In-Situ Observations of Longitudinal Compression Damage in Carbon-Epoxy Cross Ply Laminates Using Fast Synchrotron Radiation Computed Tomography

The role of longitudinal compressive failure mechanisms in notched cross-ply laminates is studied experimentally with in-situ synchrotron radiation based computed tomography. Carbon/epoxy specimens loaded monotonically in uniaxial compression exhibited a quasi-stable failure process, which was captured with computed tomography scans recorded continuously with a temporal resolutions of 2.4 seconds and a spatial resolution of 1.1 microns per voxel. A detailed chronology of the initiation and propagation of longitudinal matrix splitting cracks, in-plane and out-of-plane kink bands, shear-driven fiber failure, delamination, and transverse matrix cracks is provided with a focus on kink bands as the dominant failure mechanism. An automatic segmentation procedure is developed to identify the boundary surfaces of a kink band. The segmentation procedure enables 3-dimensional visualization of the kink band and conveys the orientation, inclination, and spatial variation of the kink band. The kink band inclination and length are examined using the segmented data revealing tunneling and spatial variations not apparent from studying the 2-dimensional section data

Cohesive Laws for Analyzing Through-Crack Propagation in Cross Ply Laminates

The laminate cohesive approach (LCA) is a methodology for the experimental characterization of cohesive through-the-thickness damage propagation in fiber-reinforced polymer matrix composites. LCA has several advantages over other existing approaches for cohesive law characterization, including: visual measurements of crack length are not required, structural effects are accounted for, and LCA can be applied when the specimen is too small to achieve steady-state fracture. In this work, the applicability of this method is investigated for two material systems: IM7/8552, a conventional prepreg, and AS4/VRM34, a non-crimp fabric cured using an out-of-autoclave process. The compact tension specimen configuration is used to propagate stable Mode I damage. Trilinear cohesive laws are characterized using the fracture toughness and the notch tip opening displacement. Test results are compared for the IM7/8552 specimens with notches machined by waterjet and by wire slurry saw. It is shown that the test results are nearly identical for both notch tip preparations methods, indicating that significant specimen preparation time and cost savings can be realized by using the waterjet to notch the specimen instead of the wire slurry saw. The accuracy of the cohesive laws characterized herein are assessed by reproducing the structural response of the test specimens using computational methods. The applicability of the characterization procedure for inferring lamina fracture toughness is also discussed

Test and analysis of stitched composite structures to assess damage containment capability

Integrally stitched composite technology shows promise in enhancing structural integrity of next-generation aircraft structures. The most recent generation of integrally stitched out-of-autoclave manufacturing is the Pultruded Rod Stitched Efficient Unitized Structure (PRSEUS) concept. While the PRSEUS concept has been shown to provide damage-containment capability for composite structures while reducing overall structural weight, the mechanisms responsible for damage containment are not well understood. The objective of this thesis is to develop and validate an analysis methodology for predicting damage initiation, progression, and containment in full-scale composite structures with stitched interfaces. The damage containment mechanisms were examined using a full-scale PRSEUS fuselage panel. Tests were performed at the FAA Full-Scale Aircraft Structural Test Evaluation and Research (FASTER) facility in a joint NASA, Boeing, Drexel, and FAA test program. The panel, with a two-bay notch severing the central stiffener, was subjected to simulated flight load conditions of combined axial tension and internal pressure. Test results showed that damage was arrested by the stitched stiffeners and was contained within the two-bay region to a load level above the anticipated flight loads. Detailed posttest examinations were conducted using non-destructive inspection techniques and destructive teardown evaluations on regions of the panel where stable damage growth occurred to identify the dominant failure mechanisms. The posttest examination results suggest that the damage containment behavior observed was a result of interaction between damage propagation in the skin and delamination of the stitched skin-stiffener interface. A global/local finite element analysis approach was developed to simulate damage progression so as to better understand the key mechanisms that enable damage containment. The two dominant damage mechanisms identified from the posttest examination were considered in the analysis: through-the-thickness crack propagation in the skin and delamination at the stiffener interface. In order to analyze the through-the-thickness crack propagation with the cohesive zone model, a refined cohesive law characterization approach was developed for multidirectional laminates using compact tension (CT) tests. Tests and analyses of geometrically scaled CT specimens demonstrated the scaling capability of the cohesive law characterization methodology. In addition, several details were addressed in order to scale progressive damage analysis techniques to the structural scale in a computationally tractable manner including global/local boundary conditions, cohesive element integration within a shell element mesh, and element size considerations. Excellent correlation between calculated and measured damage propagation and strain redistributions was achieved. Results from parametric studies suggest that modest increases in the toughness of the skin-to-stiffener interface yield significant improvements in the peak damage containment load level. This new model is the first analysis methodology capable of predicting damage containment behavior in full-scale composite structures without nonphysical manipulations. This approach represents an important step toward damage tolerance evaluation of composite structures by analysis.Ph.D., Mechanical Engineering -- Drexel University, 201

