi the period and amplitude of the tow undulation remained constant, suggesting that for this relatively fine fabric, distortions from compaction were not a problem. Because of the interest in using larger tows (to reduce cost) and more complex structures, tests were also run on 2D triaxial glass braid (113 yd/lb at 0, 225 yd/lb at +/- 45). Forming pressures of 20, 50, 200, and 500 psi were used, and short block compression tests were run. The 500 psi specimen had a 10 percent decrease in modulus and an almost 50 percent decrease in strength (vs. 20 psi). Because the total fiber wgt/panel was kept constant, the thickness varied from 0.32 to 0.22 in (49-70 percent vf). Yet, the strength value is clearly below what would be expected, even with the decrease in thickness. Photomicrographs of these samples will be taken to determine if more fabric distortion exists in the 500 psi specimens. Finally, because the ultimate goal is to be able to predict and control distortion in a variety of textile structures, a model compaction test was developed to directly measure the deformation of the tows during compaction. Layers of dry glass fabric were placed in a mold with a clear plexiglass window. The yarn amplitude and period was then calculated using image analysis of the videotaped deformation. Preliminary tests demonstrated the feasibility of this technique for simple fabrics with large tows.

Description: Textile composites are fiber reinforced materials produced by weaving, braiding, knitting, or stitching. These materials offer possible reductions in manufacturing costs compared to conventional laminated composites. Thus, they are attractive candidate materials for aircraft structures. To date, numerous experimental studies have been performed to characterize the mechanical performance of specific textile architectures. Since many materials and architectures are of interest, there is a need for analytical models to predict the mechanical properties of a specific textile composite material. Models of varying sophistication have been proposed based on mechanics of materials, classical laminated plate theory, and the finite element method. These modeling approaches assume an idealized textile architecture and generally consider a single unit cell. Due to randomness of the textile architectures produced using conventional processing techniques, experimental data obtained has been of limited use for verifying the accuracy of these analytical approaches. This research is focused on fabricating woven textile composites with highly aligned and accurately placed fiber tows that closely represent the idealized architectures assumed in analytical models. These idealized textile composites have been fabricated with three types of layer nesting configurations: stacked, diagonal, and split-span. Compression testing results have identified strength variations as a function of nesting. Moire interferometry experiments are being used to determine localized deformations for detailed correlation with model predictions.

Description: One of the most favorable characteristics of the Space Shuttle Program is the reusability of two of its primary components: the orbiter itself and the Solid Rocket Boosters (SRB). The SRB's provide the primary source of propulsion for the Space Shuttle during take-off after which they are recovered for refurbishment and reuse. During refurbishment, the SRB's are stripped of all remaining ablative (heat resistant) coating. A new layer is applied to the appropriate sections (nose cone, frustum, forward skirt, and aft skirt). It is the process of applying the ablative coating which provided the impetus for this project. The thickness of this protective layer is considered to be of primary importance to the level of thermal protection provided. The objectives of this effort are to investigate possible techniques for measuring the thickness of MCC, and if possible to test the specific capabilities of those considered good candidates for implementation. The system would be able to take measurements in real-time as close to the spray gun as possible. This will allow the information to be used in the control of the process without an inordinate time delay between a measurement and its appropriate response. The thickness of the deposited material is to be measured with less than 0.100 in if uncertainty. This is the defined tolerance window for the ablator thickness. Finally, it must operate within the confines of the chamber which encloses the turntable, robot, and spray system, and therefore is required to be insensitive to, or at least maintainable in, that environment.

Description: The following carbon-based materials are reviewed and their applications discussed: fullerenes; graphite (synthetic and manufactured); activated carbon fibers; and carbon-carbon composites. Carbon R&D activities at ORNL are emphasized.

Description: The study of the anisotropic mechanical properties of an inexpensively fabricated composite with continuous unidirectional fibers and a clear matrix was investigated. A method has been developed to fabricate these composites with aluminum fibers and a polymer matrix. These composites clearly demonstrate the properties of unidirectional composites and cost less than five dollars each to fabricate.

Description: A discussion of the American Society for Testing and Materials is given. Under the topic of composite materials characterization and evaluation, general industry practice and test methods for textile composites are presented.

Description: The JTEC Panel on Advanced Composites surveyed the status and future directions of Japanese high-performance ceramic and carbon fibers and their composites in metal, intermetallic, ceramic, and carbon matrices. Because of a strong carbon and fiber industry, Japan is the leader in carbon fiber technology. Japan has initiated an oxidation-resistant carbon/carbon composite program. With its outstanding technical base in carbon technology, Japan should be able to match present technology in the U.S. and introduce lower-cost manufacturing methods. However, the panel did not see any innovative approaches to oxidation protection. Ceramic and especially intermetallic matrix composites were not yet receiving much attention at the time of the panel's visit. There was a high level of monolithic ceramic research and development activity. High temperature monolithic intermetallic research was just starting, but notable products in titanium aluminides had already appeared. Matrixless ceramic composites was one novel approach noted. Technologies for high temperature composites fabrication existed, but large numbers of panels or parts had not been produced. The Japanese have selected aerospace as an important future industry. Because materials are an enabling technology for a strong aerospace industry, Japan initiated an ambitious long-term program to develop high temperature composites. Although just starting, its progress should be closely monitored in the U.S.

Description: Many cryogenic storage tanks use vacuum between inner and outer tank for thermal insulation. These cryogenic tanks also use a radiation shield barrier in the vacuum space to prevent radiation heat transfer. This shield is usually constructed by using multiple wraps of aluminized mylar and glass paper as inserts. For obtaining maximum thermal performance, a good vacuum level must be maintained with the insulation system. It has been found that over a period of time solid insulation materials will vaporize into the vacuum space and the vacuum will degrade. In order to determine the degradation of vacuum, the rate of outgassing of the insulation materials must be determined. Outgassing rate of several insulation materials obtained from literature search were listed in tabular form.

Description: The following is a design for a tensile tester which will be used to test the tensile strength and anisotropic properties of simple composites. These simple composites are suspected to be anisotropic primarily in a single plane. When the composites undergo a tensile force, they will undergo deformation, causing movement either to the left or right. The composites are suspect due to their method of construction. Each sample has a single layer of unidirectional continuous fibers embedded in a rubbery resin. It has been well established that a serious limitation of unidirectional fiber composites is the very large in-plane anisotropy. The design presented here incorporates a single degree of freedom such that distortion (to the left or right) due to anisotropic tendencies may be measured. The device will spend the vast majority of its time in an undergraduate materials lab. As a result, ease of use and durability are valued more highly than research grade accuracy. Additional concerns focus on the fact that this machine will be built as a student project. Issues which are dealt with during this design include: specimen configuration or shape; a method of applying consistent, linear tension force; a method of gripping specimen without affecting its overall properties; a method of collecting data; repeatability of data; ease of use; ease of construction; and cost. After the device has been constructed, it will be used to test the simple composites which were fabricated in house. A comparison will be made between composites manufactured using aluminum screening as the strengthening fibers and those manufactured using fiberglass screening.

