Damage prediction in cross-plied curved composite laminates

Analytical and experimental work is detailed which is required to predict delamination onset and growth in a curved cross plied composite laminate subjected to static and fatigue loads. The composite used was AS4/3501/6, graphite/epoxy. Analytically, a closed form stress analysis and 2-D and 3-D finite element analyses were conducted to determine the stress distribution in an undamaged curved laminate. The finite element analysis was also used to determine values of strain energy release rate at a delamination emanating from a matrix crack in a 90 deg ply. Experimentally, transverse tensile strength and fatigue life were determined from flat 90 deg coupons. The interlaminar tensile strength and fatigue life were determined from double cantilevered beam specimens. Cross plied curved laminates were tested statically and in fatigue to give a comparison to the analytical predictions. A comparison of the fracture mechanics life prediction technique and the strength based prediction technique is given

Estimation of Delamination Crack Depth Using Passive Thermography

Passive thermography is used to monitor small increases in temperature resulting from delamination damage formation in a composite hat-stiffened panel during quasi-static loading. The heating is composed of two heat generation components. The first component is an instantaneous response due to a strain release during quasi-static loading. The second component is mechanical heating, at the interface of failure, due to fracture damage. This second component produces a transient rise in temperature that is a function of the damage depth and thermal diffusivity. The first component defines the thermal start time for the transient response. A one-dimensional thermal model is used to determine the damage depth. The results are compared to ultrasonic and X-ray CT data. The advantages and limitations of the thermal technique for damage depth detection are discussed

The use of impact force as a scale parameter for the impact response of composite laminates

The building block approach is currently used to design composite structures. With this approach, the data from coupon tests are scaled up to determine the design of a structure. Current standard impact tests and methods of relating test data to other structures are not generally understood and are often used improperly. A methodology is outlined for using impact force as a scale parameter for delamination damage for impacts of simple plates. Dynamic analyses were used to define ranges of plate parameters and impact parameters where quasi-static analyses are valid. These ranges include most low-velocity impacts where the mass of the impacter is large, and the size of the specimen is small. For large-mass impacts of moderately thick (0.35-0.70 cm) laminates, the maximum extent of delamination damage increased with increasing impact force and decreasing specimen thickness. For large-mass impact tests at a given kinetic energy, impact force and hence delamination size depends on specimen size, specimen thickness, boundary conditions, and indenter size and shape. If damage is reported in terms of impact force instead of kinetic energy, large-mass test results can be applied directly to other plates of the same thickness

Use of a New Portable Instrumented Impactor on the NASA Composite Crew Module Damage Tolerance Program

Damage tolerance performance is critical to composite structures because surface impacts at relatively low energies may result in a significant strength loss. For certification, damage tolerance criteria require aerospace vehicles to meet design loads while containing damage at critical locations. Data from standard small coupon testing are difficult to apply to larger more complex structures. Due to the complexity of predicting both the impact damage and the residual properties, damage tolerance is demonstrated primarily by testing. A portable, spring-propelled, impact device was developed which allows the impact damage response to be investigated on large specimens, full-scale components, or entire vehicles. During impact, both the force history and projectile velocity are captured. The device was successfully used to demonstrate the damage tolerance performance of the NASA Composite Crew Module. The impactor was used to impact 18 different design features at impact energies up to 35 J. Detailed examples of these results are presented, showing impact force histories, damage inspection results, and response to loading

Investigation of the Leak Response of a Carbon-Fiber Laminate Loaded in Biaxial Tension

Designers of pressurized structures have been reluctant to use composite materials because of concerns over leakage. Biaxial stress states are expected to be the worst-case loading condition for allowing leakage to occur through microcracks. To investigate the leakage behavior under in-plane biaxial loading, a cruciform composite specimen was designed that would have a relatively large test section with a uniform 1:1 biaxial loading ratio. A 7.6-cm-square test section was desired for future investigations of the leakage response as a result of impact damage. Many iterations of the cruciform specimen were evaluated using finite element analysis to reduce stress concentrations and maximize the size of the uniform biaxial strain field. The final design allowed the specimen to go to relatively high biaxial strain levels without incurring damage away from the test section. The specimen was designed and manufactured using carbon/epoxy fabric with a four-ply-thick, quasi-isotropic, central test section. Initial validation and testing were performed on a specimen without impact damage. The specimen was tested to maximum biaxial strains of approximately 4500micro epsilon without apparent damage. A leak measurement system containing a pressurized cavity was clamped to the test section and used to measure the flow rate through the specimen. The leakage behavior of the specimen was investigated for pressure differences up to 172 kP

A Finite Element Analysis for Predicting the Residual Compressive Strength of Impact-Damaged Sandwich Panels

