ALBERT

Description: Conventional sandwich structure fabrication methods are labor intensive and high in cost. A low cost method is needed to produce lightweight sandwich structures. Sundstrand has developed a series of in situ composite fabrication methods in which the raw materials (skin and core materials) are placed in a closed mold, and the component is produced in one heating cycle. Internal pressure is generated by chemical agents during the thermal cycles, which consolidates the skins and produces the foam core. The finished part is a net-shape composite sandwich structure with skins and a foamed core. The in situ process reduces cost by eliminating several secondary operations that are used in conventional fabrication methods. Further, a strong molecular bond is produced between the core and skin, which eliminates adhesive bonding and prevents a weak bond section in the sandwich structure. In this investigation, we evaluated the feasibility of the in situ process using thermoset materials currently under consideration for commercial airplane fuselage applications, such as keel sections. The materials used were Hercules 855340 toughened epoxy resin in both liquid and powder forms, and 3M Scotchply PR500 resin, manufactured by 3M Corporation, in powder form. We successfully foamed these resins and produced experimental panels with AS-4/855340 Hercules prepreg skins. Chopped fibers were added to the core to increase performance of the foam. Mechanical property testing on these panels showed properties competitive with other foams. Additional experiments are required to optimize the in situ foam core sandwiches for specific properties and applications.

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

Description: Creep-rupture and tensile tests have been used to evaluate thoriated W-wire reinforced Nb-1 percent Zr alloy matrix composites fabricated via arc-spray monotape technique. A significant creep strength enhancement was observed over the unreinforced matrix alloy while matrix integrity was maintained; the fiber/matrix interface phase is noted to be a strong and ductile W/Nb alloy, which is formed due to the mutual solubility of the constituent metals. High strength, toughness, and thermal stability are demonstrated by this material system, which is also resistant to liquid alkali metal corrosion.

Description: The mechanical behavior of continuous fiber reinforced SiC/RBSN composites with strong and weak interface characteristics is evaluated. Both catastrophic and noncatastrophic failures are observed in tensile specimens. Effects of fiber/matrix interface debonding (splitting) parallel to the fibers are discussed. Micromechanical models incorporating residual stresses to calculate the critical matrix cracking strength, ultimate strength and work of pull-out are reviewed and used to predict composite response. Experimental results are compared to analytical predictions.

Description: Previous studies of a single lot of NiAl powder which had been ground under high intensity conditions in liquid nitrogen (cryomilling) indicated that this processing leads to a high strength, elevated temperature NiAl-AlN composite. Because this was the first known example of the use of the reaction milling process to produce a high temperature composite, the reproducibility of this technique was unknown. Two additional lots of NIAl powder and a lot of a Zr-doped NiAl powder have been cryomilled, and analyses indicate that AlN was formed within a NiAl matrix in all three cases. Compression testing between 1200 K and 1400 K has shown that the deformation resistance of these heats is similar to that of the first lot of NiAl-AlN; thus cryomilling can improve the creep resistance of NiAl by a factor of six. Based on this work, it is concluded that cryomilling of NiAl powder to form high temperature, high strength NiAl-AlN composites is a reproducible process.

Description: Reaction of Ni-Al alloys within the beta-NiAl phase with CrB2 was studied at 1473 K as a function of Al concentration in the alloy. Reaction of 49-50 at. pct Al alloys with CrB2 occurred by interdiffusion of Ni into CrB2 and Cr into the alloy without forming a new product phase. On the other hand, a new product phase, rich in Ni and B, formed by the reaction of alloys having Al concentrations 48 at. pct or lower with CrB2. The reaction product was observed both at the CrB2/alloy interface and along the alloy grain boundaries.

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: Notched and unnotched tension and compression properties of quasi-isotropic laminates are presently evaluated, in conjunction with compression-after-impact (CAI) strengths, for the cases of five different carbon fiber-reinforced/toughened matrix composites. For a given impact energy, CAIs were dependent on impact velocities. When compared with other matrix-toughened materials, the five presently considered were more damage-tolerant than such aircraft primary structure composite systems as T300/5208.

Description: The toughening of the PMR-15 and LARC RP-46 high temperature thermosetting polyimides is presently attempted through the construction of a semiinterpenetrating network at ply interfaces through the use of the Matrimid 5218 thermoplastic polyimide powder, whose 315-320 glass transition temperature is compatible with the PMR matrices. The 60 vol pct fiber composites thus prepared for the two resins, with and without toughening, were comprehensively characterized in flexure, tension, intralaminar and short beam shear, compression and quasi-isotropic short-block compression, as well as modes I and II interlaminar fracture toughness and compression after impact.

Description: The effects of different fiber shapes on the behavior of metal matrix composites is computationally simulated. A three-dimensional finite element model consisting of a group of nine unidirectional fibers in a three by three unit cell array of a SiC/Ti-15-3 metal matrix composite is used in the analysis. The model is employed to represent five fiber shapes that include a circle, an ellipse, a kidney, and two different cross shapes. The distribution of stresses and the composite material properties, such as moduli, coefficients of thermal expansion, and Poisson's ratios, are obtained from the finite element analysis using the various fiber shapes. Comparisons of these results are used to determine the sensitivity of the composite behavior to the different fiber shapes. In general, fiber dominated properties are not affected by fiber geometry and matrix dominated properties are only moderately affected.

Description: Three-dimensional finite element methods and the intraply hybrid micromechanics equations are used to predict composite properties for a unidirectional graphite-epoxy primary composite with S-glass fibers used as hybridizing fibers. The micromechanics equations are embedded in a computer code ICAN (Integrated Composites Analyzer). The three-dimensional finite element model consists of three-by-three unit cell array, with a total fiber volume ratio of 0.54. There is a good agreement between the composite properties and microstresses obtained from both methods. The results indicate that the finite element methods and micromechanics equations can be used to obtain the properties of intermingled hybrid composites needed for analysis/design of hybrid composite structures.

Description: The multispan beam (MSB) test was evaluated as a predictor of damage resistance and damage tolerance in quasi-isotropic graphite laminates. Materials studied were five commercial prepreg system using high-strain and intermediate-modulus carbon fibers, as well as an amorphous thermoplastic system. Failure loads and displacements in the MSB tests showed little rate dependence. Values of compressive strength after a standard low-velocity impact correlated fairly well with the MSB results.

Description: The experimental techniques and associated data analysis methods used to measure the resistance to interlaminar fracture, or 'fracture toughness', of polymer matrix composite materials are described. A review in the use of energy techniques to characterize fracture behavior in elastic solids is given. An overview is presented of the types of approaches employed in the design of delamination-resistant composite materials.

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: Three-dimensional element analyses of (0/theta/-theta)s graphite epoxy laminates, where theta = 15, 20, 25, 30, and 45 deg, subjected to axial tensile load, were performed. The interlaminar stresses in the theta/-theta interface were calculated with and without a matrix crack in the central -theta plies. The interlaminar normal stress changes from a small compressive stress when no matrix crack is present to a high tensile stress at the intersection of the matrix crack and the free edge. The analysis of local delamination from the -theta matrix crack indicates a high strain energy release rate and a localized Mode I component near the free edge, within one-ply distance from the matrix crack. To examine the stress state causing the matrix cracking, the maximum principal normal stress in a plane perpendicular to the fiber direction in the -theta ply was calculated in an uncracked laminate. The corresponding shear stress parallel to the fiber was also calculated. The principal normal stress at the laminate edge increased through the ply thickness and reached a very high tensile value at the theta/-theta interface indicating that the crack in the -theta ply may initiate at the theta/-theta interface.