Description: This paper presents an experimental and analytical evaluation of cross-plied laminates of Ti-15V-3Cr-3Al-3Sn (Ti-15-3) matrix reinforced with continuous silicon-carbide fibers (SCS-6) subjected to a complex TMF loading profile. Thermomechanical fatigue test techniques were developed to conduct a simulation of a generic hypersonic flight profile. A micromechanical analysis was used. The analysis predicts the stress-strain response of the laminate and of the constituents in each ply during thermal and mechanical cycling by using only constituent properties as input. The fiber was modeled as elastic with transverse orthotropic and temperature-dependent properties. The matrix was modeled using a thermoviscoplastic constitutive relation. The fiber transverse modulus was reduced in the analysis to simulate the fiber-matrix interface failures. Excellent correlation was found between measured and predicted laminate stress-strain response due to generic hypersonic flight profile when fiber debonding was modeled.

Description: Titanium matrix composites (TMC's) are being considered for a number of aerospace applications ranging from high performance engine components to airframe structures in areas that require high stiffness to weight ratios at temperatures up to 400 C. TMC's exhibit unique mechanical behavior due to fiber-matrix interface failures, matrix cracks bridged by fibers, thermo-viscoplastic behavior of the matrix at elevated temperatures, and the development of significant thermal residual stresses in the composite due to fabrication. Standard testing methodology must be developed to reflect the uniqueness of this type of material systems. The purpose of this paper is to review the current activities in ASTM and Versailles Project on Advanced Materials and Standards (VAMAS) that are directed toward the development of standard test methodology for titanium matrix composites.

Description: Recent work on the prediction of optimal processing and material characteristics for improved fatigue behavior of metal and intermetallic matrix composites (MMC's/IMC's) is summarized. The method is incorporated into the MMLT (Metal Matrix Laminate Tailoring) code. Excellent correlations between predictions for the isothermal fatigue life of the SCS-6/Ti-24Al-11Nb composite and experimental data are obtained at various temperatures and stress ranges. Finally, the optimal processing conditions for improved isothermal fatigue life of the composite are evaluated and the attained isothermal fatigue life improvements are shown.

Description: A general analysis method is presented to predict matrix cracks in all plies of a composite laminate, and resulting degraded laminate properties, as functions of temperature or thermal cycles. A shear lag solution of the stresses in the vicinity of cracks and a fracture mechanics crack formation criteria are used to predict cracks. Damage is modeled incrementally, which allows the inclusion of the effects of temperature dependent material properties and softening of the laminate due to previous cracking. The analysis is incorporated into an easy-to-use computer program. The analysis is correlated with experimentally measured crack densities in a variety of laminates exposed to monotonically decreasing temperatures. Crack densities are measured at the edges of specimens by microscopic inspection, and throughout the specimen volumes by x-ray and sanding down of the edges. Correlation between the analytical results and the crack densities in the interiors of the specimens was quite good. Crack densities measured at specimen edges did not agree with internal crack densities (or analyses) in some cases. A free-edge stress analysis clarified the reasons for these discrepancies.

Description: The fundamentals of the thermodynamic theory of mixtures and continuum thermochemistry are reviewed for a mixture of condensed water and polymer. A specific mixture which is mechanically elastic with temperature and water concentration gradients present is considered. An expression for the partial pressure of water in the mixture is obtained based on certain assumptions regarding the thermodynamic state of the water in the mixture. Along with a simple diffusion equation, this partial pressure expression may be used to simulate the thermostructural behavior of polymer composite materials due to water in the free volumes of the polymer. These equations are applied to a specific polymer composite material during isothermal heating conditions. The thermal stresses obtained by the application of the theory are compared to measured results to verify the accuracy of the approach.

Description: This study deals with the effect of assumed tow architecture on the elastic material properties and stress distributions of plain weave woven composites. Specifically, the examination of how a cross-section is assumed to sweep-out the tows of the composite is examined in great detail. The two methods studied are extrusion and translation. This effect is also examined to determine how sensitive this assumption is to changes in waviness ratio. 3D finite elements were used to study a T300/Epoxy plain weave composite with symmetrically stacked mats. 1/32nd of the unit cell is shown to be adequate for analysis of this type of configuration with the appropriate set of boundary conditions. At low waviness, results indicate that for prediction of elastic properties, either method is adequate. At high waviness, certain elastic properties become more sensitive to the method used. Stress distributions at high waviness ratio are shown to vary greatly depending on the type of loading applied. At low waviness, both methods produce similar results.

Description: The compression strength of a stitched and a toughened matrix graphite/epoxy composite was determined and compared to a baseline unstitched untoughened composite. Two different layups with a variety of test lengths were tested under both ambient and hot/wet conditions. No significant difference in strength was seen for the different materials when the gage lengths of the specimens were long enough to lead to a buckling failure. For shorter specimens, a 30 percent reduction in strength from the baseline was seen due to stitching for both a 48-ply quasi-isotropic and a (0/45/0/-45/90/-45/0/45/0)s laminate. Analysis of the results suggested that the decrease in strength was due to increased fiber misalignment due to the stitches. An observed increasing strength with decreasing gage length, which was seen for all materials, was explained with a size effect model. The model assumed a random distribution of flaws (misaligned fibers). The toughened materials showed a small increase in strength over the baseline material for both laminates presumably due to the compensating effects of a more compliant matrix and straighter fibers in the toughened material. The hot/wet strength of the stitched and baseline material fell 30 percent below their ambient strengths for shorter, nonbuckling specimen, while the strength of the toughened matrix material only fell 20 percent. Video images of the failing specimen were recorded and showed local failures prior to global collapse of the specimen. These images support the theory of a random distribution of flaws controlling composite failure. Failed specimen appearance, however, seems to be a misleading indication of the cause of failure.

Description: For many polymeric materials in use below the glass transition temperature, the long term viscoelastic behavior is greatly affected by physical aging. To use polymer matrix composites as critical structural components in existing and novel technological applications, this long term behavior of the material system must be understood. Towards that end, this study applied the concepts governing the mechanics of physical aging in a consistent manner to the study of laminated composite systems. Even in fiber-dominated lay-ups the effects of physical aging are found to be important in the long-term behavior of the composite. The basic concepts describing physical aging of polymers are discussed. Several aspects of physical aging which have not been previously documented are also explored in this study, namely the effects of aging into equilibrium and a relationship to the time-temperature shift factor. The physical aging theory is then extended to develop the long-term compliance/modulus of a single lamina with varying fiber orientation. The latter is then built into classical lamination theory to predict long-time response of general oriented lamina and laminates. It is illustrated that the long term response can be counterintuitive, stressing the need for consistent modeling efforts to make long term predictions of laminates to be used in structural situations.

Description: A fiber-reinforced composite composed of a BaO-Al2O3-2SiO2 (BAS) glass ceramic matrix is reinforced with CVD silicon carbide continuous fibers. A slurry of BAS glass powders is prepared and celsian seeds are added during ball melting. The slurry is cast into tapes which are cut to the proper size. Continuous CVD-SiC fibers are formed into mats of the desired size. The matrix tapes and the fiber mats are alternately stacked in the proper orientation. This tape-mat stack is warm pressed to produce a 'green' composite. The 'green' composite is then heated to an elevated temperature to burn out organic constituents. The remaining interim material is then hot pressed to form a silicon carbide fiber-reinforced celsian (BAS) glass-ceramic matrix composite which may be machined to size.

