Fracture Mechanics of Metals, Composites, Welds, and Bolted Joints
Overview of Composites In certain structural applications the use of fiber composites is advantageous over metallic structures (lighter weight, and higher stiffness). Polymer matrix composite (PMC) materials with continuous high modulus graphite fibers are very effective under high-cycle fatigue loading due to the ability of fibers to transmit and disperse the high-frequency vibration loads. A well-configured PMC structure can achieve practically infinite fatigue life, carrying relatively high loads. PMC structures subjected to high cycle fatigue usually experience damage initiation by transverse tensile failures (perpendicular to applied loading direction) in the matrix. As a result, a large number of microscopic cracks appear in the matrix, parallel to the fibers. The structural response properties and resistance to damage propagation usually remain intact at the presence of a large number of microscopic transverse tensile crack [1]. At the end of fatigue life, fiber fractures occur at stress concentration sites, such as interlaminar boundaries. The resulting local delaminations indicate onset of the damage propagation and failure stages. Composite failure is not predictable with a higher reliability compared to metallic structures due to the large number of material parameters and structural elements that contribute to the composite load redistribution and load carrying capability. The cumulative uncertainty from the large number of structural parameters that are present in PMC materials is less affected by the uncertainty associated with any one material variable. As a result, PMC structures can be designed with a higher degree of reliability. Composites are also well suited for damage tolerant design by the proper selection of fiber reinforcement patterns at damage critical regions. Composite structures are better able to redistribute stresses and redirect load paths around both discrete and distributed damage zones. PMC materials are particularly effective for damage tolerance due to flexibility of the polymer matrix that allows for small local adjustments of fiber alignment to help reduce stress concentration [2]. Fiber reinforcement configurations can be designed for the purpose of containing accidental damage. Hybrid composites that use both high-modulus and intermediate modulus fibers are effective in reducing stress concentrations as well as increasing damage energy absorption capability of PMC materials. High modulus fibers are typically made from layered anisotropic graphite, whereas intermediate modulus fibers are usually made from homogeneous materials such as fiberglass or Kevlar. Page 1 of 31 FRACTURE MECANICS OF METALS, COMPOSITES, WELDS,
Probabilistic evaluation of uncertainties and risks in aerospace components
This paper summarizes a methodology developed at NASA Lewis Research Center which computationally simulates the structural, material, and load uncertainties associated with Space Shuttle Main Engine (SSME) components. The methodology was applied to evaluate the scatter in static, buckling, dynamic, fatigue, and damage behavior of the SSME turbo pump blade. Also calculated are the probability densities of typical critical blade responses, such as effective stress, natural frequency, damage initiation, most probable damage path, etc. Risk assessments were performed for different failure modes, and the effect of material degradation on the fatigue and damage behaviors of a blade were calculated using a multi-factor interaction equation. Failure probabilities for different fatigue cycles were computed and the uncertainties associated with damage initiation and damage propagation due to different load cycle were quantified. Evaluations on the effects of mistuned blades on a rotor were made; uncertainties in the excitation frequency were found to significantly amplify the blade responses of a mistuned rotor. The effects of the number of blades on a rotor were studied. The autocorrelation function of displacements and the probability density function of the first passage time for deterministic and random barriers for structures subjected to random processes also were computed. A brief discussion was included on the future direction of probabilistic structural analysis.
CODSTRAN - Composite durability structural analysis
CODSTRAN (Composite Durability STRuctural ANalysis) is an integrated computer program being developed for the prediction of defect growth and fracture of composite structures subjected to service loads and environments. CODSTRAN is briefly described herein with respect to organization, capabilities and present status. Application of CODSTRAN current capability to a flat composite laminate with a center slit which was subjected to axial tension loading predicted defect growth which is in good agreement with C-scan ultrasonic test records.