A Continuum Damage Mechanics Model to Predict Kink-Band Propagation Using Deformation Gradient Tensor Decomposition

A new model is proposed that represents the kinematics of kink-band formation and propagation within the framework of a mesoscale continuum damage mechanics (CDM) model. The model uses the recently proposed deformation gradient decomposition approach to represent a kink band as a displacement jump via a cohesive interface that is embedded in an elastic bulk material. The model is capable of representing the combination of matrix failure in the frame of a misaligned fiber and instability due to shear nonlinearity. In contrast to conventional linear or bilinear strain softening laws used in most mesoscale CDM models for longitudinal compression, the constitutive response of the proposed model includes features predicted by detailed micromechanical models. These features include: 1) the rotational kinematics of the kink band, 2) an instability when the peak load is reached, and 3) a nonzero plateau stress under large strains

Development of a Mesoscale Finite Element Constitutive Model for Fiber Kinking

A mesoscale finite element material model is proposed to analyze structures that fail by the fiber kinking damage mode. To evaluate the assumptions of the mesoscale model, the results were compared with those of a high-fidelity micromechanical model. A direct comparison between the two models shows remarkable correlation, indicating that the key features of the fiber kinking phenomenon are appropriately accounted for in the mesoscale model. The mesoscale model is applied to structural analysis cases to demonstrate the capabilities of the model. A verification study is conducted with an unnotched compression specimen and preliminary validation is demonstrated with a notched compression specimen. The results show that the model is successful at representing the kinematics of fiber kinking while at the same time highlighting the need for further verification and validation

Modeling Fiber Kinking at the Microscale and Mesoscale

A computational micromechanics (CMM) model is employed to interrogate the assumptions of a recently developed mesoscale continuum damage mechanics (CDM) model for fiber kinking. The CMM model considers an individually discretized three dimensional fiber and surrounding matrix accounting for nonlinearity in the fiber, matrix plasticity, fiber/matrix interface debonding, and geometric nonlinearity. Key parameters of the CMM model were measured through experiments. In particular, a novel experimental technique to characterize the in situ longitudinal compressive strength of carbon fibers through indentation of micropillars is presented. The CDM model is formulated on the basis of Budiansky's fiber kinking theory (FKT) with a constitutive deformation-decomposition approach to alleviate mesh size sensitivity. In contrast to conventional mesoscale CDM models that prescribe a constitutive response directly, the response of the proposed model is an outcome of material nonlinearity and large rotations of the fiber direction following FKT. Comparison of the predictions from the CMM and CDM models shows remarkable correlation in strength, post-peak residual stress, and fiber rotation, with less than 10% difference between the two models in most cases. Additional comparisons are made with several fiber kinking models proposed in the literature to highlight the efficacy of the two models. Finally, the CMM model is exercised in parametric studies to explore opportunities to improve the longitudinal compression strength of a ply through the use of nonconventional microstructures

Assessment of Damage Containment Features of a Full-Scale PRSEUS Fuselage Panel Through Test and Teardown

An area that shows promise in enhancing structural integrity of aircraft and aerospace structures is the integrally stitched composite technology. The most recent generation of this technology is the Pultruded Rod Stitched Efficient Unitized Structure (PRSEUS) concept developed by Boeing Research and Technology and the National Aeronautics and Space Administration. A joint test program on the assessment of damage containment capabilities of the PRSEUS concept for curved fuselage structures was conducted recently at the Federal Aviation Administration William J. Hughes Technical Center. The panel was subjected to axial tension, internal pressure, and combined axial tension and internal pressure load conditions up to fracture, with a through-the-thickness, two-bay notch severing the central stiffener. For the purpose of future progressive failure analysis development and verification, extensive post failure nondestructive and teardown inspections were conducted. Detailed inspections were performed directly ahead of the notch tip where stable damage progression was observed. These examinations showed: 1) extensive delaminations developed ahead of the notch tip, 2) the extent and location of damage, 3) the typical damage mechanisms observed in composites, and 4) the role of stitching and warp-knitting in the failure mechanisms. The objective of this paper is to provide a summary of results from these posttest inspections