Description: The thermomechanical behavior of continuous-fiber reinforced titanium based metal-matrix composites (MMC) is studied using the finite element method. A thermoviscoplastic unified state variable constitutive theory is employed to capture inelastic and strain-rate sensitive behavior in the Timetal-21s matrix. The SCS-6 fibers are modeled as thermoplastic. The effects of residual stresses generated during the consolidation process on the tensile response of the composites are investigated. Unidirectional and cross-ply geometries are considered. Differences between the tensile responses in composites with perfectly bonded and completely debonded fiber/matrix interfaces are discussed. Model simulations for the completely debonded-interface condition are shown to correlate well with experimental results.

Description: The design of a materials-science, educational experiment is presented. The student should understand the fundamentals of polymer processing and mechanical property testing of materials. The ability to use American Society for Testing and Materials (ASTM) standards is also necessary for designing material test specimens and testing procedures. The objectives of the experiment are (1) to understand the concept of laminated composite materials, processing, testing, and quality assurance of thermoplastic composites and (2) to observe an application example of recycled plastics.

Description: In this research, thermal residual stresses were incorporated in an analysis of fiber-bridged matrix cracks in unidirectional and cross-ply titanium matrix composites (TMC) containing center holes or center notches. Two TMC were investigated, namely, SCS-6/Timelal-21S laminates. Experimentally, matrix crack initiation and growth were monitored during tension-tension fatigue tests conducted at room temperature and at an elevated temperature of 200 C. Analytically, thermal residual stresses were included in a fiber bridging (FB) model. The local R-ratio and stress-intensity factor in the matrix due to thermal and mechanical loadings were calculated and used to evaluate the matrix crack growth behavior in the two materials studied. The frictional shear stress term, tau, assumed in this model was used as a curve-fitting parameter to matrix crack growth data. The scatter band in the values of tau used to fit the matrix crack growth data was significantly reduced when thermal residual stresses were included in the fiber bridging analysis. For a given material system, lay-up and temperature, a single value of tau was sufficient to analyze the crack growth data. It was revealed in this study that thermal residual stresses are an important factor overlooked in the original FB models.

Description: Advanced metal matrix composites may be one of the most promising technologies for reducing cost in structural components without compromise to strength or stiffness. A microlight 12.50 N (2.81 lb), two-axis, solar array drive assembly (SADA) was made for the Advanced Materials Applications to Space Structures (AMASS) Program flight experiment. The SADA had both its inner and outer axis housings fabricated from silicon carbide particulate reinforced alumimun. Two versions of the housings were made. The first was machined from a solid billet of material. The second was plaster cast to a near net shape that required minimal finish machining. Both manufacturing methods were compared upon completion. Results showed a cost savings with the cast housing was possible for quantities greater than one and probable for quantities greater than two. For quantities approaching ten, casting resulted in a reduction factor of almost three in the cost per part.

Description: A micromechanical formulation is presented for the prediction of the overall thermo-inelastic behavior of multiphase composites which consist of short fibers. The analysis is an extension of the generalized method of cells that was previously derived for inelastic composites with continuous fibers, and the reliability of which was critically examined in several situations. The resulting three dimensional formulation is extremely general, wherein the analysis of thermo-inelastic composites with continuous fibers as well as particulate and porous inelastic materials are merely special cases.

Description: A user's guide for the computer program mccm.f is presented. The program is based on a recently developed solution methodology for the inelastic response of an arbitrarily layered, concentric cylinder assemblage under thermomechanical loading which is used to model the axisymmetric behavior of unidirectional metal matrix composites in the presence of various microstructural details. These details include the layered morphology of certain types of ceramic fibers, as well as multiple fiber/matrix interfacial layers recently proposed as a means of reducing fabrication-induced, and in-service, residual stress. The computer code allows efficient characterization and evaluation of new fibers and/or new coating systems on existing fibers with a minimum of effort, taking into account inelastic and temperature-dependent properties and different morphologies of the fiber and the interfacial region. It also facilitates efficient design of engineered interfaces for unidirectional metal matrix composites.

Description: In this study, the mechanical response of hybrid titanium composite laminates (HTCL) was evaluated at room and elevated temperatures. Also, the use of an elastic-plastic laminate analysis program for predicting the tensile response from constituent properties was verified. The improvement in mechanical properties achieved by the laminates was assessed by comparing the results of static strength and constant amplitude fatigue tests to those for monolithic titanium sheet. Two HTCL were fabricated with different fiber volume fractions, resin layer thicknesses, and resins. One panel was thicker and was more poorly bonded in comparison to other. Consequently, the former had a lower tensile strength, while fewer cracks grew in this panel and at a slower rate. Both panels showed an improvement in fatigue life of almost two orders of magnitude. The model predictions were also in good agreement with the experimental results for both HTCL panels.

Description: The major goal of this project was to obtain basic information on compression failure properties of carbon fiber composites. To do this, we investigated fiber effects, matrix effects, and fiber/matrix interface effects. Using each of nine fiber types, we prepared embedded single-fiber specimens, single-ply specimens, and full laminates. From the single-fiber specimens, in addition to the standard fragmentation test analysis, we were able to use the low crack density data to provide information about the distribution of fiber flaws. The single-ply specimens provided evidence of a correlation between the size of kink band zones and the quality of the interface. Results of the laminate compression experiments mostly agreed with the results from single-ply experiments, although the ultimate compression strengths of laminates were higher. Generally, these experiments showed a strong effect of interfacial properties. Matrix effects were examined using laminates subjected to precracking under mixed-mode loading conditions. A large effect of precracking conditions on the mode 1 toughness of the laminates was found. In order to control the properties of the fiber/matrix interface, we prepared composites of carbon fiber and polycarbonate and subjected these to annealing. The changes in interfacial properties directly correlated with changes in compression strength.

Description: A methodology is described which uses finite element analysis of various laminates to computationally simulate the effects of delamination damage initiation and growth on the structural behavior of laminated composite structures. The delamination area is expanded according to a set pattern. As the delamination area increases, how the structural response of the laminate changes with respect to buckling and strain energy release rate are investigated. Rules are presented for laminates of different configurations, materials and thickness. These results demonstrate that computational simulation methods can provide alternate methods to investigate the complex delamination damage mechanisms found in composite structures.

Description: Thermomechanical response of a cross-ply SCS-6/Timetal-21S composite subjected to a generic hypersonic flight profile with the temperature ranging from -130 C to 816 C was evaluated experimentally and analytically. A two dimensional micromechanical anlaysis, VISCOPLY, was used to predict the stress-strain response of the laminate and of the constituents in each ply during thermomechanical loading conditions. In the analysis, the fiber was modeled as elastic with transverse orthotropic and temperature dependent properties and the matrix was modeled using a thermoviscoplastic constitutive relation. The fiber transverse modulus was reduced in the analysis to simulate fiber-matrix interface failure. Reasonable agreement was found between measured and predicted laminate stress-strain response when fiber-matrix debonding was modeled.

Description: The fatigue resistance of a multiaxial braided (3-D) graphite/expoxy composite in both unnotched and post impacted conditions has been evaluated. The material tested is a (+/- 30/0 deg) multiaxial braid constructed from AS4/12K tow graphite fibers and British Petroleum E905L epoxy resin. These materials were braided as dry preforms and the epoxy was added using a resin transfer molding process (RTM). The unnotched and post-impact specimens were tested in compression-compression fatigue at 10 Hz with a stress ratio of R=10. The unnotched tension-tension fatigue specimens were tested at S Hz with a stress ration of R=0.1. Damage initiation and growth was documented through the application of radiography and ultrasonic through transmission (C-scans). Visible inspection of surface and edge damage was also noted to describe the initiation and progression of damage in these materials. The mechanisms leading to damage initiation were established and failure modes were determined. Stiffness and strength degradation were measured as a function of applied cycles. These 3-D braided composite results were compared to strain levels currently used to design primary structure in commercial aircraft composite components made from prepreg tape and autoclave cured.

