An experimental analysis of specimens taken from a thick, filament-wound composite material pressure vessel (cylinder) was performed by testing tensile coupons with various semi-elliptical surface notches. The strength of specimens with small notches was found to be notch insensitive. The strength of specimens with larger notches depended on the size of the notch. The fracture toughness of the laminate was found by applying a general fracture-toughness parameter approach. Using this value, several approaches were employed to predict failure loads. The accuracy of the approaches depended on the size of the notches. In general, the linear-elastic fracture mechanics method overpredicted the failure strength of specimens with intermediate sized notches, but predicted failure strength accurately for specimens with large notches. A strength of materials approach accurately predicted notched strength only for specimens with small notches. Notched strength was more accurately predicted for all notch sizes using an empirical approach, with the notch area used to predict failure instead of the notch depth, which was used in the linear-elastic fracture mechanics and strength of materials approaches. / M.S.

A coupled electromagnetic/heat transfer model capable of simulating microwave processing of composite materials in a cylindrical resonant cavity was developed. The two-dimensional model simulates processing of axisymmetric material loads in cylindrical resonant cavities operating in the TM₀₁₀ mode. The model consists of an electromagnetic model and a heat transfer model which are coupled by the heat generation term in the heat transfer equation. Heat generation in the process material is due to dielectric loss in the material and is related to the dielectric loss factor ofthe material, the processing frequency, and the magnitude of the electric field. The finite-element method was used to develop both the electromagnetic and heat transfer models. The electromagnetic model, based on Maxwell's equations, allows anisotropic conductivity and permittivity and accounts for resonance. A novel technique for determining resonance was developed for use in the electromagnetic model. The technique can be used to design microwave applicator/material systems. The heat transfer model allows anisotropic thermal conductivity and can be used to simulate heating by microwaves only, by convection only, or by a combination of microwaves and convection. The coupled model can account for the temperature dependence of dielectric properties. The electromagnetic and heat transfer models were verified by comparison to cases for which analytical solutions were available. The coupled model was then used to simulate microwave processing of nylon 66 and composite specimens of S-glass/polycarbonate. Microwave and convective heating were used alone and in combination to heat a thick cylinder of material. Comparisons are made between microwave, convective, and combined processes and the advantages and disadvantages of microwave processing are discussed. / M.S.

The primary objective of this study was to investigate the notch sensitivity of ARALL 2 and ARALL 3 laminates subjected to uniaxial tensile loading. An experimental program was designed to test notched 0° and 90° ARALL specimens with three different hole diameters, 0.125 in, 0.250 in, and 0.500 inches. Unnotched specimens were tested to determine the elastic properties, including the shear modulus of of the ARALL laminates. Comparison of ARALL 2 and ARALL 3 laminates has shown that ARALL 3 laminates exhibit higher strength than the corresponding ARALL 2 specimens. Based on the experimental observations, a failure mechanism has been proposed for notched ARALL laminates. The failure of 0° ARALL laminates is governed by fiber failure in the aramid/epoxy layer. Experimental results for the off-axis elastic properties are compared with the predictions from transformation equations. Finite element analysis of notched laminates was performed in order to gain a better understanding of the experimental results. A linear analysis was found to be unsuitable for predicting the complete response of ARALL laminates. A Successive Yielding Model was used for modelling the behavior of the ARALL laminates. Predictions of this Successive Yielding Model are in excellent agreement with experimental results. Finite element analysis was also used to study the end effects and for establishing the specimen geometry. / M.S.

The compression strength of dropped-ply, graphite-epoxy laminated plates for the delamination mode of failure is studied by analysis and corroborated with experiments. The nonlinear response of the test specimens is modeled by a geometrically nonlinear finite element analysis. The methodology for predicting delamination is based on a quadratic interlaminar stress criterion evaluated at a characteristic distance from the ply drop-off. The details of the complex state of stress in the region of the thickness discontinuity are studied using three-dimensional solid elements, while the uniform sections of the plate are modeled with quadrilateral shell elements. A geometrically nonlinear transition element was developed to couple the shell elements to the solid elements. The analysis was performed using the COmputational MEchanics Testbed (COMET), an advanced structural analysis software environment developed at the NASA Langley Research Center to provide a framework for research in structural analysis methods. Uniaxial compression testing of dropped-ply, graphite-epoxy laminated plates has confirmed that delamination along the interfaces above and/or below the dropped plies is a common mode of failure initiation. The compression strength of specimens exhibiting a linear response is greater than the compression strength of specimens with the same layup exhibiting geometrically nonlinear response. Experimental and analytical results also show a decrease in laminate strength with increasing number of dropped plies. For linear response there is a large decrease in compression strength with increasing number of dropped plies. For nonlinear response there is less of a reduction in compression strength with increasing number of dropped plies because the nonlinear response causes a redistribution and concentration of interlaminar stresses toward the unloaded edges of the laminate. / Ph. D.