Full-Scale Test and Analysis of a PRSEUS Fuselage Panel to Assess Damage-Containment Features

Stitched composite technology has the potential to substantially decrease structural weight through enhanced damage containment capabilities. The most recent generation of stitched composite technology, the Pultruded Rod Stitched Efficient Unitized Structure (PRSEUS) concept, has been shown to successfully arrest damage at the sub-component level through tension testing of a three stringer panel with damage in the form of a two-bay notch. In a joint effort undertaken by the National Aeronautics and Space Administration (NASA), the Federal Aviation Administration (FAA), and the Boeing Company, further studies are being conducted to characterize the damage containment features of the PRSEUS concept. A full-scale residual strength test will be performed on a fuselage panel to determine if the load capacity will meet strength, deformation, and damage tolerance requirements. A curved panel was designed, fabricated, and prepared for residual strength testing. A pre-test Finite Element Model (FEM) was developed using design allowables from previous test programs to predict test panel deformation characteristics and margins of safety. Three phases of testing with increasing damage severity include: (1) as manufactured; (2) barely visible impact damage (BVID) and visible impact damage (VID); and (3) discrete source damage (DSD) where the panel will be loaded to catastrophic failure. This paper presents the background information, test plan, and experimental procedure. This paper is the first of several future articles reporting the test preparations, results, and analysis conducted in the test program

Mode I Cohesive Law Characterization of Through-Crack Propagation in a Multidirectional Laminate

A method is proposed and assessed for the experimental characterization of through-the-thickness crack propagation in multidirectional composite laminates with a cohesive law. The fracture toughness and crack opening displacement are measured and used to determine a cohesive law. Two methods of computing fracture toughness are assessed and compared. While previously proposed cohesive characterizations based on the R-curve exhibit size effects, the proposed approach results in a cohesive law that is a material property. The compact tension specimen configuration is used to propagate damage while load and full-field displacements are recorded. These measurements are used to compute the fracture toughness and crack opening displacement from which the cohesive law is characterized. The experimental results show that a steady-state fracture toughness is not reached. However, the proposed method extrapolates to steady-state and is demonstrated capable of predicting the structural behavior of geometrically-scaled specimens

Systematic Evaluation of Candidate Blood Markers for Detecting Ovarian Cancer

Epithelial ovarian cancer is a significant cause of mortality both in the United States and worldwide, due largely to the high proportion of cases that present at a late stage, when survival is extremely poor. Early detection of epithelial ovarian cancer, and of the serous subtype in particular, is a promising strategy for saving lives. The low prevalence of ovarian cancer makes the development of an adequately sensitive and specific test based on blood markers very challenging. We evaluated the performance of a set of candidate blood markers and combinations of these markers in detecting serous ovarian cancer.We selected 14 candidate blood markers of serous ovarian cancer for which assays were available to measure their levels in serum or plasma, based on our analysis of global gene expression data and on literature searches. We evaluated the performance of these candidate markers individually and in combination by measuring them in overlapping sets of serum (or plasma) samples from women with clinically detectable ovarian cancer and women without ovarian cancer. Based on sensitivity at high specificity, we determined that 4 of the 14 candidate markers--MUC16, WFDC2, MSLN and MMP7--warrant further evaluation in precious serum specimens collected months to years prior to clinical diagnosis to assess their utility in early detection. We also reported differences in the performance of these candidate blood markers across histological types of epithelial ovarian cancer.By systematically analyzing the performance of candidate blood markers of ovarian cancer in distinguishing women with clinically apparent ovarian cancer from women without ovarian cancer, we identified a set of serum markers with adequate performance to warrant testing for their ability to identify ovarian cancer months to years prior to clinical diagnosis. We argued for the importance of sensitivity at high specificity and of magnitude of difference in marker levels between cases and controls as performance metrics and demonstrated the importance of stratifying analyses by histological type of ovarian cancer. Also, we discussed the limitations of studies (like this one) that use samples obtained from symptomatic women to assess potential utility in detection of disease months to years prior to clinical detection