Description: Delaminations in laminated composite materials can degrade the compressive strength of these materials. Delaminations can form as a result of impact damage or processing flaws. In order to better understand the effects of these delaminations on the compressive behavior of laminated composite plates, programs have been conducted to assess the criticality of prescribed delaminations of known size, shape, and location on the compression strength of laminated composites. A review of these programs is presented along with highlights of pertinent findings from each.

Description: A hyridopolysilazane-derived ceramic fiber reinforced monoclinic celsian phase barium aluminum silicate glass-ceramic matrix composite material is prepared by ball-milling an aqueous slurry of BAS glass powder and fine monoclinic celsian seeds. The fibers improve the mechanical strength and fracture toughness and with the matrix provide superior dielectric properties.

Description: The present invention provides a fixture for supporting an elongated specimen for crush testing. The fixture comprises a base plate, four guiding rods, a sliding plate, four support rods and two collars. The guiding rods connect to the base plate and extend in a direction substantially perpendicular to the base plate. The sliding plate has linear bearings which encircle the guiding rods and enable translation of the sliding plate along the axis of each guiding rod. The four supporting rods mount to the base plate and also extend in a direction substantially perpendicular to the base plate. Each support rod has a keyway for a wedge which contacts the elongated specimen and holds the specimen in place during crushing. Each collar lies above the sliding plate and holds a pair of support rods on their ends opposite the ends connected to the base plate. A spherical bearing sits on top of the sliding plate and transfers an applied load to the sliding plate, which moves downward and crushes the elongated specimen.

Description: The use of acoustic emission and acousto-ultrasonics to characterize impact damage in composite structures is being performed on both graphite epoxy and kevlar bottles. Further development of the acoustic emission methodology to include neural net analysis and/or other multivariate techniques will enhance the capability of the technique to identify failure mechanisms during fracture. The acousto-ultrasonics technique will be investigated to determine its ability to predict regions prone to failure prior to the burst tests. The combination of the two methods will allow for simple nondestructive tests to be capable of predicting the performance of a composite structure prior to being placed in service and during service.

Description: A computational simulation procedure is presented for nonlinear analyses which incorporates microstress redistribution due to progressive fracture in ceramic matrix composites. This procedure facilitates an accurate simulation of the stress-strain behavior of ceramic matrix composites up to failure. The nonlinearity in the material behavior is accounted for at the constituent (fiber/matrix/interphase) level. This computational procedure is a part of recent upgrades to CEMCAN (Ceramic Matrix Composite Analyzer) computer code. The fiber substructuring technique in CEMCAN is used to monitor the damage initiation and progression as the load increases. The room-temperature tensile stress-strain curves for SiC fiber reinforced reaction-bonded silicon nitride (RBSN) matrix unidirectional and angle-ply laminates are simulated and compared with experimentally observed stress-strain behavior. Comparison between the predicted stress/strain behavior and experimental stress/strain curves is good. Collectively the results demonstrate that CEMCAN computer code provides the user with an effective computational tool to simulate the behavior of ceramic matrix composites.

Description: The ability to accurately predict the thermomechanical deformation response of advanced composite materials continues to play an important role in the development of these strategic materials. Analytical models that predict the effective behavior of composites are used not only by engineers performing structural analysis of large-scale composite components but also by material scientists in developing new material systems. For an analytical model to fulfill these two distinct functions it must be based on a micromechanics approach which utilizes physically based deformation and life constitutive models and allows one to generate the average (macro) response of a composite material given the properties of the individual constituents and their geometric arrangement. Here the user guide for the recently developed, computationally efficient and comprehensive micromechanics analysis code, MAC, who's predictive capability rests entirely upon the fully analytical generalized method of cells, GMC, micromechanics model is described. MAC is a versatile form of research software that 'drives' the double or triple ply periodic micromechanics constitutive models based upon GMC. MAC enhances the basic capabilities of GMC by providing a modular framework wherein (1) various thermal, mechanical (stress or strain control), and thermomechanical load histories can be imposed; (2) different integration algorithms may be selected; (3) a variety of constituent constitutive models may be utilized and/or implemented; and (4) a variety of fiber architectures may be easily accessed through their corresponding representative volume elements.

Description: The mechanics of laminated composite materials is presented in a clear manner with only essential derivations included. The constitutive equations in all of their forms are developed and then summarized in a separate section. The effects of hygrothermal effects are included. The prediction of the engineering constants for a laminate are derived. Strength of laminated composites is not covered.

Description: The Textile Composite Analysis for Design (TEXCAD) code provides the materials/design engineer with a user-friendly desktop computer (IBM PC compatible or Apple Macintosh) tool for the analysis of a wide variety of fabric reinforced woven and braided composites. It can be used to calculate overall thermal and mechanical properties along with engineering estimates of damage progression and strength. TEXCAD also calculates laminate properties for stacked, oriented fabric constructions. It discretely models the yarn centerline paths within the textile repeating unit cell (RUC) by assuming sinusoidal undulations at yarn cross-over points and uses a yarn discretization scheme (which subdivides each yarn not smaller, piecewise straight yarn slices) together with a 3-D stress averaging procedure to compute overall stiffness properties. In the calculations for strength, it uses a curved beam-on-elastic foundation model for yarn undulating regions together with an incremental approach in which stiffness properties for the failed yarn slices are reduced based on the predicted yarn slice failure mode. Nonlinear shear effects and nonlinear geometric effects can be simulated. Input to TEXCAD consists of: (1) materials parameters like impregnated yarn and resin properties such moduli, Poisson's ratios, coefficients of thermal expansion, nonlinear parameters, axial failure strains and in-plane failure stresses; and (2) fabric parameters like yarn sizes, braid angle, yarn packing density, filament diameter and overall fiber volume fraction. Output consists of overall thermoelastic constants, yarn slice strains/stresses, yarn slice failure history, in-plane stress-strain response and ultimate failure strength. Strength can be computed under the combined action of thermal and mechanical loading (tension, compression and shear).

Description: Presented are the results of an investigation of the twisting/warping deformation occurring in open-section composite beams. A series of C and L channels were manufactured using both hand layup and the innovative 'hot-drape forming' techniques. A transverse tip load was applied at the free end of the cantilevered open-section beams. The test setup allowed the tip load to be applied at various locations along the plane of and at the beam's shear center. Charts are included in this report depicting various angles of ply layups, loads applied, and load application points. A major verification resulting from this study is that the shear center of an open section composite beam can be altered, if not completely controlled, through laminate layup. Also, it was observed that the choice of the material system does not have an effect on the amount of deformation, as expected, and the material affects the location of an unsymmetric open section composite beam's true shear center. The results from this study have provided a foundation for further investigation into the apparent shifting of the shear center location in open-section composite beams.