Description: The large mismatch in thermoelastic properties of the fiber and matrix phases in advanced metal matrix composites, coupled with high consolidation temperatures, produces severe residual stresses that can be large enough to initiate microcracks in the matrix phase adjacent to the fiber/matrix interface. Previous investigations have demonstrated that the use of a compliant interfacial layer between fiber and matrix phases has the potential for reducing these residual stresses. In this paper, the influence of multiple compliant layers in reducing residual thermal stresses is investigated.

Description: The tensile creep and creep-recovery behavior of a hot-pressed unidirectional SiC-fiber/Si3N4-matrix composite was investigated at 1200 C in air, in order to determine how various sustained and cyclic creep loading histories would influence the creep rate, accumulated creep strain, and the amount of strain recovered upon specimen unloading. The data accumulated indicate that the fundamental damage mode for sustained tensile creep at stresses of 200 and 250 MPa was periodic fiber fracture and that the creep life and the failure mode at 250 MPa were strongly influenced by the rate at which the initial creep stress was applied. Cyclic loading significantly lowered the duration of primary creep and the overall creep-strain accumulation. The implications of the results for microstructural and component design are discussed.

Description: Monolithic ceramic materials have proven their usefulness in many applications, yet, their potential for critical structural applications is limited because of their sensitivity to small imperfections. To overcome this extreme sensitivity to small imperfections, ceramic matrix composite materials have been developed that have the ability to withstand some distributed damage. A borosilicate glass reinforced with several layers of silicon-carbide fiber mat has been studied. Four-point flexure and tension tests were performed not only to determine some of the material properties, but also to initiate a controlled amount of damage within each specimen. Acousto-ultrasonic (AU) measurements were performed periodically during mechanical testing. This paper will compare the AU results to the mechanical test results and data from other nondestructive methods including acoustic emission monitoring and X-ray radiography. It was found that the AU measurements were sensitive to the damage that had developed within the material.

Description: Microstructural changes occurring during sliding wear of self-mated Al2O3 SiC whisker-reinforced composites were studied using optical, scanning electron microscopy and transmission electron microscopy. Pin-on-disc specimens were slid in air at 2.7 m/s sliding velocity under a 26.5 N load for 1 h. Wear tests were conducted at 23, 600, 800 and 1200 C. Mild wear with a wear factor of 2.4 x 10 exp -7 - 1.5 x 10 exp -6 cu mm /N per m was experienced at all test temperatures. The composite showed evidence of wear by fatigue mechanisms at 800 C and below. Tribochemical reaction (SiC oxidation and reaction of SiO2 and Al2O3) leads to intergranular failure at 1200 C. Distinct microstructural differences existing at each test temperature are reported.

Description: This paper examines the use of a thin layer of Ultra High Molecular Weight Polyethylene (UHMWPE) on the outer surface of carbon/epoxy composite materials as a method of improving impact resistance and damage tolerance through hybridization. Flat 16-ply laminates as well as honeycomb sandwich structures with eight-ply facesheets were tested in this study. Instrumented drop-weight impact testing was used to inflict damage upon the specimens. Evaluation of damage resistance included instrumented impact data, visual examination, C-scanning and compression after impact (CAI) testing. The results show that only one lamina of UHMWPE did not improve the damage tolerance (strength retention) of the 16-ply flat laminate specimens or the honeycomb sandwich beams, however, a modest gain in impact resistance (detectable damage) was found for the honeycomb sandwich specimens that contained an outer layer of UHMWPE.

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: Chemical and hydrodynamic aspects of wetting and interfacial phenomena during the solidification processing of metal-matrix composites are reviewed. Significant experimental results on fiber-matrix interactions and wetting under equilibrium and non-equilibrium conditions in composites of engineering interest have been compiled, based on a survey of the recent literature. Finally, certain aspects of wetting relevant to stir-casting and infiltration processing of composites are discussed.

Description: The inelastic deformation mechanisms were evaluated for a model titanium-based, fiber-reinforced composite: a beta titanium alloy (Ti-15V-3Al-3Cr-3Sn) reinforced with SiC (SCS-6) fibers. The primary emphasis of this article is to illustrate the sequence in which damage and plasticity evolved for this system. The mechanical responses and the results of detailed microstructural evaluations for the 0(8), 90(8), and +/- 45(2s) line oriented laminates are provided. It is shown that the characteristics of the reaction zone around the fiber play a very important role in the way damage and plasticity evolve, particularly in the microyield regime of deformation, and must be included in any realistic constitutive model. Fiber-matrix debonding was a major damage mode for the off-axis systems. The tension test results are also compared with the predictions of a few constitutive models.

Description: The requirements for electromagnetic interference (EMI) shielding in aerospace structures are more complicated than those for ground structures because of their weight limitations. As a result, the best EMI shielding materials must combine low density, high strength, and high elastic modulus with high shielding ability. EMI shielding characteristics were calculated for shields formed from pristine and intercalated graphite fiber/epoxy composites and compare to preliminary experimental results for these materials and to the characteristics of shields made from aluminum. Calculations indicate that effective EMI shields could be fabricated from intercalated graphite composites which would have less than 12 percent of the mass of conventional aluminum shields, based on mechanical properties and shielding characteristics alone.

Description: CTE (coefficient of thermal expansion) mismatch-induced stresses as they affect the fiber-matrix bond integrity of Al2O3 fiber-reinforced superalloy composites are examined. Of the three individual stress components, only the radial stress directly affects the integrity of the fiber-matrix interface. It is noted that a compressive radial stress leads to a clamping action on the fiber and is therefore beneficial to the integrity of the fiber-matrix bond. A radial tensile stress, on the other hand, can cause debonding of the fiber from the matrix for a weak fiber-matrix bond.

Description: The role of the fiber matrix interface bond on the transverse ductility of continuous fiber reinforced composites has been investigated. Two specific systems have been considered: an Aluminum alloy matrix reinforced by Alumina fibers, characterized by a strong interface and a Titanium alloy reinforced by coated Silicon Carbide fibers, characterized by a weak interface. A micro-mechanical study indicates that the bond condition has a significant effect on the state of stress in the matrix which in turn dictates the available matrix ductility. The micro-mechanical predictions are in good agreement with the experimental results for the two systems.

Description: Hot isostatic pressing (HIPing) was found to increase the thermal diffusivity/conductivity of uniaxial silicon carbide fiber-reinforced reaction-bonded silicon nitride (RBSN) matrix composites, as the result of the densification of the matrix, the increase in the grain size of the silicon carbide and the improved thermal contact between the fibers and the matrix. Transverse to the fiber direction the thermal diffusivity/conductivity was found to be a function of the surrounding gaseous atmosphere due to the access of the gas phase to the fiber-matrix interface, which was facilitated by the existence of an interfacial gap due to the thermal expansion mismatch between the fibers and the matrix. The interfacial conductance was found to exhibit a strong positive temperature dependence as the result of the closure of the interfacial gap with increasing temperature.

