Publications

Abstract not provided.

Abstract not provided.

Abstract not provided.

Interlaminar fracture is a failure mode that fiber-reinforced polymer composites (FRPC) are commonly susceptible to during loading. The strain energy release rate associated with delaminations can be the limiting factor in a laminate’s design. Standard test methods have been developed to measure the critical strain energy release rates using precracked coupons, such as the double cantilever beam (DCB). However, since the adherends in these coupons are laminates themselves, often the crack can initiate a secondary crack within one of the adherends and propagate along a secondary interface as well as the primary, precracked, interface. Deconvoluting the effects of the two cracks, a bridged ply, and multiple crack tips can turn a relatively simple test in determining a material property into a very complicated structural problem. In most cases, it is best to scrap the data collected after the crack has jumped interfaces and start with a fresh specimen. For fabric composites, this phenomenon can be quite common due to the variation in bond line thickness between plies resulting from the architecture of the fabric itself (tow size, weave architecture) as well as manufacturing flaws (voids, foreign object debris). This study aims to use the crack jumping phenomenon to learn more about the characteristics of the process zone through the insertion of designed flaws as well as design a method for evaluating the fracture properties of a toughened film adhesive in a co-cured context.

Physical aging of polymers is a thermodynamic phenomenon that occurs in the glassy regime. Upon cooling, the thermal contraction is restricted by a lack of adequate free volume within the polymer structure. This leaves the polymer in a state of thermodynamic non-equilibrium which relieves itself over long timescales. Time temperature superposition is typically used to accelerate this aging process to achieve validation of properties over the service life of the material. The shift factors determine the degree to which the material time is accelerated in an isothermal environment at elevated temperature. This is typically achieved with dynamic mechanical thermal analysis (DMTA). This method works well for neat polymers but fiber reinforced polymer composites (FRPC) have significantly higher stiffnesses and typical DMTA testing is limited to under 20 N of force. Due to the large unit cell for a fabric composite and geometrical limitations in the thickness of a ply, a higher force method would be more useful. In this study, an electrodynamic test frame was used to determine the shift factors for a glass fiber reinforced polymer (GFRP) composite which has a thermoset matrix. The goal is to determine whether the shift factors differ for different orientations of the composite. For an orthotropic material, directional dependent shift factors would increase material model complexity significantly.

Abstract not provided.

As the complexity of composite laminates rises, the use of hybrid structures and multi-directional laminates, large operating temperature ranges, the process induced residual stresses become a significant factor in the design. In order to properly model the initial stress state of a structure, a solid understanding of the stress free temperature, the temperature at which the initial crosslinks are formed, as well as the contribution of cure shrinkage, must be measured. Many in industry have moved towards using complex cure kinetics models with the assistance of commercial software packages such as COMPRO. However, in this study a simplified residual stress model using the coefficient of thermal expansion (CTE) mismatch and change in temperature from the stress free temperature are used. The limits of this simplified model can only be adequately tested using an accurate measure of the stress free temperature. Only once that is determined can the validity of the simplified model be determined. Various methods were used in this study to test for the stress free temperature and their results are used to validate each method. Two approaches were taken, both involving either cobonded carbon fiber reinforced polymer (CFRP) or glass fiber reinforced polymer (GFRP) to aluminum. The first method used a composite-aluminum plate which was allowed to warp due to the residual stress. The other involved producing a geometrical stable hybrid composite-aluminum cylinder which was then cut open to allow it to spring in. Both methods placed the specimens within an environmental chamber and tracked the residual stress induced deformation as the temperature was ramped beyond the stress free temperature. Both methods revealed a similar stress free temperature that could then be used in future cure modeling simulations.

The concept of progressive failure modeling is an ongoing concern within the composite community. A common approach is to employ a building block approach where constitutive material properties lead to lamina level predictions which then lead to laminate predictions and then up to structural predictions. There are advantages to such an approach, developments can be made within each step and the whole workflow can be updated. However, advancements made at higher length scales can be hampered by insufficient modeling at lower length scales. This can make industry wide evaluations of methodologies more complicated. For instance, significant advances have been made in recent years to strain rate independent failure theories on the lamina level. However, since the Northwestern Theory is stress dependent, for adequate use in a progressive damage model, a similarly robust constitutive model must also be employed to calculate these lamina level stresses. An improper constitutive model could easily cause a valid failure model to produce incorrect results. Also, any global strain rate applied to a multi-directional laminate will produce a spectrum of local lamina level strain rates so it is important for the constitutive law to account for strain rate dependent deformation.