Description: This document is the detailed test plan for the series of tests enumerated in the preceding section. The purpose of this plan is to present the test objectives, test parameters and procedures, expected performance and data analysis plans, criteria for success, test schedules, and related safety provisions and to describe the test articles, test instrumentation, and test facility requirements. Initial testing will be performed to screen four composite materials for suitability for SSTO LH2 tank loads and environmental conditions. The laminates for this testing will be fabricated by fiber placement, which is the manufacturing approach identified as baseline for the tank wall. Even though hand layup will be involved in fabricating many of the internal structural members of the tank, no hand-layup laminates will be evaluated in the screening or subsequent characterization testing. This decision is based on the understanding that mechanical properties measured for hand-layup material should be at least equivalent to properties measured for fiber-placed material, so that the latter should provide no less than a conservative approximation of the former. A single material will be downselected from these screening tests. This material will be subsequently characterized for impact-damage tolerance and durability under conditions of mechanical and thermal cycling, and to establish a preliminary design database to support ongoing analysis. Next, testing will be performed on critical structural elements fabricated from the selected material. Finally, the 8-foot diameter tank article, containing the critical structural features of the full-scale tank, will be fabricated by fiber placement and tested to verify its structural integrity and LH2 containment.

Description: The first part of the task was to select up to three promising thrust structure constructions and to select materials for screening tests. Part of the nondestructive evaluation and inspection (NDE/I) and integrated health management (IHM) task is to acquire and develop NDE/I sensor technologies and to integrate those sensors into the full scale test articles which will be produced under the TA2 program. Review of the anticipated fault modes and the available sensor technology data indicates that three sensor technologies should be assessed for the in-situ monitoring of the composite primary structure elements. These are: ultrasonics (dry contact), acoustic emissions, and fiber optics (embedded or attached). In fact, a combination of sensor technologies will be needed to detect and evaluate the fault modes; not only do sensor technology have specific capabilities and applicability, but the three Gr/Ep primary structures being demonstrated under the TA2 effort have differing requirements based on their respective failure modes and designs.

Description: The difference in thermal expansion characteristics of epoxy matrices and graphite fibers can produce significant residual stresses in the fibers during curing of composite materials. Tests on single fiber glass-epoxy and graphite-epoxy composite specimens were conducted in which the glass and graphite fibers were preloaded in tension, and the epoxy matrix was cast around the fibers. The fiber tension was monitored while the matrix was placed around the fiber and subjected to the temperature-time curing cycle. Two mechanisms responsible for producing stress in embedded fibers were identified as matrix thermal expansion and contraction and matrix cure shrinkage. A simple analysis based on the change in fiber tension during the curing cycle was conducted to estimate the produced stresses. Experimental results on single fiber glass- and graphite-epoxy composites show that the fiber was subjected to significant tensile stresses when the temperature was raised from the first to the second dwell period. When initial fiber pretension is about 60 percent of the fiber failure load, these curing-induced stresses can cause tensile fracture of the embedded fiber.

Description: A study of past composite aircraft structures programs was conducted to determine the lessons learned during the programs. The study focused on finding major underlying principles and practices that experience showed have significant effects on the development process and should be recognized and understood by those responsible for using of composites. Published information on programs was reviewed and interviews were conducted with personnel associated with current and past major development programs. In all, interviews were conducted with about 56 people representing 32 organizations. Most of the people interviewed have been involved in the engineering and manufacturing development of composites for the past 20 to 25 years. Although composites technology has made great advances over the past 30 years, the effective application of composites to aircraft is still a complex problem that requires experienced personnel with special knowledge. All disciplines involved in the development process must work together in real time to minimize risk and assure total product quality and performance at acceptable costs. The most successful programs have made effective use of integrated, collocated, concurrent engineering teams, and most often used well-planned, systematic development efforts wherein the design and manufacturing processes are validated in a step-by-step or 'building block' approach. Such approaches reduce program risk and are cost effective.

Description: Various test methods commonly used for measuring properties of tape laminate composites were evaluated to determine their suitability for the testing of textile composites. Three different types of textile composites were utilized in this investigation: two-dimensional (2-D) triaxial braids, stitched uniweave fabric, and three-dimensional (3-D) interlock woven fabric. Four 2-D braid architectures, five stitched laminates, and six 3-D woven architectures were tested. All preforms used AS4 fibers and were resin-transfer-molded with Shell RSL-1895 epoxy resin. Ten categories of material properties were investigated: tension, open-hole tension, compression, open-hole compression, in-plane shear, filled-hole tension, bolt bearing, interlaminar tension, interlaminar shear, and interlaminar fracture toughness. Different test methods and specimen sizes were considered for each category of test. Strength and stiffness properties obtained with each of these methods are documented in this report for all the material systems mentioned above.

Description: Residual strength results are presented for four composite material systems that have been exposed for up to 10 years to the environment at five different locations on the North American continent. The exposure locations are near where the Bell Model 206L helicopters, which participated in a flight service program sponsored by NASA Langley Research Center and the U.S. Army, were flying in daily commercial service. The composite material systems are (1) Kevlar-49 fabric/F-185 epoxy; (2) Kevlar-49 fabric/LRF-277 epoxy; (3) Kevlar-49 fabric/CE-306 epoxy; and (4) T-300 graphite/E-788 epoxy. Six replicates of each material were removed and tested after 1, 3, 5, 7, and 10 years of exposure. The average baseline strength was determined from testing six as-fabricated specimens. More than 1700 specimens have been tested. All specimens that were tested to determine their strength were painted with a polyurethane paint. Each set of specimens also included an unpainted panel for observing the weathering effects on the composite materials. A statistically based procedure has been used to determine the strength value above which at least 90 percent of the population is expected to fall with a 95-percent confidence level. The computed compression strengths are 80 to 90 percent of the baseline (no-exposure) strengths. The resulting compression strengths are approximately 8 percent below the population mean strengths. The computed short-beam-shear strengths are 83 to 92 percent of the baseline (no-exposure) strengths. The computed tension strength of all materials is 93 to 97 percent of the baseline (no-exposure) strengths.

Description: The objective of this task is to develop the fluted core flexible blankets, also referred to as the Tailorable Advanced Blanket Insulation (TABI), to a technology readiness level (TRL) of 6. This task is one of the six tasks under TA 3, Lightweight Durable TPS study, of the Single Stage to Orbit (SSTO) program. The purpose of this task is to develop a durable and low maintenance flexible TPS blanket material to be implemented on the SSTO vehicle.

Description: This TA 2 document (with support from TA 1) describes the trade study plan that will identify the most suitable structural configuration for an SSTO winged vehicle capable of delivering 25,000 lbs to a 220 nm circular orbit at 51.6 degree inclination For this most suitable configuration the structural attachment of the wing, and the most suitable GCPS composite materials for intertank, wing, tail and thrust structure are identified. This trade study analysis uses extensive information derived in the TA 1 trade study plan and is identified within the study plan. In view of this, for convenience, the TA 1 study plan is included as an appendix to this document.

Description: Four fiber/resin systems were compared for resistance to damage and damage tolerance. One toughened epoxy and three toughened bismaleimide (BMI) resins were used, all with IM7 carbon fiber reinforcement. A statistical design of experiments technique was used to evaluate the effects of impact energy, specimen thickness, and impactor diameter on the damage area, as computed by C-scans, and residual compression-after-impact (CAI) strength. Results showed that two of the BMI systems sustained relatively large damage zones yet had an excellent retention of CAI strength.