Description: Microstructural aspects of alloy solidification within the interstices of porous compacts of platelet-shaped single crystals of alpha-SiC, when the latter are infiltrated with a hot metal under pressure, have been described. Microstructural evidence is presented of selective reorientation of platelets and nonhomogeneous solute distribution under shear of pressurized melt, of constrained growth of primary solid within finite width zones, and of the modulation of coring due to microsegregation as a result of variations in the pore size of compacts.

Description: Countergravity, pressure-assisted infiltration with a 2014 Al alloy of suitably tamped porous compacts of platelet shaped single crystals of alpha (hexagonal) silicon carbide was used to measure particulate wettability and infiltration kinetics under dynamic conditions relevant to pressure casting of composites. A threshold pressure P(th) for ingression of the infiltrant was identified based on the experimental penetration length versus pressure profiles for a range of experimental variables which included infiltration pressure, infiltration time, SiC size and SiC surface chemistry. The results showed that P(th) decreased whereas the penetration length increased with increasing SiC size and infiltration time. Cu-coated SiC led to lower P(th) and larger penetration lengths compared to uncoated SiC under identical conditions. These observations have been discussed in the light of theoretical models of infiltration and the kinetics of wetting.

Description: This paper investigates the unnotched tensile properties of two-dimensional (2D) triaxial braid-reinforced composites both experimentally and analytically. The materials are graphite fibers in an epoxy matrix. Three different reinforcing fiber architectures were considered. There were considerable differences in the observed elastic constants from different size strain gage and extensometer readings. Larger strain gages gave more consistent results and correlated better with the extensometer readings. Experimental strains correlated reasonably well with analytical predictions in the longitudinal, 0 deg, fiber direction but not in the transverse direction. Tensile strength results were not always predictable even in reinforcing directions. Minor changes in braid geometry led to disproportionate strength variations. The unit cell structure of the triaxial braid was discussed with the assistance of computer analysis of the microgeometry. Photomicrographs of braid geometry were used to improve upon the computer graphics representations of unit cells. These unit cells were used to predict the elastic moduli with various degrees of sophistication. The simple and the complex analyses were generally in agreement, but none adequately matched the experimental results for all the braids.

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: Concerns related to the proper preparation of composite specimens for microstructural analysis are examined. Proper preparation will minimize the amount of surface and subsurface damage at each stage of the procedure so that the microstructural features of the final-polished specimen can be accurately determined as a function of the composite's response to processing, testing, or service conditions. This requires that an optimum combination of abrasive type, size, and bond be applied during each grinding, lapping, and polishing step. Machine settings, such as polishing speed, force, and relative polishing direction, are also important. Guidelines are given for each step of the six-stage specimen preparation process: sectioning, planar grinding, sample integrity, polishing, and etching.

Description: This paper examines the effect of the morphology of the SCS6 silicon carbide fiber on the evolution of residual stresses in SiC/Ti composites. A micromechanics model based on the concentric cylinder concept is presented which is used to calculate residual stresses in a SiC/Ti composite during axisymmetric cooling by a spatially uniform temperature change. The silicon carbide fiber is modeled as a layered material with five distinct transversely isotropic and orthotropic, elastic layers, whereas the titanium matrix is taken to be isotropic, with temperature-dependent elastoplastic properties. The results arc compared with those obtained based on the assumption that the silicon carbide fiber is isotropic and homogeneous.

Description: A probabilistic evaluation of an eight ply graphite-epoxy quasi-isotropic laminate was completed using the Integrated Composite Analyzer (ICAN) in conjunction with Monte Carlo simulation and Fast Probability Integration (FPI) techniques. Probabilistic input included fiber and matrix properties, fiber misalignment, fiber volume ratio, void volume ratio, ply thickness and ply layup angle. Cumulative distribution functions (CDFs) for select laminate properties are given. To reduce the number of simulations, a Fast Probability Integration (FPI) technique was used to generate CDFs for the select properties in the absence of fiber misalignment. These CDFs were compared to a second Monte Carlo simulation done without fiber misalignment effects. It was found that FPI requires fewer simulations to obtain the cumulative distribution functions as opposed to Monte Carlo simulation techniques. Furthermore, FPI provides valuable information regarding the sensitivities of composite properties to the constituent properties, fiber volume ratio and void volume ratio.

Description: A modified sedimentation process was used in the production of a functionally gradient material (FGM), NiAl/Al2O3. A simple finite element model was used to guide our design and fabrication efforts by estimating residual stress states as a function of composite structure. This approach could lead to tailored designs that enhance or avoid specific residual stress states. Thermal cycling tests were factored into the model to predict time dependent or steady-state internal temperature and stress profiles. Four-point bend tests were conducted to establish the mechanical load-displacement behavior of a single interlayer FGM at room temperature, 800 and 1000 K. Room temperature bend strength of the FGM was 3-4 times that of the base NiAl. At elevated temperatures, composite fracture occurred in a gradual, noncatastrophic mode involving NiAl retardation of a succession of cracks originating in the alumina face.

Description: Reusable, oxidation protected reinforced carbon carbon (RCC) has been successfully flown on forty Shuttle Orbiter flights. Thermal testing of the silicon carbide coated, reinforced carbon-carbon to determine its oxidation characteristics has been performed in both radiant and convective (plasma arc jet) heating test facilities. Subsurface oxidation of the RCC substrate as a result of oxygen penetrating micro cracks (fizzures) in the coating was characterized as a function of temperature and pressure for both convective and radiant environments. High temperature testing was performed to establish coating recession for over-temperature flight conditions experienced on abort trajectories. Suggested methods for using these test data to establish multi-mission reuse (i.e., mission life) and single mission limits are presented.

Description: The effect of aeroconvective heating environment similar to that observed a spacecraft ascent or reentry from orbit, on the performance of a commercial carbon-reinforced ceramic matrix material specimens of two configurations (orthotropic and quasi-isotropic), fabricated by the Societe Europenne Propulsion (SEP) process was investigated using the NASA Ames Research Center 20 Megawatt Panel Test facility. The performance of the commercial material was compared with the SEP prepared materials. It was found that, whereas the quasi-isotropic SEP specimens exhibited a much higher mass loss rate and a significant dimensional change upon exposure to the thermal environment than did the orthotropic ones, the commercial SEP-like materials did not exhibit these characteristics. There was no greater mass loss rate for the quasi-isotropic specimens, and no dimension changes were observed. The Nicalon reinforced materials in both configurations, as fabricated by SEP or by the commercial source, showed no mass changes and no dimensional changes.

Description: The next generation of hypersonic vehicles (NASP, SSTO) that require reusable thermal protection systems will experience acreage surface temperatures in excess of 1100 C. More important, they will experience a more severe physical environment than the Space Shuttle due to non-pristine launching and landing conditions. As a result, maintenance, inspection, and replacement factors must be more thoroughly incorporated into the design of the TPS. To meet these requirements, an advanced thermal protection system was conceived, designated 'TOPHAT'. This system consists of a toughened outer ceramic matrix composite (CMC) attached to a rigid reusable surface insulator (RSI) which is directly bonded to the surface. The objective of this effort was to evaluate this concept in an aeroconvective environment, to determine the effect of impacts to the CMC material, and to compare the results with existing thermal protection systems.