A simple analysis method has been developed for predicting the residual compressive strength of impact-damaged sandwich panels. The method is tailored for honeycomb core-based sandwich specimens that exhibit an indentation growth failure mode under axial compressive loading, which is driven largely by the crushing behavior of the core material. The analysis method is in the form of a finite element model, where the impact-damaged facesheet is represented using shell elements and the core material is represented using spring elements, aligned in the thickness direction of the core. The nonlinear crush response of the core material used in the analysis is based on data from flatwise compression tests. A comparison with a previous analysis method and some experimental data shows good agreement with results from this new approach

Comparison of impact results for several polymeric composites over a wide range of low impact velocities

Static indentation, falling weight, and ballistic impact tests were conducted in clamped plates made of AS4/3501-6 and IM7/8551-7 prepreg tape. The transversely isotropic plates were nominally 7-mm thick. Pendulum and ballistic tests were also conducted on simply supported plates braided with Celion 12000 fibers and 3501-6 epoxy. The 20 degree braided plates were about 5-mm thick. The impactors had spherical or hemispherical shapes with a 12.7 mm diameter. Residual compression strength and damage size were measured. For a given kinetic energy, damage size was least for IM7/8551-7 and greatest for the braided material. Strengths varied inversely with damage size. For a given damage size, strength loss as a fraction of original strength was least for the braided material and greatest for AS4/3501-6 and IM7/8551-7. Strength loss for IM7/8551-7 and AS4/3501-6 was nearly equal. No significant differences were noticed between damage sizes and residual compression strengths for the static indentation, falling weight, and ballistic tests of AS4/3501-6 and IM7/8551-7. For the braided material, sizes of damage were significantly less and compression strengths were significantly more for the falling weight tests than for the ballistic tests

Out-of-plane properties

This paper summarizes three areas of research which were performed to characterize out-of-plane properties of composite materials. In the first investigation, a series of tests was run to characterize the through-the-thickness tensile strength for a variety of composites that included 2D braids, 2D and 3D weaves, and prepreg tapes. A new test method based on a curved beam was evaluated. Failures were significantly different between the 2D materials and the 3D weaves. The 2D materials delaminated between layers due to out-of-plane tensile stresses while the 3D weaves failed due to the formation of radial cracks between the surface plies caused by high circumferential stresses along the inner radius. The strength of the 2D textile composites did not increase relative to the tapes. Final failure in the 3D weaves was caused by a circumferential crack similar to the 2D materials and occurred at a lower bending moment than in other materials. The early failures in the 3D weaves were caused by radial crack formation rather than a low through-the-thickness strength. The second investigation focused on the development of a standard impact test method to measure impact damage resistance. The only impact tests that currently exist are compression after impact (CAI) tests which incorporate elements of both damage resistance and damage tolerance. A new impact test method is under development which uses a quasi-static indentation (QSI) test to directly measure damage resistance. Damage resistance is quantified in terms of the contact force to produce a unit of damage where a metric for damage may be area in C-scan, depth of residual dent , penetration, damage growth, etc. A final draft of an impact standard that uses a QSI test method will be presented to the ASTM Impact Task Group on impact. In the third investigation, the impact damage resistance behavior of a variety of textile materials was studied using the QSI test method. In this study, the force where large damage initiates was measured and the delamination size as a function of force was determined. The force to initiate large damage was significantly lower in braids and weaves. The delamination diameter - impact forace relationship was quanitfied using a damage resistance parameter, Q(*), which related delamination diameter to imapct force over a range of delamination sizes. Using this Q(*) parameter to rate the materials, the stitched uniweaves, toughened epoxy tapes, and through-the-thickness orthogonal interlock weave were the most damage resistant

Through-the-thickness tensile strength of textile composites

A series of tests was run to characterize the through-the-thickness tensile strength for a variety of composites that included 2D and 3D braids, 2D and 3D weaves, and prepreg tapes. A new test method based on a curved beam was evaluated. The through-the-thickness deformations were characterized using moire interferometry. Failures were significantly different between the 2D and 3D materials. The 2D materials delaminated between layers due to out-of-plane tensile stresses. The strength of the 2D textile composites did not increase relative to the tapes. The 3D materials failed due to the formation of radial cracks caused by high circumferential stresses along the inner radius. A circumferential crack similar to the 2D materials produced the final failure. Final failure in the 3D materials occurred at a lower bending moment than in other materials. The early failures were caused by radial crack formation rather than low through-the-thickness strength

A Model for Simulating the Response of Aluminum Honeycomb Structure to Transverse Loading

A 1-dimensional material model was developed for simulating the transverse (thickness-direction) loading and unloading response of aluminum honeycomb structure. The model was implemented as a user-defined material subroutine (UMAT) in the commercial finite element analysis code, ABAQUS(Registered TradeMark)/Standard. The UMAT has been applied to analyses for simulating quasi-static indentation tests on aluminum honeycomb-based sandwich plates. Comparison of analysis results with data from these experiments shows overall good agreement. Specifically, analyses of quasi-static indentation tests yielded accurate global specimen responses. Predicted residual indentation was also in reasonable agreement with measured values. Overall, this simple model does not involve a significant computational burden, which makes it more tractable to simulate other damage mechanisms in the same analysis