Description: This TA 2 document describes the selection process that will be used to identify the most suitable structural configuration for an SSTO winged vehicle capable of delivering 25,000 lbs to a 220 nm circular orbit at 51.6 degree inclination. The most suitable unpressurized graphite composite structures and material selections is within this configuration and will be the prototype design for subsequent design and analysis and the basis for the design and fabrication of payload bay, wing, and thrust structure full scale test articles representing segments of the prototype structures. The selection process for this TA 2 trade study is the same as that for the TA 1 trade study. As the trade study progresses additional insight may result in modifications to the selection criteria within this process. Such modifications will result in an update of this document as appropriate.

Description: Reliable estimation of thermal properties is extremely important in the utilization of new advanced materials, such as composite materials. The accuracy of these estimates can be increased if the experiments are designed carefully. The objectives of this study are to design optimal experiments to be used in the prediction of these thermal properties and to then utilize these designs in the development of an estimation procedure to determine the effective thermal properties (thermal conductivity and volumetric heat capacity). The experiments were optimized by choosing experimental parameters that maximize the temperature derivatives with respect to all of the unknown thermal properties. This procedure has the effect of minimizing the confidence intervals of the resulting thermal property estimates. Both one-dimensional and two-dimensional experimental designs were optimized. A heat flux boundary condition is required in both analyses for the simultaneous estimation of the thermal properties. For the one-dimensional experiment, the parameters optimized were the heating time of the applied heat flux, the temperature sensor location, and the experimental time. In addition to these parameters, the optimal location of the heat flux was also determined for the two-dimensional experiments. Utilizing the optimal one-dimensional experiment, the effective thermal conductivity perpendicular to the fibers and the effective volumetric heat capacity were then estimated for an IM7-Bismaleimide composite material. The estimation procedure used is based on the minimization of a least squares function which incorporates both calculated and measured temperatures and allows for the parameters to be estimated simultaneously.

Description: Composite materials are widely used in various types of modern engineering structures. Traditional studies on composite structures have been based on the assumption that the material properties of the composites are characterized by a priori known elastic moduli, and no uncertainties of these moduli have been considered. However, the composite materials are invariably subject to a certain amount of scatter in their measured elastic moduli. To a large extent, the properties of composite materials are dependent on the fabrication process. But even the composite materials manufactured by the same process demonstrate differences in their elastic properties. This paper proposes a new, non-probabilistic method to predict the variability in the natural frequencies of the composite cylindrical shell, resulting from the unavoidable scatter in elastic moduli. The available measurements of elastic moduli are fitted by the four-dimensional uncertainty ellipsoid. The upper and lower bounds of the natural frequency are derived. With these bounds, designers will have a better understanding of the real dynamic behavior of the structure.

Description: Thermo-oxidative stability (TOS) test results are significantly influenced by the formation and growth or presence of interlaminar and interlaminar cracks in the cut edges of all carbon-fiber-crosslinked high-temperature polymer matrix composites(exp 1-5) (i.e., unidirectional, crossplied, angle-plied, and fabric composites). The thermo-oxidative degradation of these composites is heavily dependent on the surface area that is exposed to the harmful environment and on the surface-to-volume ratio of the structure under study. Since the growth of cracks and voids on the composite surfaces significantly increases the exposed surface areas, it is imperative that the interaction between the aging process and the formation of new surface area as the aging time progresses be understood.

Description: The weldability of W-Cu composite sheet was investigated using simulated and welded joints. The welded joints were produced in a vacuum hot press. Tensile test results showed that simulated joints can provide strength and failure mode data which can be used in joint design for actual weldments. Although all of the welded joints had flaws, a number of these joints were as strong as the W-Cu composite base material.

Description: An improved composite flexible blanket insulation is presented comprising top silicon carbide having an interlock design, wherein the reflective shield is composed of single or double aluminized polyimide and wherein the polyimide film has a honeycomb pattern.

Description: A stitched RFI graphite-epoxy panel with a fuel access door was analyzed using a finite element analysis and loaded to failure in compression. The panel was initially 56-inches long and 36.75-inches wide and the oval access door was 18-inches long and 15-inches wide. The panel was impact damaged with impact energy of 100 ft-lb prior to compressive loading; however, no impact damage was detectable visually or by A-scan. The panel carried a failure load of 695,000 Ib and global failure strain of .00494 in/in. Analysis indicated the panel would fail due to collapse at a load of 688,100 Ib. The test data indicate that the maximum strain in a region near the access door was .0096 in/in and analysis indicates a local surface strain of .010 in/in at the panel's failure load. The panel did not fail through the impact damage, but instead failed through bolt holes for attachment of the access door in a region of high strain.

Description: A hydrostatic stress-dependent, anisotropic model of viscoplasticity is formulated as an extension of Bodner's model. This represents a further extension of the isotropic Bodner model over that made to anisotropy by Robinson and MitiKavuma. Account is made of the inelastic deformation that can occur in metallic composites under hydrostatic stress. A procedure for determining the material parameters is identified that is virtually identical to the established characterization procedure for the original Bodner model. Characterization can be achieved using longitudinal/transverse tensile and shear tests and hydrostatic stress tests; alternatively, four off-axis tensile tests can be used. Conditions for a yield stress minimum under off-axis tension are discussed. The model is applied to a W/Cu composite; characterization is made using off-axis tensile data generated at NASA Lewis Research Center (LeRC).

Description: A new piston concept, made of carbon-carbon refractory-composite material, has been developed that overcomes a number of the shortcomings of aluminum pistons. Carbon-carbon material, developed in the early 1960's, is lighter in weight than aluminum, has higher strength and stiffness than aluminum and maintains these properties at temperatures over 2500 F. In addition, carbon-carbon material has a low coefficient of thermal expansion and excellent resistance to thermal shock. An effort, called the Advanced Carbon-Carbon Piston Program was started in 1986 to develop and test carbon-carbon pistons for use in spark ignition engines. The carbon-carbon pistons were designed to be replacements for existing aluminum pistons, using standard piston pin assemblies and using standard rings. Carbon-carbon pistons can potentially enable engines to be more reliable, more efficient and have greater power output. By utilizing the unique characteristics of carbon-carbon material a piston can: (1) have greater resistance to structural damage caused by overheating, lean air-fuel mixture conditions and detonation; (2) be designed to be lighter than an aluminum piston thus, reducing the reciprocating mass of an engine, and (3) be operated in a higher combustion temperature environment without failure.

Description: A low pressure processor was developed for preparing a well-consolidated polyimide composite laminate. Prepreg plies were formed from unidirectional fibers and a polyamic acid resin solution. Molding stops were placed at the sides of a matched metal die mold. The prepreg plies were cut shorter than the length of the mold in the in-plane lateral direction and were stacked between the molding stops to a height which was higher than the molding stops. The plies were then compressed to the height of the stops and heated to allow the volatiles to escape and to start the imidization reaction. After removing the stops from the mold, the heat was increased and 0 - 500 psi was applied to complete the imidization reaction. The heat and pressure were further increased to form a consolidated polyimide composite laminate.

