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Over the past two decades significant technological advances have completely changed the way in which experimental testing is conducted in Structural Impact Dynamics applications. Probably the two most significant advances have been the advent of high speed digital video cameras and the use of Digital Image Correlation techniques to measure deformations and strains at high rates. These advances have led to significantly more accurate measurements of material and structural response under high rate loading, which has also led to advances in computational modeling techniques for Impact Dynamics. In this address we will review the past, present and what the future may hold for experimental methods in the field of Structural Impact Dynamics.

The effect of axial tow alignment within a laminate ply stack on the impact penetration threshold for a series of composite panels was evaluated; specifically, the effect of a lateral shift in alignment to induce fiber nesting. Panels were fabricated from braided T700S carbon fiber and TenCate Advanced Composites's TC275-1 epoxy resin prepreg. Axial tows in each ply were aligned, offset, or rotated to evaluate the influence of such parameters on impact penetration resistance. Panel-to-panel variation in thickness, resin content, and fiber volume ratio were measured. Ultimately, process-related deviations drove penetration limits on impact. Influence of axial tow alignment was difficult to discern outside of the processing-induced variations between panels.

This work presents the results of an experimental study of ice particle impacts on a flat glass plate. The experiment was conducted at the Ballistics Impact Laboratory of NASA Glenn Research Center. The main objective of the experiment was to gain understanding about the modifications needed to the experimental configuration for a future parametric study at a larger range of values for particle diameters and other parameters. This was achieved by studying the effect of the velocity of an impacting ice particle on the post-impact fragment size and distribution for a reduced range of impacting particle diameters. Pre-impact particle diameter and velocity data were captured with a high-speed side camera. Post-impact fragment data were captured in a single frame with a 29-megapixel camera located above and normal to the target. Repeat runs were conducted for ice particles with diameters ranging from 1.7 to 2.9 millimeters, impacting at velocities between 39 and 98 meters per second. The fragment areas were measured, and the corresponding equivalent diameters and histogram distributions were calculated. Analysis of the data showed that the average equivalent diameter for the fragments in a run was an order of magnitude smaller than the diameter of the impacting ice particle. The histograms for equivalent diameter distribution were nonnormal with long tails, with most of the fragments having equivalent diameters concentrated toward the minimum value of the fragment size that could be resolved. Factors affecting the accuracy of the data during the digital imaging analysis were identified. Needed modifications to the setup to handle small size ice particles and other testing conditions were also identified.

This presentation gives an overview of the NASA Advanced Composites Project and a summary of the progress and plans of the High Energy Impact Dynamics Team.

Gas gun experiments can generate useful data for the design of jet engine containment shields at much lower costs. To replicate the damage modes similar to that on a containment shield in fan-blade-out (FBO) testing, the gas gun experiment has to be carefully designed. This work focuses on the design of projectiles. Gas gun experiments were performed for flat composite panel targets with three different projectiles. FBO conditions were simulated using spin pit tests. The damage modes on the flat panels used in the gas gun tests were compared with damage modes on cylindrical composite containment shields used in spin pit tests. The results show that to generate similar damage modes, it is critical to ensure the shape of the projectile used in a gas gun test accounts for the deformation of the released blade during initial contact in the spin pit test.

The purpose of this presntation is to provide an executive overview of the HEDI effort for NASAs Advanced Composites Program and establish the foundation for the remaining papers to follow in the 2018 SciTech special session NASA ACC High Energy Dynamic Impact. The paper summarizes the work done for the Advanced Composites Program to advance our understanding of the behavior of composite materials during high energy impact events and to advance the ability of analytical tools to provide predictive simulations. The experimental program carried out at GRC is summarized and a status on the current development state for MAT213 will be provided. Future work will be discussed as the HEDI effort transitions from fundamental analysis and testing to investigating sub-component structural concept response to impact events.

High fidelity analysis methods known as Progressive Damage Analysis (PDA) methods, capable of reliably predicting the onset and progression of damage in composite materials, are being developed for HEDI event simulation. Four state-of-the-art PDA methods are being investigated: LS-DYNA MAT162, LS-DYNA MAT261, Smooth-Particle Galerkin (SPG), and EMU Peridynamics. Validation of these PDA models aims to follow a building block approach, starting with coupon- and component-level development. As part of the overall effort, material characterization testing was performed to bridge gaps between existing experimental data and the material property inputs required to predict ballistic impact behavior at the component-level. The material models were updated with the results of the coupon-level testing and were then used to predict panel behavior and damage in ballistic impact events. To assess the accuracy of the PDA methods, these pre-test predictions were compared to the results of ballistic impact testing.