Description: An analytical study of the effects of changes in composite lamina properties on the laminate coefficient of thermal expansion, CTE, has been made. Low modulus graphite/epoxy (T300/934) and high modulus graphite/epoxy (P75/934, P100/934, P120/934), graphite/aluminum (P100/Al), and graphite/glass (HMS/Gl) composite materials were considered in quasi-isotropic and near-zero CTE laminate configurations. The effects of changes in lamina properties on the laminate CTE strongly depend upon the type of composite material as well as the laminate configuration. A 10 percent change in the lamina transverse CTE resulted in changes as large as 0.22 ppm/C in the laminate CTE of a quasi-isotropic Gr/934 laminates. No significant differences were observed in the sensitivities of the laminate CTEs of the P100/934 and P120/934 composite materials due to identical changes in lamina properties. Large changes in laminate CTE can also result from measured temperature and radiation effects on lamina properties.

Description: Ultrasonic waves suffer energy flux deviation in graphite/epoxy because of the large anisotropy. The angle of deviation is a function of the elastic coefficients. For nonlinear solids, these coefficients and thus the angle of deviation is a function of stress. Acoustoelastic theory was used to model the effect of stress on flux deviation for unidirectional T300/5208 using previously measured elastic coefficients. Computations were made for uniaxial stress along the x3 axis (fiber axis) and the x1 for waves propagating in the x1x3 plane. These results predict a shift as large as three degrees for the quasi-transverse wave. The shift in energy flux offers a new nondestructive technique of evaluating stress in composites.

Description: A model is described for predicting the wear behavior of whisker reinforced ceramics. The model was successfully applied to a silicon carbide whisker reinforced alumina ceramic composite subjected to sliding contact. The model compares the friction forces on the whiskers due to sliding, which act to pull or push them out of the matrix, to the clamping or compressive forces on the whiskers due to the matrix, which act to hold the whiskers in the composite. At low temperatures, the whiskers are held strongly in the matrix and are fractured into pieces during the wear process along with the matrix. At elevated temperatures differential thermal expansion between the whiskers and matrix can cause loosening of the whiskers and lead to pullout during the wear process and to higher wear. The model, which represents the combination of elastic stress analysis and a friction heating analysis, predicts a transition temperature at which the strength of the whiskers equals the clamping force holding them in the matrix. Above the transition the whiskers are pulled out of the matrix during sliding, and below the transition the whiskers are simply fractured. The existence of the transition gives rise to a dual wear mode or mechanism behavior for this material which was observed in laboratory experiments. The results from this model correlate well with experimentally observed behavior indicating that the model may be useful in obtaining a better understanding of material behavior and in making material improvements.

Description: The objective of this study is to determine the energy dissipation processes in polymer-matrix composites during impact of ballistic projectiles. These processes include heat, fiber deformation and breakage, matrix deformation and fracture, and interfacial delamination. In this study, experimental measurements were made, using specialized specimen designs and test methods, to isolate the energy consumed by each of these processes during impact in the ballistic range. Using these experiments, relationships between material parameters and energy dissipation were examined. Composites with the same matrix but reinforced with Kevlar, PE, and graphite fabric were included in this study. These fibers were selected based on the differences in their intrinsic properties. Matrix cracking was found to be one of the most important energy absorption mechanisms during impact, especially in ductile samples such as Spectra-900 PE and Kevlar-49 reinforced polymer. On the contrary, delamination dominated the energy dissipation in brittle composites such as graphite reinforced materials. The contribution from frictional forces was also investigated and the energy partitioning among the different processes evaluated.

Description: The uniaxial response of a continuous fiber elastic-perfectly plastic composite is modeled herein as a two-element composite cylinder. An axisymmetric analytical micromechanics solution is obtained for the rate-independent elastic-plastic response of the two-element composite cylinder subjected to tensile loading in the fiber direction for the case wherein the core fiber is assumed to be a transversely isotropic elastic-plastic material obeying the Tsai-Hill yield criterion, with yielding simulating fiber failure. The matrix is assumed to be an isotropic elastic-plastic material obeying the Tresca yield criterion. It is found that there are three different circumstances that depend on the fiber and matrix properties: fiber yield, followed by matrix yielding; complete matrix yield, followed by fiber yielding; and partial matrix yield, followed by fiber yielding, followed by complete matrix yield. The order in which these phenomena occur is shown to have a pronounced effect on the predicted uniaxial effective composite response.

Description: Several lay-ups of SCS-6/Ti-15-3 composites were investigated. Static and fatigue tests were conducted for both notched and unnotched specimens at room and elevated temperatures. Test results indicated that the stress in the 0 fibers is the controlling factor in fatigue life. The static and fatigue strength of these materials is shown to be dependent on the level of residual stresses and the fiber/ matrix interfacial strength. Fatigue tests of notched specimens showed that cracks can initiate and grow many fiber spacings in the matrix material without breaking fibers. These matrix cracks can significantly reduce the residual strength of notched composite.

Description: The transverse properties of an aluminum alloy metal matrix composite reinforced by continuous alumina fibers have been investigated. The composite is subjected to both mechanical and cyclic thermal loading. The ductility can vary by an order of magnitude according to the operating conditions. For high mechanical and low thermal loading the ductility is small, for low mechanical and high thermal loading the ductility is an order of magnitude higher. Experiments on a beam in bending confirm that the ductility is strongly dependent on the loading conditions. The observations suggest a means of utilizing the inherent ductility of the matrix.

Description: The computer code 'METCAN' (METal matrix Composite ANalyzer) developed at NASA Lewis Research Center can be used to predict the high temperature behavior of metal matrix composites using the room temperature constituent properties. A reference manual that characterizes some common composites is being developed from METCAN generated data. Typical plots found in the manual are shown for graphite/copper. These include plots of stress-strain, elastic and shear moduli, Poisson's ratio, thermal expansion, and thermal conductivity. This manual can be used in the preliminary design of structures and as a guideline for the behavior of other composite systems.

Description: The Ultraviolet Coronagraph Spectrograph (UVCS) is an optical instrument to be flown on the European spacecraft Solar Heliospheric Observatory (SOHO) to the sun-earth L1 point. The stability requirements of the instrument require the moisture content of the pseudoisotropic composite material not to exceed 0.06 percent during alignment and calibration. This paper describes the steps necessary to meet this requirement. These steps include a dynamic moisture content analysis, selection of bake out conditions and moisture controls, verification sampling, and use of witness specimens to monitor the moisture content during the prelaunch life of the structure.

Description: One of the critical technology needs of large precision reflectors for future astrophysical and optical communications satellites lies in the area of structural materials. Results from a materials research and development program at NASA Langley Research Center to provide materials for these reflector applications are discussed. Advanced materials that meet the reflector panel requirements are identified, and thermal, mechanical and durability properties of candidate materials after exposure to simulated space environments are compared. A parabolic, graphite-phenolic honeycomb composite panel having a surface accuracy of 70.8 microinches rms and an areal weight of 1.17 lbm/sq ft was fabricated with T50/ERL1962 facesheets, a PAEI thermoplastic surface film, and Al and SiO(x) coatings.