Description: Progressive failure is a crucial concern when using laminated composites in structural design. Therefore the ability to model damage and predict the life of laminated composites is vital. The purpose of this research was to experimentally verify the application of the continuum damage model, a progressive failure theory utilizing continuum damage mechanics, to a toughened material system. Damage due to tension-tension fatigue was documented for the IM7/5260 composite laminates. Crack density and delamination surface area were used to calculate matrix cracking and delamination internal state variables, respectively, to predict stiffness loss. A damage dependent finite element code qualitatively predicted trends in transverse matrix cracking, axial splits and local stress-strain distributions for notched quasi-isotropic laminates. The predictions were similar to the experimental data and it was concluded that the continuum damage model provided a good prediction of stiffness loss while qualitatively predicting damage growth in notched laminates.

Description: There are no well-developed technologies for recycling composite materials other than grinding to produce fillers. New approaches are needed to reclaim these valuable resources. Chemical or tertiary recycling, conversion of polymers into low molecular weight hydrocarbons for reuse as chemicals or fuels, is emerging as the most practical means for obtaining value from waste plastics and composites. Adherent Technologies is exploring a low-temperature catalytic process for recycling plastics and composites. Laboratory results show that all types of plastics, thermosets as well as thermoplastics, can be converted in high yields to valuable hydrocarbon products. This novel catalytic process runs at 200 C, conversion times are rapid, the process is closed and, thus, nonpolluting, and no highly toxic gas or liquid products have been observed so no negative environmental impact will result from its implementation. Tests on reclamation of composite materials show that epoxy, imide, and engineering thermoplastic matrices can be converted to low molecular weight hydrocarbons leaving behind the reinforcing fibers for reuse as composite reinforcements in secondary, lower-performance applications. Chemical recycling is also a means to dispose of sensitive or classified organic materials without incineration and provides a means to eliminate or reduce mixed hazardous wastes containing organic materials.

Description: Approximately 20 sq m of protective thermal blankets, largely composed of Teflon, were retrieved from the Long Duration Exposure Facility after the spacecraft spent approximately 5.7 years in space. Examination of these blankets revealed that they contained thousands of hypervelocity impact features ranging from micron-sized craters to penetration holes several millimeters in diameter. We conducted impact experiments to reproduce such features and to understand the relationships between projectile size and the resulting crater or penetration hole diameter over a wide range of impact velocities. Such relationships are needed to derive the size and mass frequency distribution and flux of natural and man-made particles in low-earth orbit. Powder propellant and light-gas guns were used to launch soda-lime glass spheres into pure Teflon targets at velocities ranging from 1 to 7 km/s. Target thickness varied over more than three orders of magnitude from finite halfspace targets to very thin films. Cratering and penetration of massive Teflon targets is dominated by brittle failure and the development of extensive spall zones at the target's front and, if penetrated, the target's rear side. Mass removal by spallation at the back side of Teflon targets may be so severe that the absolute penetration hole diameter can become larger than that of a standard crater. The crater diameter in infinite halfspace Teflon targets increases, at otherwise constant impact conditions, with encounter velocity by a factor of V (exp 0.44). In contrast, the penetration hole size in very thin foils is essentially unaffected by impact velocity. Penetrations at target thicknesses intermediate to these extremes will scale with variable exponents of V. Our experimental matrix is sufficiently systematic and complete, up to 7 km/s, to make reasonable recommendations for velocity-scaling of Teflon craters and penetrations. We specifically suggest that cratering behavior and associated equations apply to all impacts in which the shock-pulse duration of the projectile is shorter than that assigned a unique projectile size, provided an impact velocity is known or assumed. This calibration seems superior to the traditional ballistic-limit approach.

Description: Silicon carbide with a refractory oxide coating is potentially a very attractive ceramic system. It offers the desirable mechanical and physical properties of SiC and the environmental durability of a refractory oxide. The development of a thermal shock resistant plasma-sprayed mullite coating on SiC is discussed. The durability of the mullite/SiC in oxidizing, reducing, and molten salt environments is discussed. In general, this system exhibits better behavior than uncoated SiC. Areas for further developments are discussed.

Description: Traditional design approaches for composite materials have employed deterministic criteria for failure analysis. New approaches are required to predict the reliability of composite structures since strengths and stresses may be random variables. This report will examine and compare methods used to evaluate the reliability of composite laminae. The two types of methods that will be evaluated are fast probability integration (FPI) methods and Monte Carlo methods. In these methods, reliability is formulated as the probability that an explicit function of random variables is less than a given constant. Using failure criteria developed for composite materials, a function of design variables can be generated which defines a 'failure surface' in probability space. A number of methods are available to evaluate the integration over the probability space bounded by this surface; this integration delivers the required reliability. The methods which will be evaluated are: the first order, second moment FPI methods; second order, second moment FPI methods; the simple Monte Carlo; and an advanced Monte Carlo technique which utilizes importance sampling. The methods are compared for accuracy, efficiency, and for the conservativism of the reliability estimation. The methodology involved in determining the sensitivity of the reliability estimate to the design variables (strength distributions) and importance factors is also presented.

Description: This invention is a semi-interpentrating polymer network which includes a high performance thermosetting polyimide having a nadic end group acting as a crosslinking site and a high performance linear thermoplastic polyimide. Provided is an improved high temperature matrix resin which is capable of performing in the 200 to 300 C range. This resin has significantly improved toughness and microcracking resistance, excellent processability, mechanical performance, and moisture and solvent resistances.

Description: Advanced composite cylinders, manufactured by filament winding, provide a cost effective solution to many present structural applications; however, the compressive performance of filament-wound cylinders is lower than comparable shells fabricated from unidirectional tape. The objective of this study was to determine the cause of this reduction in thin filament-wound cylinders by relating the manufacturing procedures to the quality of the cylinder and to its compressive performance. The experiments on cylinder buckling were complemented by eigenvalue buckling analysis using a detailed geometric model in a finite element analysis. The applicability of classical buckling analyses was also investigated as a design tool.

Description: A method for predicting the damped dynamic characteristics of thick composite laminates and plates is presented. Unified damping mechanics relate the damping of composite plates to constituent properties, fiber volume ratio, fiber orientation, laminate configuration, plate geometry, temperature, and moisture. Discrete layer damping mechanics for thick laminates, entailing piecewise continuous displacement fields and including the effects of interlaminar shear damping, are described. A semi-analytical method for predicting the modal damping and natural frequencies of thick simply-supported specialty composite plates is included. Applications demonstrate the validity, merit, and ranges of applicability of the new theory. The applications further illustrate the significance of interlaminar shear damping, and investigate the effects of lamination, thickness aspect ratio, fiber content, and temperature.

Description: The non-linear viscoplastic behavior of fibrous periodic composites is analyzed by discretizing the unit cell into triangular subvolumes. A set of these subvolumes can be configured by the analyst to construct a representation for the unit cell of a periodic composite. In each step of the loading history the total strain increment at any point is governed by an integral equation which applies to the entire composite. A Fourier series approximation allows the incremental stresses and strains to be determined within a unit cell of the periodic lattice. The non-linearity arising from the viscoplastic behavior of the constituent materials comprising the composite is treated as a fictitious body force in the governing integral equation. Specific numerical examples showing the stress distributions in the unit cell of a fibrous tungsten/copper metal-matrix composite under viscoplastic loading conditions are given. The stress distribution resulting in the unit cell when the composite material is subjected to an overall transverse stress loading history perpendicular to the fibers is found to be highly heterogeneous, and typical homogenization techniques based on treating the stress and strain distributions within the constituent phases as homogeneous result in large errors under inelastic loading conditions.