This study looks at the feasibility of using structural optimization techniques to address the problem of designing composite fuselage frames for crashworthiness. A key feature of any optimization strategy for increasing structural crashworthiness is a progressive failure analysis. Currently, the most widely used analysis methods for progressive failure of composite structures are considered too expensive computationally for practical optimization in today's computing environment. Developing an efficient analysis method for progressive failure of composite frames is a first step in the optimization for crashworthiness. In the current work a progressive failure analysis for thin-walled open cross-section curved composite frames is developed using a Vlasov type beam theory. A curved thin-walled composite beam theory is developed and a finite element implementation of the beam theory is used for progressive failure analysis. The accuracy and limitations of this analysis method are discussed. A model for progressive failure of the composite fuselage frame is developed from an extension of the laminate progressive failure analysis of Tsai-Wu. Comparisons based on a limited amount of available experimental data are encouraging. The first major failure event is captured by the theory, and the prediction of total energy absorbed follows the trend of the experimental data. It is believed that this accuracy is sufficient for preliminary design and optimization for crashworthiness. This progressive failure analysis is then incorporated into a frame optimization for crashworthiness based on the genetic algorithm method. The optimization methodology is demonstrated analytically to obtain frame designs with substantially increased crashworthlness. Laminate stacking sequence and cross-section shape are design variables for optimization / Ph. D.

The effect of thermoreversible physical aging on the linear viscoelastic creep properties of a thermoplastic composite was investigated. Radel X/IM7, an amorphous composite material considered for use in the next generation high speed transport aircraft, was studied. The operating environment for the aircraft material will be near 188°C (370°F) with a service life in excess of 60,000 hours at temperature. Accurate predictions of the viscoelastic properties of the material are essential to insure that design strength and stiffness requirements are met for the entire service life. The effect of physical aging on the creep response was studied using momentary tensile creep tests conducted at increasing aging times following a rapid quench from above the glass transition temperature (Tg) to a sub-Tg aging temperature. As the aging time increased, the creep response of the material significantly decreased. The tensile creep compliance data for each aging time were fit to the empirical equation for the creep compliance D(t): D(t)-Dₒ<i>e</i> ^{t/tₒ)m} where Dₒ, tₒ,and m are fitting parameters determined using a nonlinear fitting program based on the Levenberg-Marquardt finite difference algorithm. The short-term creep compliance curves, obtained at various aging times, were then shifted to form a momentary master compliance curve. The double logarithmic aging shift rate μ and its dependence on sub-T_g aging temperature were determined. The aging characterization process was conducted on unidirectional specimens with 0, 90, and 45 degree fiber direction orientations. This permitted the calculation of the complete principal compliance matrix for the composite material. The effect of physical aging becomes more apparent during long-term tests when creep and aging occur simultaneously. This results in a gradual stiffening and decrease in the creep response with increased time. Predictions based solely on the Time-Temperature Superposition Principle would significantly over-predict the creep response if physical aging effects were ignored. Theoretical predictions for long-term creep compliance were made using an effective time theory and compared to long-term experimental data for each fiber orientation. Finally, experimental results of a long-term test of a 30 degree fiber angle orientation specimen were compared to theoretical predictions obtained by transforming the principal compliance matrix to the 30 degree orientation. / Ph. D.

This investigation addresses the interaction mechanisms of time dependent material behavior and cyclic damage during fatigue loading of fiber reinforced composite laminates. A new term 'damorheology' has been coined to describe such physical behavior. The lamina has been chosen as the building block and a cross ply laminate configuration was the selected test case. The chosen material system is the Radel X/T65-42 thermoplastic composite by Amoco. The fatigue performance at the lamina level is represented by the dynamic stiffness, residual strength and fatigue life of unidirectional laminates. The time dependent behavior is represented at the lamina level by a Pseudo-Analog Mechanical model. The thermo-rheological characterization procedure combines mechanical (creep) and thermal (dynamic mechanical analysis) techniques. / Ph. D.

This thesis demonstrates the use of fiber optic methods for nondestructive testing of composite materials and aluminum specimens using the acousto-ultrasound approach. A noncontact method using a hybrid interferometer is devised for measuring absolute surface acoustic wave (SAW) amplitudes. The J1..J4 spectrum analysis technique is used for calibrating the piezoelectric transducer cylinder (PZT) and JO/J2 spectrum analysis technique is used for demodulating the SAW signal from the interferometer. An extrinsic Fabry-Perot interferometric (EFPI) sensor is utilized for sensing acoustic emission, measuring speed and attenuation in aluminum and composite specimens. A broadband preamplifier is designed for amplifying signals from the EFPI sensor. Theoretical and practical minimum detectable air gap change of an EFPI sensor are calculated for the system. The directional sensitivity of the EFPI sensor to SAW is studied. / Master of Science

Three test methods were employed to characterize the response of unidirectional Boron/Aluminum metal matrix composite material under monotonic and cyclic loading conditions, namely: Iosipescu Shear, Off-Axis Tension and Compression. The characterization of the elastic and plastic response includes the elastic material properties, yielding and subsequent hardening of the unidirectional composite under different stress ratios in the material principal coordinate system. The elastic response is compared with the prediction of the transformation theory, based on the far field stress ōₓₓ, the Pagano-Halpin Model, and finite element analysis. Yield loci were generated for different stress ratios and were compared for the three different test methods, taking into account residual stresses and specimen geometry. The yield locus for in-plane shear was compared with the prediction of an analytical micromechanical model. The influence of the scatter in the experimental data on the predicted yield surface was also analyzed. Likewise the experimental material strength in tension and compression was compared with the Maximum Stress and the Tsai-Wu failure criterion. / M.S.

A finite element model based on the quasi-three dimensional displacement field of Pipes and Pagano [1] with nonlinear strain-displacement relations is developed to study the free edge problem of composite laminates. Numerical results are presented to show the difference between the results of the nonlinear and the linear analyses. It is observed that the stresses obtained in the nonlinear analysis differ from the stresses obtained in the linear analysis by 10% in most of the cases, and in some cases they differ as much as 40%. / Master of Science