Description: Load-controlled isothermal and nonisothermal fatigue lives of a (0-deg)s SiC/Ti-15-3 were evaluated at temperatures between 150 and 550 C and a target strain range of about 0.45 percent. In nonisothermal fatigue tests, load was first cycled at minimum temperature and then temperature was cycled at zero load. For fatigue tests with peak temperatures at or above 300 C, fatigue life was dramatically reduced compared to that at 150 C. The shortest life was produced by the nonisothermal test with the greatest temperature range (Delta T = 400 C) and highest peak temperature (T(max) = 550 C). Vacuum testing showed that much of the life reduction under isothermal and nonisothermal conditions was related to environmental effects, although the nature of the fatigue-environment interaction was decidedly different for the isothermal and nonisothermal test cycles which were studied.

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: The 1200 C and 1300 C isothermal and cyclic oxidation behavior of Al2O3 continuous fiber-reinforced/NiAl composites were studied. Oxidation resulted in formation of Al2O3 external scales in a similar manner as scales formed on monolithic NiAl. The isothermal oxidation of an Al2O3/NiAl composite resulted in oxidation of the matrix along the fiber/matrix interface near the fiber ends. This oxide acted as a wedge between the fiber and the matrix, and, under cyclic oxidation conditions, led to further oxidation along the fiber lengths and eventual cracking of the composite. The oxidation behavior of composites in which the Al2O3 fibers were sputter coated with nickel prior to processing was much more severe. This was attributed to open channels around the fibers which formed during processing, most likely as a result of the diffusion of the nickel coating into the matrix.

Description: Nicalon silicon carbide 3D yarn with silicon carbide matrix composites made through a chemical vapor infiltration (CVI) process were investigated under tensile and flexural loading at 23, 1200 and 1550 C in air. The effectiveness of a chemical vapor deposition (CVD) SiC surface coating was also evaluated in severe oxidizing environment. Acoustic emission sensors and in situ optical microscopy were used at room temperature to monitor the failure mechanisms. It is shown that the level of tensile stress at which nonlinear behavior begins is not drastically reduced at 1200 and 1550 C when composites were protected by a SiC surface coating. Extensive fiber pull-out was observed only in the 1550 C specimen. Similar behaviors were also found in flexural specimens.

Description: The purpose was to characterize damage initiation and growth in notched titanium matrix composites at room temperature. Double edge notched or center open hole SCS-6/Ti-15-3 specimens containing 0 deg plies or containing both 0 and 90 deg plies were fatigued. The specimens were tested in the as-fabricated (ASF) and in heat-treated conditions. A local strain criterion using unnotched specimen fatigue data was successful in predicting fatigue damage initiation. The initiation stress level was accurately predicted for both a double edge notched unidirectional specimen and a cross-plied center hole specimen. The fatigue produced long multiple cracks growing from the notches. These fatigue cracks were only in the matrix material and did not break the fibers in their path. The combination of matrix cracking and fiber/matrix debonding appears to greatly reduce the stress concentration around the notches. The laminates that were heat treated showed a different crack growth pattern. In the ASF specimens, matrix cracks had a more tortuous path and showed considerable more crack branching. For the same specimen geometry and cyclic stress, the (0/90/0) laminate with a hole had far superior fatigue resistance than the matrix only specimen with a hole.

Description: A study was made to determine the relevance of impacter shape to nonvisible damage and tensile residual strength of a 36 mm thick graphite/epoxy motor case. The shapes of the impacters were as follows: 12.7 mm and 25.4 mm diameter hemispheres, a sharp corner, and a 6.3 mm diameter bolt-like rod. The investigation revealed that damage initiated when the contact pressure exceeded a critical level. However, the damage was not visible on the surface until an even higher pressure was exceeded. The impact energy to initiate damage or cause visible damage on the surface increased approximately with impacter diameter to the third power. The reduction in strength for nonvisible damage increased with increasing diameter, 9 and 30 percent for the 12.7 mm and 25.4 mm diameter hemispheres, respectively. The corner impacter made visible damage on the surface for even the smallest impact energy. The rod impacter acted like a punch and sliced through the composite. Even so, the critical level of pressure to initiate damage was the same for the rod and hemispherical impacters. Factors of safety for nonvisible damage increased with increasing kinetic energy of impact. The effects of impacter shape on impact force, damage size, damage visibility, and residual tensile strength were predicted quite well assuming Hertzian contact and using maximum stress criteria and a surface crack analysis.

Description: An investigation was conducted to characterize and model the fatigue crack growth (FCG) behavior of an SCS-6/Ti-15-3 metal matrix composite. Part of the study was conducted using a fatigue loading stage mounted inside a scanning electron microscope (SEM). The results of the study reveal that the fatigue crack growth behavior of the composite is a function of specimen geometry, fiber orientation, and interaction of local stress fields with the highly anisotropic composite. In the case of (0)8 oriented single edge notch specimens and (90)8 oriented compact tension (CT) specimens, the crack growth was normal to the loading direction. However, for the (0)8 CT specimens, the crack grew mostly parallel to the loading and the fiber direction. The unusual fatigue behavior of the (0)8 CT specimens is attributed to the specimen geometry and the associated high tensile bending stresses perpendicular to the fiber direction.

Description: A previously developed formulation for modeling the thermomechanical behavior of chemically decomposing, polymeric materials is verified by simulating the response of carbon phenolic specimens during two high temperature tests: restrained thermal growth and free thermal expansion. Plane strain and plane stress models are used to simulate the specimen response, respectively. In addition, the influence of the poroelasticity constants upon the specimen response is examined through a series of parametric studies.

Description: XD synthesis, powder blending, and hot pressing techniques have been utilized to produce NiAl composites containing 4, 7.5, 15, and 25 vol pct alumina whiskers and hybrid composite materials with 15 vol pct Al2O3 + 10 or 20 vol pct, nominally 1 micron TiB2 particles. The resistance to slow plastic flow was determined at 1200 and 1300 K via compression testing in air under constant velocity conditions. The stress-strain behavior of the intermetallic composites depended on the fraction of second phases where the 4 and 7.5 percent Al2O3 materials flowed at a nominally constant stress after about 2 percent deformation, while all the other composites exhibited diffuse yielding followed by strain softening. The flow stress-strain rate properties increased with volume fraction of Al2O3 whiskers except for the 4 and 7.5 percent materials, which had similar strengths. The hybrid composite NiAl + 15Al2O3 + 10TiB2 was substantially stronger than the materials simply containing alumina. Deformation in these composites can be described by the Kelly and Street model of creep in perfectly bonded, rigid, discontinuous fiber materials.

Description: An infrared thermographic system was used to measure the surface temperature profile of composite materials under ballistic impact. The heat deposited was calculated based on the temperature profiles. The extent of damage induced in the materials was determined qualitatively from the measured data. The relative contribution of frictional heat to total energy absorption was evaluated, and the effect of the shape of the projectile on the extent of damage and temperature distribution in the composites was examined. The results show that graphite and polyethylene composite are more effective than Kevlar composite in dissipating heat during the ballistic impact penetration process due to their higher thermal conductivity.