Delaminations are of great concern to any fiber reinforced polymer composite (FRPC) structure. In order to develop the most efficient structure, designers may incorporate hybrid composites to either mitigate the weaknesses in one material or take advantage #of the strengths of another. When these hybrid structures are used at service temperatures outside of the cure temperature, residual stresses can develop at the dissimilar interfaces. These residual stresses impact the initial stress state at the crack tip of any flaw in the structure and govern whether microcracks, or other defects, grow into large scale delaminations. Recent experiments have shown that for certain hybrid layups which are used to determine the strain energy release rate, G, there may be significant temperature dependence on the apparent toughness. While Nairn and Yokozeki believe that this effect may solely be attributed to the release of stored strain energy in the specimen as the crack grows, others point to a change in the inherent mode mixity of the test, like in the classic interface crack between two elastic layers solution given by Suo and Hutchinson. When a crack is formed at the interface of two dissimilar materials, while the external loading, in the case of a double cantilever beam (DCB), is pure mode I, the stress field at the crack tip produces a mixed-mode failure. Perhaps a change in apparent toughness with temperature can be the result of an increase in mode mixity. This study serves to investigate whether the residual stress formed at the bimaterial interface produces a noticeable shift in the strain energy release rate-mode mixing curve.

This work is to characterize the mechanical performances of the selected composites with four different overlap lengths of 0.25 in, 0.5 in, 0,75 in and 1.0 in. The composite materials in this study were one carbon composite (AS4C/UF3662) and one glass (E-glass/UF3662) composite. They both had the same resin of UF 3362, but with different fibers of carbon AS4C and E-glass. The mechanical loading in this study was limited to the quasi-static loading of 2 mm/min, which was equivalent to 5x10^(-4) strain rate. Digital cameras were set up to record images during the mechanical testing. The full-field deformation data obtained from Digital Image Correlation (DIC) and the side view of the specimens were used to understand the different failure modes of the composites. The maximum load and the ultimate strength with consideration of the location of the failure for the different overlap lengths were compared and plotted together to understand the effect of the overlap lengths on the mechanical performance of the overlapped composites.

Abstract not provided.

Abstract not provided.

Process-induced residual stresses occur in composite structures composed of dissimilar materials. As these residual stresses could result in fracture, their consideration when designing composite parts is necessary. However, the experimental determination of residual stresses in prototype parts can be time and cost prohibitive. Alternatively, it is possible for computational tools to predict potential residual stresses. Therefore, the objectives of the presented work are to demonstrate an efficient method for simulating residual stresses in composite parts, as well as the potential value of statistical methods during analyses for which material properties are unknown. Specifically, a simplified residual stress modeling approach is implemented within Sandia National Laboratories’ SIERRA/SolidMechanics code. Concurrent with the model development, bi-material composite structures are designed and manufactured to exhibit significant residual stresses. Then, the presented modeling approach is rigorously verified and validated through simulations of the bi-material composite structures’ manufacturing processes, including a mesh convergence study, sensitivity analysis, and uncertainty quantification. The simulations’ final results show adequate agreement with the experimental measurements, indicating the validity of a simple modeling approach, as well as a necessity for the inclusion of material parameter uncertainty in the final residual stress predictions.

Abstract not provided.

Abstract not provided.

Abstract not provided.

Experiments were performed to characterize the mechanical response of a 15 pcf flexible polyurethane foam to large deformation at different strain rates and temperatures. Results from these experiments indicated that at room temperature, flexible polyurethane foams exhibit significant nonlinear elastic deformation and nearly return to their original undeformed shape when unloaded. However, when these foams are cooled to temperatures below their glass transition temperature of approximately -35 o C, they behave like rigid polyurethane foams and exhibit significant permanent deformation when compressed. Thus, a new model which captures this dramatic change in behavior with temperature was developed and implemented into SIERRA with the name Flex_Foam to describe the mechanical response of both flexible and rigid foams to large deformation at a variety of temperatures and strain rates. This report includes a description of recent experiments. Next, development of the Flex Foam model for flexible polyurethane and other flexible foams is described. Selection of material parameters are discussed and finite element simulations with the new Flex Foam model are compared with experimental results to show behavior that can be captured with this new model.

