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This report documents the research activities for space suit survivability material enhancements. Self-sealing mechanisms for the pressure envelope were addressed, as were improvements in materials for cut, puncture, and hypervelocity impact resistance.

The mechanical properties of textile composites are dictated by the arrangement of yarns contained with the material. Thus to develop a comprehensive understanding of the performance of these materials, it is necessary to develop a geometrical model of the fabric structure. This task is quite complex, as the fabric is made form highly flexible yarn systems which experience a certain degree of compressability. Furthermore there are tremendous forces acting on the fabric during densification typically resulting in yarn displacement and misorientation. The objective of this work is to develop a methodology for characterizing the geometry of yarns within a fabric structure including experimental techniques for evaluating these models. Furthermore, some applications of these geometric results to mechanical prediction models are demonstrated. Although more costly than its predecessors, the present analysis is based on the detailed architecture developed by one of the authors and his colleagues and accounts for many of the geometric complexities that other analyses ignore.

A glossary was developed to define textile terminology applicable to the manufacture of composites. Terms describing fabric structure were illustrated for clarity. Descriptive terms for defects from both textile and composites industry were included.

A probabilistic model utilizing random material characteristics to predict damage evolution in textile laminates is presented. Model is based on a division of each ply into two sublaminas consisting of cells. The probability of cell failure is calculated using stochastic function theory and maximal strain failure criterion. Three modes of failure, i.e. fiber breakage, matrix failure in transverse direction, as well as matrix or interface shear cracking, are taken into account. Computed failure probabilities are utilized in reducing cell stiffness based on the mesovolume concept. A numerical algorithm is developed predicting the damage evolution and deformation history of textile laminates. Effect of scatter of fiber orientation on cell properties is discussed. Weave influence on damage accumulation is illustrated with the help of an example of a Kevlar/epoxy laminate.

One of the greatest difficulties in developing detailed models of the mechanical response of textile reinforced composites is an accurate model of the reinforcing elements. In the case of elastic property prediction, the variation of fiber position may not have a critical role in performance. However, when considering highly localized stress events, such as those associated with cracks and holes, the exact position of the reinforcement probably dominates the failure mode. Models were developed for idealized reinforcements which provide an insight into the local behavior. However, even casual observations of micrographical images reveals that the actual material deviates strongly from the idealized models. Some of the deviations and causes are presented for triaxially braided and three dimensionally woven textile composites. The necessary modeling steps to accommodate these variations are presented with some examples. Some of the ramifications of not accounting for these discrepencies are also addressed.

Aircraft wings and rotor-blades are subject to undesirable bending and twisting excursions that arise from unsteady aerodynamic forces during high speed flight, abrupt maneuvers, or hard landings. These bending excursions can range in amplitude from wing-tip flutter to failure. A continuous-filament construction 'smart' laminated composite box-beam spar is described which corrects itself when subject to undesirable bending excursions or flutter. The load-bearing spar is constructed so that any tendency for the wing or rotor-blade to bend from its normal position is met by opposite twisting of the spar to restore the wing to its normal position. Experimental and theoretical characterization of these spars was made to evaluate the torsion-flexure coupling associated with symmetric lay-ups. The materials used were uniweave AS-4 graphite and a matrix comprised of Shell 8132 resin and U-40 hardener. Experimental tests were conducted on five spars to determine spar twist and bend as a function of load for 0, 17, 30, 45 and 60 deg fiber angle lay-ups. Symmetric fiber lay-ups do exhibit torsion-flexure couplings. Predictions of the twist and bend versus load were made for different fiber orientations in laminated spars using a spline function structural analysis. The analytical results were compared with experimental results for validation. Excellent correlation between experimental and analytical values was found.

The objective of this study was to examine the effect of the unit cell architecture on the mechanical response of textile reinforced composite materials. Specifically, the study investigated the effect of unit cell size on the tensile properties of 2D triaxially braided graphite epoxy laminates. The figures contained in this paper reflect the presentation given at the conference. They may be divided into four sections: (1) a short definition of the material system tested; (2) a statement of the problem and a review of the experimental results; (3) experimental results consist of a Moire interferometry study of the strain distribution in the material plus modulus and strength measurements; and (4) a short summary and a description of future work will close the paper.

This paper investigates the unnotched tensile properties of two-dimensional (2D) triaxial braid-reinforced composites both experimentally and analytically. The materials are graphite fibers in an epoxy matrix. Three different reinforcing fiber architectures were considered. There were considerable differences in the observed elastic constants from different size strain gage and extensometer readings. Larger strain gages gave more consistent results and correlated better with the extensometer readings. Experimental strains correlated reasonably well with analytical predictions in the longitudinal, 0 deg, fiber direction but not in the transverse direction. Tensile strength results were not always predictable even in reinforcing directions. Minor changes in braid geometry led to disproportionate strength variations. The unit cell structure of the triaxial braid was discussed with the assistance of computer analysis of the microgeometry. Photomicrographs of braid geometry were used to improve upon the computer graphics representations of unit cells. These unit cells were used to predict the elastic moduli with various degrees of sophistication. The simple and the complex analyses were generally in agreement, but none adequately matched the experimental results for all the braids.

The unnotched tensile properties of 2-D triaxial braid reinforced composites from both an experimental and an analytical viewpoint are studied. The materials are graphite fibers in an epoxy matrix. Three different reinforcing fiber architectures were considered. Specimens were cut from resin transfer molded (RTM) composite panels made from each braid. There were considerable differences in the observed elastic constants from different size strain gage and extensometer reading. Larger strain gages gave more consistent results and correlated better with the extensometer reading. Experimental strains correlated reasonably well with analytical predictions in the longitudinal, 0 degrees, fiber direction but not in the transverse direction. Tensile strength results were not always predictable even in reinforcing directions. Minor changes in braid geometry led to disproportionate strength variations. The unit cell structure of the triaxial braid was discussed with the assistance of computer analysis of the microgeometry. Photomicrographs of braid geometry were used to improve upon the computer graphics representations of unit cells. These unit cells were used to predict the elastic moduli with various degrees of sophistication. The simple and the complex analyses were generally in agreement but none adequately matched the experimental results for all the braids.