Description: The effect of heat treatment on material properties of Sic/Ti-15-3 was measured by vibration tests. Heat treatment changes the microstructure, which stiffens the matrix and reduces its damping capacity. Test results illustrate how the changes in matrix material affect the stiffness and damping properties of the composite. Damping was found to be more sensitive than stiffness to microstructural changes in the matrix. Effects of heat treatment temperature and exposure time are presented.

Description: The effective fatigue crack driving force and crack opening profiles were determined analytically for fatigue tested unidirectional composite specimens exhibiting fiber bridging. The crack closure pressure due to bridging was modeled using two approaches: the fiber pressure model and the shear lag model. For both closure models, the Bueckner weight function method and the finite element method were used to calculate crack opening displacements and the crack driving force. The predicted near crack tip opening profile agreed well with the experimentally measured profiles for single edge notch SCS-6/Ti-15-3 metal matrix composite specimens. The numerically determined effective crack driving force, Delta K(eff), was calculated using both models to correlate the measure crack growth rate in the composite. The calculated Delta K(eff) from both models accounted for the crack bridging by showing a good agreement between the measured fatigue crack growth rates of the bridged composite and that of unreinforced, unbridged titanium matrix alloy specimens.

Description: The requirements for high specific strength refractory materials of prospective military, civil, and space propulsion systems are presently addressed in the context of emerging capabilities in metal- and intermetallic-matrix composites. The candidate systems encompass composite matrix compositions of superalloy, Nb-Zr refractory alloy, Cu-base, and Ti-base alloy types, as well as such intermetallics as TiAl, Ti3Al, NiAl, and MoSi2. The brittleness of intermetallic matrices remains a major consideration, as does their general difficulty of fabrication.

Description: A development status evaluation is presented for the reaction-bonded SiC- and Si3N4-matrix types of fiber-reinforced ceramic-matrix composite (FRCMC). A variety of reaction-bonding methods are being pursued for FRCMC fabrication: CVI, CVD, directed metal oxidation, and self-propagating high-temperature synthesis. Due to their high specific modulus and strength, toughness, and fabricability, reaction-bonded FRCMC are important candidate materials for such heat-engine components as combustor liners, nozzles, and turbine and stator blading. The improvement of long-term oxidative stability in these composites is a major goal of current research.

Description: The Knudsen cell technique and coupons of carbon coated Si3N4 and BN coated SiC were employed to study the possible reactions at the SiC/C/Si3N4 and SiC/BN/SiC interface. Carbon reacts with Si3N4 to form gaseous N2 and solid SiC. Solid SiC acts as a physical barrier to the reaction, which prevents the generation of high N2 pressure predicted from thermochemical calculations. Thus, deleterious effects of the reaction to the composite are limited. Limited reactions between BN and C-rich SiC was observed. However, the vapor pressure was so low that it is not likely to cause any interfacial instability. The predicted formation of a BN-C solid solution was not observed.

Description: The potential of using interface layer to reduce thermal stresses in the matrix of composites with a mismatch in coefficients of thermal expansion of fiber and matrix has been investigated. It was found that compliant layers, with properties of readily available materials, do not have the potential to reduce thermal stresses significantly. However, interface layers with high coefficient of thermal expansion can compensate for the mismatch and reduce thermal stresses in the matrix significantly.

Description: The flexural strength and fracture toughness of 30 vol pct SiC whisker-reinforced Si3N4 material were determined as a function of temperature from 25 to 1400 C in an air environment. It was found that both strength and toughness of the composite material were almost the same as those of the monolithic counterpart. The room-temperature strength was retained up to 1100 C; however, appreciable strength degradation started at 1200 C and reached a maximum at 1400 C due to stable crack growth. In contrast, the fracture toughness of the two materials was independent of temperature with an average value of 5.66 MPa sq rt m. It was also observed that the composite material exhibited no rising R-curve behavior at room temperature, as was the case for the monolithic material. These results indicate that SiC whisker addition to the Si3N4 matrix did not provide any favorable effects on strength, toughness and R-curve behavior.

Description: The room-temperature mechanical properties of SiC fiber reinforced reaction bonded silicon nitride composites were measured after 100 hrs exposure at temperatures to 1400 C in nitrogen and oxygen environments. The composites consisted of approx. 30 vol percent uniaxially aligned 142 micron diameter SiC fibers in a reaction bonded Si3N4 matrix. The results indicate that composites heat treated in a nitrogen environment at temperatures to 1400 C showed deformation and fracture behavior equivalent to that of the as-fabricated composites. Also, the composites heat treated in an oxidizing environment beyond 400 C yielded significantly lower tensile strength values. Specifically in the temperature range from 600 to 1000 C, composites retained approx. 40 percent of their as-fabricated strength, and those heat treated in the temperatures from 1200 to 1400 C retained 70 percent. Nonetheless, for all oxygen heat treatment conditions, composite specimens displayed strain capability beyond the matrix fracture stress; a typical behavior of a tough composite.

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: Data from a sonic fatigue test of a blade-stiffened carbon/carbon panel is analyzed to determine the progression of damage to failure. The reduction in stiffness, as observed from acceleration measurements taken during the test, is correlated with the physical damage. Damage was measured through visual inspection, thermographic measurements, and through the novel use of vibration data collected using a scanning laser vibrometer.

Description: An overview of NASA LaRC's research on thermal residual stresses and their effect on the dimensional stability of carbon fiber reinforced polymer-matrix composites is presented. The data show that thermal residual stresses can induce damage in polymer matrix composites and significantly affect the dimensional stability of these composites by causing permanent residual strains and changes in CTE. The magnitude of these stresses is primarily controlled by the laminate configuration and the applied temperature change. The damage caused by thermal residual stresses initiates at the fiber/matrix interface and micromechanics level analyses are needed to accurately predict it. An increased understanding of fiber/matrix interface interactions appears to be the best approach for improving a composite's resistance to thermally induced damage.

Description: Fiber push-out tests have been performed on a ceramic matrix composite consisting of carborundum-sintered SiC fibers, with a BN coating, embedded in a reaction-bonded SiC matrix. Analysis of the push-out data, utilizing the most complete theory presently available, shows that one of the fiber/coating/matrix interfaces has a low fracture energy (one-tenth that of the fiber) and a moderate sliding resistance of about 8 MPa. The debonded sliding interface shows some continuous but minor abrasion, which appears to increase the sliding resistance, but overall the system exhibits very clean smooth sliding. The tensile response of a full-scale composite is then modeled using data obtained here and known fiber strengths to demonstrate the good composite behavior predicted for this material.