Hybrid composites allow designers to develop efficient structures, which strategically exploit a material's strengths while mitigating possible weaknesses. However, elevated temperature curing processes and exposure to thermally-extreme service environments lead to the development of residual stresses. These stresses form at the hybrid composite's bi-material interfaces, significantly impacting the stress state at the crack tip of any pre-existing flaw within the structure and affecting the probability that small defects will grow into large-scale delaminations. Therefore, in this study, a carbon fiber reinforced composite (CFRP) is co-cured with a glass fiber reinforced composite (GFRP), and the mixed-mode fracture toughness is measured across a wide temperature range (-54°C to +71°C). Upon completion of the testing, the measured results and observations are used to develop high-fidelity finite element models simulating both the formation of residual stresses throughout the composite manufacturing process, as well as the mixed-mode testing of the hybrid composite. The stress fields predicted through simulation assist in understanding the trends observed during the completed experiments. Furthermore, the modeled predictions indicate that failure to account for residual stress effects during the analysis of composite structures could lead to non-conservative structural designs and premature failure.

Multi-material composite structures develop residual stresses during the curing process due to dissimilar material properties, which eventually may lead to failure in the form of fracture, delamination, or disbonding. Experimentally determining residual stresses can be both time and cost prohibitive, whereas accurate simulated predictions of residual stresses can be cheaper and provide equivalent information during the design process. Residual stresses can be simulated through several different approaches of varying complexity. The method employed in this study assumes the majority of residual stresses are developed due the mismatch of coefficients of thermal expansion and polymer shrinkage, which is indirectly accounted for by calibrating the simulation with an experimentally determined stress free temperature. This method has shown success in predicting the residual stress states across different material combinations and structures in previous studies. Simply using single, or nominal, inputs to the simulation may provide a reasonable prediction, but will be unable to provide any confidence when failure could occur. Therefore, one must consider the natural stochastic behavior of the materials and geometry through an uncertainty quantification study. However, a limitation in performing uncertainty quantification studies for more complex models exists due to the large number of material and geometry parameters that need to be considered. The results from a previously conducted survey of sensitivity analysis methods were leveraged to reduce the number of parameters considered during an uncertainty quantification study, as well as decrease the computational cost in determining the sensitive parameters. This allowed the application of uncertainty quantification methods to validate more complex multi-material structures against experimental results. The structure that will be considered is a multi-material split ring comprised of three layers: Aluminum, glass fiber composite, and carbon fiber composite.

Process-induced residual stresses occur in composite structures composed of dissimilar materials. As these residual stresses could result in fracture, their consideration when designing composite parts is necessary. However, the experimental determination of residual stresses in prototype parts can be time and cost prohibitive. Alternatively, it is possible for computational tools to predict potential residual stresses. Therefore, a process modeling methodology was developed and implemented into Sandia National Laboratories' SIERRA/Solid Mechanics code. This method requires the specification of many model parameters to form accurate predictions. These parameters, which are related to the mechanical and thermal behaviors of the modeled composite material, can be determined experimentally, but at a potentially prohibitive cost. Furthermore, depending upon a composite part's specific geometric and manufacturing process details, it is possible that certain model parameters may have an insignificant effect on the simulated prediction. Therefore, to streamline the material characterization process, formal parameter sensitivity studies can be applied to determine which of the required input parameters are truly relevant to the simulated prediction. Then, only those model parameters found to be critical will require rigorous experimental characterization. Numerous sensitivity analysis methods exist in the literature, each offering specific strengths and weaknesses. Therefore, the objective of this study is to compare the performance of several accepted sensitivity analysis methods during the simulation of a bi-material composite strip's manufacturing process. The examined sensitivity analysis methods include both simple techniques, such Monte Carlo and Latin Hypercube sampling, as well as more sophisticated approaches, such as the determination of Sobol indices via a polynomial chaos expansion or a Gaussian process. The relative computational cost and critical parameter list are assessed for each of the examined methods and conclusions are drawn regarding the ideal sensitivity analysis approach for future residual stress investigations.