Ballistic impact experiments were performed on triaxially braided polymer matrix composites to study the heat generated in the material due to projectile velocity and penetration damage. Quantifying the heat generation phenomenon is crucial for attaining a better understanding of composite behavior and failure under impact loading. The knowledge gained can also be used to improve physics-based models which can numerically simulate impact of composites. Triaxially braided (0/+60/-60) composite panels were manufactured with T700S standard modulus carbon fiber and two epoxy resins. The PR520 (toughened) and 3502 (untoughened) resin systems were used to make different panels to study the effects of resin properties on temperature rise. Ballistic impact tests were conducted on these composite panels using a gas gun, and different projectile velocities were applied to study the effect on the temperature results. Temperature contours were obtained from the rear surface of the panel during the test through a high speed, infrared (IR) thermal imaging system. The contours show that high temperatures were locally generated and more pronounced along the axial tows for the T700S/PR520 composite specimens; whereas, tests performed on T700S/3502 composite panels using similar impact velocities demonstrated a widespread area of lower temperature rises. Nondestructive, ultrasonic C-scan analyses were performed to observe and verify the failure patterns in the impacted panels. Overall, the impact experimentation showed temperatures exceeding 525 K (485degF) in both composites which is well above the respective glass transition temperatures for the polymer constituents. This expresses the need for further high strain rate testing and measurement of the temperature and deformation fields to fully understand the complex behavior and failure of the material in order to improve the confidence in designing aerospace components with these materials.

An experimental study was conducted to measure the effects of long term hygrothermal aging on the impact penetration resistance of triaxially braided polymer composites. Flat panels of three different materials were subjected to repeated cycles of high and low temperature and high and low humidity for two years. Samples of the panels were periodically tested under impact loading during the two year time period. The purpose of the study was to identify and quantify any degradation in impact penetration resistance of these composites under cyclic temperature and humidity conditions experienced by materials in the fan section of commercial gas turbine engines for a representative aircraft flight cycle. The materials tested consisted of Toray ® T700S carbon fibers in a 2D triaxial braid with three different resins, Cycom® PR520, a toughened resin, Hercules® 3502, an untoughened resin and EPON 862, intermediate between the two. The fiber preforms consisted of a quasi-isotropic 0/+60/-60 braid with 24K tows in the axial direction and 12K tows in the bias directions. The composite panels were manufactured using a resin transfer molding process producing panels with a thickness of 0.125 inches. The materials were tested in their as-processed condition and again after one year and two years of aging (1.6 years in the case of E862). The aging process involved subjecting the test panels to two cycles per day of high and low temperature and high and low humidity. A temperature range of -60degF to 250degF and a humidity range of 0 to 85% rh was used to simulate extreme conditions for composite components in the fan section of a commercial gas turbine engine. Additional testing was conducted on the as-processed PR520 composite under cryogenic conditions. After aging there was some change in the failure pattern, but there was no reduction in impact penetration threshold for any of the three systems, and in the case of the 3502 system, a significant increase in penetration threshold. There was also an increase in the penetration resistance of the PR520 system impacted under cryogenic conditions.

The Federal Aviation Administration is working with the European Aviation Safety Agency to determine the certification base for proposed new engines that would not have a containment structure on large commercial aircraft. Equivalent safety to the current fleet is desired by the regulators, which means that loss of a single fan blade will not cause hazard to the Aircraft. The NASA Glenn Research Center and The Naval Air Warfare Center (NAWC), China Lake, collaborated with the FAA Aircraft Catastrophic Failure Prevention Program to design and test lightweight composite shields for protection of the aircraft passengers and critical systems from a released blade that could impact the fuselage. LS-DYNA® was used to predict the thickness of the composite shield required to prevent blade penetration. In the test, two composite blades were pyrotechnically released from a running engine, each impacting a composite shield with a different thickness. The thinner shield was penetrated by the blade and the thicker shield prevented penetration. This was consistent with pre-test LS-DYNA predictions. This paper documents the analysis conducted to predict the required thickness of a composite shield, the live fire test from the full scale rig at NAWC China Lake and describes the damage to the shields as well as instrumentation results.