Description: The application of composite materials to aircraft construction has provided the designer with increased flexibility. The orientation of plies can be tailored to provide additional aeroelastic performance unobtainable with an isotropic material. A tailored laminate is made up of plies of several orientations, usually 0 deg, 45 deg, -45 deg, and 90 deg. The direction of the 0 deg plies, does not need to be oriented with the leading edge, but can be varied to obtain a wide variety of structural properties. Also, the number of plies of each orientation varies from one zone to another on the planform. Thus, a thick laminate with mainly 0 deg plies may form the root zone, and a thinner laminate with mainly +45 deg plies may form the leading edge zone. Tailored laminates were designed using complicated optimization programs. Unfortunately, many tailored designs must be modified before they are manufactured. The modification adds weight and decreases performance. One type of modification is ply interleaving, an overlap of plies between zones on the laminate. These interleaves are added to ensure that zones with varying ply percentages can be connected without loss of strength. In this paper, the constraints needed to eliminate interleaves in the laminate optimization process will be described and implemented in a structural optimization problem. The method used has the potential to prevent changes to composite laminates late in the design cycle.

Description: Linearly elastic fiber reinforced composite discs and laminates in plane stress with variable local orientation and concentration of one or two fiber fields embedded in the matrix material, are considered. The thicknesses and the domain of the discs or laminates are assumed to be given, together with prescribed boundary conditions and in-plane loading along the edge. The problem under study consists in determining throughout the structural domain the optimum orientations and concentrations of the fiber fields in such a way as to maximize the integral stiffness of the composite disc or laminate under the seven loading. Minimization of the integral stiffness can also be performed. The optimization is performed subject to a prescribed bound on the total cost or weight of the composite that for given unit cost factors or specific weights determines the amounts of fiber and matrix materials in the structure. Examples are presented.

Description: Finite element algorithms have been developed to analyze linear anisotropic viscoelastic plates, with or without holes, subjected to mechanical (bending, tension), temperature, and hygrothermal loadings. The analysis is based on Laplace transforms rather than direct time integrations in order to improve the accuracy of the results and save on extensive computational time and storage. The time dependent displacement fields in the transverse direction for the cross ply and angle ply laminates are calculated and the stacking sequence effects of the laminates are discussed in detail. Creep responses for the plates with or without a circular hole are also studied. The numerical results compare favorably with analytical solutions, i.e. within 1.8 percent for bending and 10(exp -3) 3 percent for tension. The tension results of the present method are compared with those using the direct time integration scheme.

Description: The production of a fiberglass/metal composite material suitable for building habitats and manufacturing facilities was the project for Clemson. The concept and development of the knowledge necessary to produce glass fibers originated in the spring semester. During the summer, while at Johnson Space Center, fiberglass from a rock composition similar to ones found at the Apollo 16 site on the moon was successfully produced. The project this year was a continuation of last year's studies. We addressed the following problems which emerged as the work progressed: (1) Methods for coating the fibers with a metal were explored. We manufactured composites in two stages: Glass fibers without any coating on them; and fibers coated with metals as they were made. This proved to be a difficult process. Future activities include using a chemical vapor deposition process on fibers which have been made. (2) A glass furnace was developed which relies primarily on solar energy for melting the glass. The temperature of the melted glass is maintained by electrical means. The design is for 250 kg of glass per day. An electrical engineering student developed a scheme for controlling the melting and manufacturing process from the earth. This was done to minimize the human risk. Graphite refractories are relied on to contain the melt. (3) The glass composition chosen for the project is a relatively pure anorthite which is available in the highland regions of the lunar surface. A major problems with this material is that it melts at a comparatively high temperature. This problem will be solved by using graphite refractory materials for the furnace. The advantage of this glass composition is that it is very stable and does not tend to crystallize. (4) We have also refined the experimental furnace and fiber making machinery which we will be using at Johnson Space Center this summer. We believe that we will be able to draw and coat glass fibers in a vacuum for use in composites. We intend to make and test the mechanical properties of these composites.

Description: Recent investigations of space construction techniques have explored the used of composite materials in the construction of space stations and platforms. These composites offer superior strength to weight ratio and are thermally stable. For example, a composite material being considered is laminates of graphite fibers in an epoxy matrix. The overall effective elastic constants of such a medium can be calculated from fiber and matrix properties by using an effective modulus theory as shown in Datta, el. al. The investigation of propagation and scattering of elastic waves in composite materials is necessary in order to develop an ability to characterize cracks and predict the reliability of composite structures. The objective of this investigation is the characterization of a surface breaking crack by ultrasonic techniques. In particular, the use of Lamb waves for this purpose is studied here. The Lamb waves travel through the plate, encountering a crack, and scatter. Of interest is the modeling of the scattered wave in terms of the Lamb wave modes. The direct problem of propagation and scattering of Lamb waves by a surface breaking crack has been analyzed. This would permit an experimentalist to characterize the crack by comparing the measured response to the analytical model. The plate is assumed to be infinite in the x and y directions with a constant thickness in the z direction. The top and bottom surfaces are traction free. Solving the governing wave equations and using the stress-free boundary conditions results in the dispersion equation. This equation yields the guided modes in the homogeneous plate. The theoretical model is a hybrid method that combines analytical and finite elements techniques to describe the scattered displacements. A finite region containing the defects is discretized by finite elements. Outside the local region, the far field solution is expressed as a Fourier summation of the guided modes obtained from the dispersion equation. Continuity of tractions and displacements at the boundaries of the two regions provides the necessary equations to determine the expansion coefficients and the nodal displacements. In the hybrid method used here these defects can be of arbitrary shapes as well as inclusions of different materials.

Description: The subject of this paper is the buckling of laminated plates, with a preexisting delamination, subjected to in-plane loading. Each laminate is modelled as an orthotropic Mindlin plate. The analysis is carried out by a combination of the finite element and asymptotic expansion methods. By applying the finite element method, plates with general delamination regions can be studied. The asymptotic expansion method reduces the number of unknown variables of the eigenvalue equation to that of the equation for a single Kirchhoff plate. Numerical results are presented for several examples. The effects of the shape, size, and position of the delamination on the buckling load are studied through these examples.

Description: An incremental, nonlinear, finite element program capable of tracing the damage that occurs in a notched laminated composite, before ultimate failure takes place, is described. Computer predictions for the ultimate failure load and failure modes are compared to experimental results for two laminates containing holes and loaded in uniaxial tension. The comparison is quite favorable.

Description: The time-to-failure of a single fiber is modeled as a functional of the fiber load history and reasonable forms for this functional are proposed. Earlier models by Daniels and Coleman are shown to be special cases of the proposed model and apparent disparities in their behavior are discussed. Techniques are presented for determining analytically the asymptotic distributions of the tensile strength and time-to-failure for bundles of a large number of fibers. For smaller bundles, exact results are far too cumbersome to be of use so that efficient Monte Carlo simulation procedures are proposed.

Description: Residual stresses in composites are induced during fabrication and by environmental exposure. The theory formulated can describe the shrinkage commonly observed after a thermal expansion test. Comparison between the analysis and experimental data for laminates of various material systems indicates that the residual stress-free temperature can be lower than the curing temperature, depending on the curing process. Effects of residual stresses on ply failure including the acoustic emission characteristics are discussed.

Description: A theory of plate deformation is derived which accounts for the effects of transverse shear deformation, transverse normal strain, and a nonlinear distribution of the in-plane displacements with respect to the thickness coordinate. The theory is compared with lower order plate theories through application to a particular problem involving a plate acted upon by a sinusoidal surface pressure. Comparison is also made with exact elasticity solution of this problem. It is found that when the ratio of the characteristic length of the load pattern to the plate thickness is of the order of unity, lower order theories are inadequate and the present high order theory is required to give meaningful results. Results are given for the bending of symmetric cross-ply and angle-ply laminates. Comparison with exact elasticity solutions indicates that the present plate theory is sufficiently accurate for predicting the behavior of thick laminates.