Fiber reinforced polymer composites are frequently used in hybrid structures where they are co-cured or co-bonded to dissimilar materials. For autoclave cured composites, this interface typically forms at an elevated temperature that can be quite different from the part’s service temperature. As a result, matrix shrinkage and CTE mismatch can produce significant residual stresses at this bi-material interface. This study shows that the measured critical strain energy release rate, Gc, can be quite sensitive to the residual stress state of this interface. If designers do not properly account for the effect of these process induced stresses, there is danger of a nonconservative design. Tests including double cantilever beam (DCB) and end notched flexure (ENF) were conducted on a co-cured GFRP-CFRP composite panel across a wide range of temperatures. These results are compared to tests performed on monolithic GFRP and CFRP panels.

Fiber reinforced polymer composites are frequently used in hybrid structures where they are co-cured or co-bonded to dissimilar materials. For autoclave cured composites, this interface typically forms at an elevated temperature that can be quite different from the part’s service temperature. As a result, matrix shrinkage and CTE mismatch can produce significant residual stresses at this bi-material interface. This study shows that the measured critical strain energy release rate, Gc, can be quite sensitive to the residual stress state of this interface. If designers do not properly account for the effect of these process induced stresses, there is danger of a nonconservative design. Tests including double cantilever beam (DCB) and end notched flexure (ENF) were conducted on a co-cured GFRP-CFRP composite panel across a wide range of temperatures. These results are compared to tests performed on monolithic GFRP and CFRP panels.

The strain-rate-dependent matrix-dominated failure of multiple fiber-reinforced polymer matrix composite systems was evaluated over the range of quasi-static (10−4) to dynamic (103 s−1) strain rates using available experimental data from literature. The strain rate dependent parameter, m, was found to relate strain-rate dependent lamina behavior linearly to the logarithm of strain rate. The parameter was characterized for a class of laminates comprised of epoxy-based matrices and either carbon or glass fibers, and determined to be approximately 0.055 regardless of fiber type. The strain-rate-dependent Northwestern Failure Criteria were found to fit all data in superior agreement to classical approaches across all strain rates evaluated based on solely lamina-level properties. It was determined that using the determined m value with the Northwestern Failure Criteria provided an accurate prediction of material behavior regardless of fiber type for the identified material class, which significantly reduces the material characterization testing required for the typical building block approach used by industry for computational analysis validation.

The failure progression of a fiber-reinforced toughened-matrix composite (IM7/8552) was experimentally characterized at quasi-static (10−4 s−1) strain rate using crossply and quasi-isotropic laminate specimens. A progressive failure framework was proposed to benchmark the initiation and progression of damage within composite laminates based on the matrix-dominated failure modes. The Northwestern Failure Theory (NU Theory) was used to provide a set of physics-based failure criteria for predicting the matrix-dominated failure of embedded plies using the lamina-based transverse tension, transverse compression, and shear failure strengths. The NU Theory was used to predict the first-ply-failure (FPF) of embedded plies in [0/904]s and [02/452/−452/902]s laminates for the embedded 90° and 45° plies. The Northwestern Criteria were found to provide superior prediction of the matrix-dominated embedded ply failure for all evaluated cases compared to the classical approaches. The results indicate the potential to use the Northwestern Criteria to provide the predictive baseline for damage propagation in composite laminates based on experimentally identified damage response on a length scale-relevant basis.

Process induced residual stresses commonly occur in composite structures composed of dissimilar materials. These residual stresses form due to differences in the composite materials coefficients of thermal expansion as well as the shrinkage upon cure exhibited by most thermoset polymer matrix materials. Depending upon the specific geometric details of the composite structure and the materials curing parameters, it is possible that these residual stresses can result in interlaminar delamination and fracture within the composite as well as plastic deformation in the structures metallic materials. It is important to consider potential residual stresses when designing composite parts and their manufacturing processes. However, the experimental determination of residual stresses in prototype parts can be prohibitive, both in terms of financial and temporal costs. As an alternative to physical measurement, it is possible for computational tools to be used to quantify potential residual stresses in composite prototype parts. A simplified method for simulating residual stresses was previously validated with two simple bi-material structures. Continuing on, the objective of this study is to further validate the simplified method for simulating residual stresses for bi-material split rings of different composites and layup variations. The validation process uses uncertainty quantification to develop a distribution of possible simulated residual stress states that are compared to experimentally measured residual stress states of fabricated structures similar to those simulated. The results of the comparisons indicate that the proposed finite element modeling approach is capable of accurately simulating the formation of residual stresses in composite structures and a temperature independent material model is adequate within the composites glassy region.