Description: A general purpose micromechanics analysis that discretely models the yarn architecture within the textile repeating unit cell was developed to predict overall, three dimensional, thermal and mechanical properties, damage initiation and progression, and strength. This analytical technique was implemented in a user-friendly, personal computer-based, menu-driven code called Textile Composite Analysis for Design (TEXCAD). TEXCAD was used to analyze plain weave and 2x2, 2-D triaxial braided composites. The calculated tension, compression, and shear strengths correlated well with available test data for both woven and braided composites. Parametric studies were performed on both woven and braided architectures to investigate the effects of parameters such as yarn size, yarn spacing, yarn crimp, braid angle, and overall fiber volume fraction on the strength properties of the textile composite.

Description: The goals of this research program were to: (1) determine how microstructural factors, especially the architecture of reinforcing fibers, control stiffness, strength, and fatigue life in 3D woven composites; (2) identify mechanisms of failure; (3) model composite stiffness; (4) model notched and unnotched strength; and (5) model fatigue life. We have examined a total of eleven different angle and orthogonal interlock woven composites. Extensive testing has revealed that these 3D woven composites possess an extraordinary combination of strength, damage tolerance, and notch insensitivity in compression and tension and in monotonic and cyclic loading. In many important regards, 3D woven composites far outstrip conventional 2D laminates or stitched laminates. Detailed microscopic analysis of damage has led to a comprehensive picture of the essential mechanisms of failure and how they are related to the reinforcement geometry. The critical characteristics of the weave architecture that promote favorable properties have been identified. Key parameters are tow size and the distributions in space and strength of geometrical flaws. The geometrical flaws should be regarded as controllable characteristics of the weave in design and manufacture. In addressing our goals, the simplest possible models of properties were always sought, in a blend of old and new modeling concepts. Nevertheless, certain properties, especially regarding damage tolerance, ultimate failure, and the detailed effects of weave architecture, require computationally intensive stochastic modeling. We have developed a new model, the 'binary model,' to carry out such tasks in the most efficient manner and with faithful representation of crucial mechanisms. This is the final report for contract NAS1-18840. It covers all work from April 1989 up to the conclusion of the program in January 1993.

Description: A variety of high performance polycrystalline ceramic fibers are currently being considered as reinforcement for high temperature ceramic matrix composites. However, under mechanical loading about 800 C, these fibers display creep related instabilities which can result in detrimental changes in composite dimensions, strength, and internal stress distributions. As a first step toward understanding these effects, this study examines the validity of a mechanism-based empirical model which describes primary stage tensile creep and stress relaxation of polycrystalline ceramic fibers as independent functions of time, temperature, and applied stress or strain. To verify these functional dependencies, a simple bend test is used to measure stress relaxation for four types of commercial ceramic fibers for which direct tensile creep data are available. These fibers include both nonoxide (SCS-6, Nicalon) and oxide (PRD-166, FP) compositions. The results of the Bend Stress Relaxation (BSR) test not only confirm the stress, time, and temperature dependencies predicted by the model, but also allow measurement of model empirical parameters for the four fiber types. In addition, comparison of model tensile creep predictions based on the BSR test results with the literature data show good agreement, supporting both the predictive capability of the model and the use of the BSR text as a simple method for parameter determination for other fibers.

Description: Global/local method in conjunction with a special macro finite element is used to gain computational efficiency in the simulation of textile composites behavior. Results are included to demonstrate the effectiveness of the method. Also, 2D finite elements are used to study boundary effects in plain weave composite specimens subjected to extension, shear, and flexure loads. Effective extension, shear, and flexural moduli were found to be quite sensitive to specimen size. For extension and flexure loads stress distributions were affected by a free surface, but the free surface boundary effect did not appear to propagate very far into the interior. For shear load, the boundary effect appeared to propagate much further into the interior. The report is in the form of two technical articles, the first describes the global/local method while the second describes the use of the 2D finite elements.

Description: In this Progress Report, we describe our continuing research activities concerning the development and implementation of advanced ultrasonic nondestructive evaluation methods applied to the inspection and characterization of complex composite structures. We explore the feasibility of implementing medical linear array imaging technology as a viable ultrasonic-based nondestructive evaluation method to inspect and characterize complex materials. As an initial step toward the application of linear array imaging technology to the interrogation of a wide range of complex composite structures, we present images obtained using an unmodified medical ultrasonic imaging system of two epoxy-bonded aluminum plate specimens, each with intentionally disbonded regions. These images are compared with corresponding conventional ultrasonic contact transducer measurements in order to assess whether these images can detect disbonded regions and provide information regarding the nature of the disbonded region. We present a description of a standoff/delay fixture which has been designed, constructed, and implemented on a Hewlett-Packard SONOS 1500 medical imaging system. This standoff/delay fixture, when attached to a 7.5 MHz linear array probe, greatly enhances our ability to interrogate flat plate specimens. The final section of this Progress Report describes a woven composite plate specimen that has been specially machined to include intentional flaws. This woven composite specimen will allow us to assess the feasibility of applying linear array imaging technology to the inspection and characterization of complex textile composite materials. We anticipate the results of this on-going investigation may provide a step toward the development of a rapid, real-time, and portable method of ultrasonic inspection and characterization based on linear array technology.

Description: This study examines the delamination evolution, under quasi-static conditions, of laminated polymeric composites with mechanically nonlinear resin rich interfaces. The constitutive behavior of the interface is represented by two models developed by Needleman and Tvegaard. These models assumed that the interfacial tractions, a function of only the interfacial displacement, will behave similarly to the interatomic forces generated during the interatomic seperation. The interface material's parameters control the load at which the delamination growth initiates and the final delamination size. A wide range of damage accumulation responses have been obtained by varying the model parameters. These results show that Tvergaard's model has been found to be better suited of the two models in predicting damage evolution for the configurations examined.

Description: This Note evaluates the piecewise-uniform approach to tailoring as a mean of improving the shear buckling loads of composite plates. This design approach is referred to herein as stiffness tailoring or, more simply, as tailoring. The primary objectives are to determine the tailoring patterns and the degree of concentration of the material used to achieve the tailoring in each pattern that maximize the shear buckling load and to quantify the maximum relative improvement that can be achieved in the buckling load compared to uniform plates.

Description: Experimental methods were developed, adapted, and applied to the characterization of a metal matrix composite system, namely, silicon carbide/aluminim (SCS-2/6061 Al), and its constituents. The silicon carbide fiber was characterized by determining its modulus, strength, and coefficient of thermal expansion. The aluminum matrix was characterized thermomechanically up to 399 C (750 F) at two strain rates. The unidirectional SiC/Al composite was characterized mechanically under longitudinal, transverse, and in-plane shear loading up to 399 C (750 F). Isothermal and non-isothermal creep behavior was also measured. The applicability of a proposed set of multifactor thermoviscoplastic nonlinear constitutive relations and a computer code was investigated. Agreement between predictions and experimental results was shown in a few cases. The elastoplastic thermomechanical behavior of the composite was also described by a number of new analytical models developed or adapted for the material system studied. These models include the rule of mixtures, composite cylinder model with various thermoelastoplastic analyses and a model based on average field theory. In most cases satisfactory agreement was demonstrated between analytical predictions and experimental results for the cases of stress-strain behavior and thermal deformation behavior at different temperatures. In addition, some models yielded detailed three-dimensional stress distributions in the constituents within the composite.