Description: Results of an assessment of the public risk associated with the release of carbon fibers from crash-fire accidents of civil aircraft having carbon composite structures are presented. The overall national impact is shown to be extremely low in 1993. Personal injury is found to be extremely unlikely. Based on these findings, the risk of electrical failure from carbon fibers should not prevent the exploitation of composites in aircraft, and additional protection of aircraft avionics to guard aginst carbon fibers is unnecessary.

Description: A fatigue analysis technique developed to predict damage growth in notched laminates is described. Features of the analysis include: criteria to relate matrix failure to cyclic stresses in and between plies; correlation of delamination growth with strain-release rate; and in-plane shear modulus change is related to cyclic shear stresses. A simplified finite element model is used to determine stresses in laminates that contain matrix damage. Failure criteria are integrated with the finite element model to form the fatigue analysis.

Description: The damage tolerance of composites was investigated. Results show that severe degradation in material strength may occur due to impact damage and that reduced strain allowables should be considered to compensate for possible impact damage. The mechanisms of failure involved in impact so that local damage will be reduced and arrest of propagating fracture initiated at impact locations are examined. Compression strength reductions for damage due to impact by a 1.27 cm diameter spherical projectile in thick laminates representative of wing skin panels are presented. Also discussed are the results of concepts recently evaluated to improve damage tolerance. These concepts range from improvements at the materials level to advanced structural configurations designed to arrest or limit the growth of propagating fractures. The results indicate that substantial improvements in the damage tolerance of graphite-epoxy composite structures can be achieved through the proper combination of materials and structural design.

Description: Progress in the development of verified design technology for generic advanced-composite structural components loaded in compression is reported. Generic structural configurations material systems and load ranges of interest for a given application were investigated using structural procedures, structural analysis procedures, and laboratory testing of structural specimens. Both flat and curved composite compression panels that are designed either to be buckling resistant or to have postbuckling strength depending on the expected application of the panels were considered.

Description: The degree of notch sensitivity of composites in compression and whether their failures can be predicted over a wide range of plate and hole sizes. The notch sensitivity of composites is investigated by comparing actual failure loads of laminates with circular holes, with the extreme failure that would be expected from an ideal notch insensitive material and from an ideal notch sensitive material. The predictability question is addressed by applying the point stress failure criterion to a wide range of plate widths and hole sizes and comparing with available experimental data. The severity of impact is explored by comparing strength reductions resulting from impact with those resulting from comparable size circular holes. Finally, comparison is made of the differences to be expected from the effects of cracks and circular holes on failure strength.

Description: Out-of-plane tensile tests of a woven fabric carbon-carbon composite were performed in a scanning electron microscope equipped with a tensile stage and a videotape recording system. The composite was prepared from T-300 8-harness satin graphite fabric and a phenolic resin. The (0/90/0/90/0 sub 1/2) sub 2 laminate, with a Theta describing the orientation of the warp fibers of the fabric, was cured at 160 C and pyrolized at 871 C. This was followed by four cycles of resin impregnation, curing, and pyrolysis. A micrograph of the cross section of the composite is presented. Inspection of the specimen fracture surface revealed that the filaments had no residual matrix bonded to them. Further inspection revealed that the fracture was interlaminar in nature. Failure occurred where filaments of adjacent plies had the same orientation. Thus it is postulated that improvement in transverse tensile strength of 2-D carbon-carbon depends on the improvement of the filament-matrix bond strength.

Description: Results in the measurement of slowly varying mechanical loading functions on composites using optical time domain reflectometry (OTDR) in imbedded optical fiber during both simulated manufacture and use are reviewed. First, the basic theoretical and experimental principles of the OTDR system are described. Next, the mechanical system of the composite and the imbedded fiber is analyzed. Results of measurement obtained for various loading functions applied to material specimens are then described and system limitations on spatial resolution, strain amplitude sensitivity, and frequency response are explained in terms of the range and resolution limits of the OTDR system.

Description: Research on three classes of materials that show potential for allowing significant increases in operating temperatures in gas turbine engines is discussed. Monolithic ceramics, ceramic matrix composites, and carbon-carbon composites are discussed. Sintering, hot pressing, and densification are discussed.

Description: The overall objectives of this program are to provide a more fire-resistant commercial aircraft interior and to improve the fuselage insulation barrier between the cabin interior and an exterior fuel fire. Significant secondary objectives are to reduce the smoke and toxic gas production of the materials and to meet the end item use requirements pertaining to wearability, color fastness, and aesthetic appeal. It is shown that the fuselage insulation materials must meet stringent requirements pertaining to acoustic attenuation, low density, and water repellency.

Description: Many of the flame-resistant nonmetallic materials that were developed for the Apollo and Skylab programs are discussed for commercial and military applications. Interchanges of information are taking place with the government agencies, industries, and educational institutions, which are interested in applications of fire-safe nonmetallic materials. These materials are particularly applicable to the design of aircraft, mass transit interiors, residential and public building constructions, nursing homes and hospitals, and to other fields of fire safety applications. Figures 22, 23 and 24 show the potential nonaerospace applications of flame-resistant aerospace materials are shown.

Description: The fabrication of several composite structural articles including DC-10 upper aft rudders, L-1011 vertical fins and composite biomedical appliances are discussed. Innovative composite processing methods are included.

Description: Manufacturers are developing composite versions of structural components on existing aircraft. Development involves testing of various material options before selecting one and then extensive testing to develop an adequate data base of material strength and stiffness properties. Design options are narrowed through analysis and a varied spectrum of development tests on small and large subcomponents. In parallel with this, a suitable production process including economical ply preparation and cure at high temperature and pressure is evolved, tools are designed and fabricated, and full scale components are then manufactured for ground qualification tests, flight tests, and airline service. The various tests include many that are required by the FAA for flight certification, which must precede airline service. Inspection and repair methods to insure adequate maintenance in service are also developed.

Description: The fatigue, fracture, and impact behavior of composite materials are investigated. Bolted and bonded joints are included. The solutions developed are generic in scope and are useful for a wide variety of structural applications. The analytical tools developed are used to demonstrate the damage tolerance, impact resistance, and useful fatigue life of structural composite components. Standard tests for screening improvements in materials and constituents are developed.

Description: The effect of fiber/matrix interactions on the mechanical properties of thermoplastic carbon fiber composites was determined. The experimental approach was a multi-faceted one involving the following areas: characterization of the surface of carbon fibers using X-ray photoelectron spectroscopy (XPS), secondary ion mass spectroscopy (SIMS) and scanning transmission electron microcopy (STEM); determination of the functional groups on carbon fiber surfaces using an elemental tagging scheme - derivatization; determination of the polar and dispersion contribution to the surface energy of carbon fibers by measuring wetting forces in a series of liquids having known polar and dispersion components; and study of the interaction of thermoplastic polymers with carbon surfaces by solution adsorption, STEM and fiber critical length.