The Federal Aviation Administration is working with the European Aviation Safety Agency to determine the certification base for proposed new engines that would not have a containment structure on large commercial aircraft. Equivalent safety to the current fleet is desired by the regulators, which means that loss of a single fan blade will not cause hazard to the Aircraft. The NASA Glenn Research Center and The Naval Air Warfare Center (NAWC), China Lake, collaborated with the FAA Aircraft Catastrophic Failure Prevention Program to design and test lightweight composite shields for protection of the aircraft passengers and critical systems from a released blade that could impact the fuselage. In the test, two composite blades were pyrotechnically released from a running engine, each impacting a composite shield with a different thickness. The thinner shield was penetrated by the blade and the thicker shield prevented penetration. This was consistent with pre-test predictions. This paper documents the live fire test from the full scale rig at NAWC China Lake and describes the damage to the shields as well as instrumentation results.

The Federal Aviation Administration (FAA) is working with the European Aviation Safety Agency to determine the certification base for proposed new engines that would not have a containment structure on large commercial aircraft. Equivalent safety to the current fleet is desired by the regulators, which means that loss of a single fan blade will not cause hazard to the aircraft. NASA Glenn and Naval Air Warfare Center (NAWC) China Lake collaborated with the FAA Aircraft Catastrophic Failure Prevention Program to design and test a shield that would protect the aircraft passengers and critical systems from a released blade that could impact the fuselage. This report documents the live-fire test from a full-scale rig at NAWC China Lake. NASA provided manpower and photogrammetry expertise to document the impact and damage to the shields. The test was successful: the blade was stopped from penetrating the shield, which validates the design analysis method and the parameters used in the analysis. Additional work is required to implement the shielding into the aircraft.

FAA fan blade-out certification testing on turbofan engines occurs very late in an engine's development program and is very costly. It is of utmost importance to approach the FAA Certification engine test with a high degree of confidence that the containment structure will not only contain the high-energy debris, but that it will also withstand the cyclic loads that occur with engine spooldown and continued rotation as the non-running engine maintains a low rotor RPM due to forced airflow as the engine-out aircraft returns to an airport. Accurate rig testing is needed for predicting and understanding material behavior of the fan case structure during all phases of this fan blade-out event.

Impact damage tolerance and damage resistance is a critical metric for application of polymer matrix composites where failure caused by impact damage could compromise structural performance and safety. As a result, several materials and/or design approaches to improve impact damage tolerance have been investigated over the past several decades. Many composite toughening methodologies impart a trade-off between increased fracture toughness and compromised in-plane strength and modulus. In large part, mechanical tests to evaluate composite damage tolerance include static methods such as Mode I, Mode II, and mixed mode failures. However, ballistic impact damage resistance does not always correlate with static properties. The intent of this paper is to evaluate the influence of a thermoplastic polyurethane veil interleave on the static and dynamic performance of composite test articles. Static coupon tests included tension, compression, double cantilever beam, and end notch flexure. Measurement of the resistance to ballistic impact damage were made to evaluate the composites response to high speed impact. The interlayer material showed a decrease of in-plane performance with only a moderate improvement to Mode I and Mode II fracture toughness. However, significant benefit to impact damage tolerance was observed through ballistic tests.

The U.S. Federal Aviation Administration (FAA) and the National Aeronautics and Space Administration (NASA) are actively involved in improving the predictive capabilities of transient finite element computational methods for application to safety issues involving unintended impacts on aircraft and aircraft engine structures. One aspect of this work involves the development of an improved deformation and failure model for metallic materials, known as the Tabulated Johnson-Cook model, or MAT224, which has been implemented in the LS-DYNA commercial transient finite element analysis code (LSTC Corp., Livermore, CA) (Ref. 1). In this model the yield stress is a function of strain, strain rate and temperature and the plastic failure strain is a function of the state of stress, temperature and strain rate. The failure criterion is based on the accumulation of plastic strain in an element. The model also incorporates a regularization scheme to account for the dependency of plastic failure strain on mesh size. For a given material the model requires a significant amount of testing to determine the yield stress and failure strain as a function of the three-dimensional state of stress, strain rate and temperature. In addition, experiments are required to validate the model. Currently the model has been developed for Aluminum 2024 and validated against a series of ballistic impact tests on flat plates of various thicknesses (Refs. 1 to 3). Full development of the model for Titanium 6Al-4V is being completed, and mechanical testing for Inconel 718 has begun. The validation testing for the models involves ballistic impact tests using cylindrical projectiles impacting flat plates at a normal incidence (Ref. 2). By varying the thickness of the plates, different stress states and resulting failure modes are induced, providing a range of conditions over which the model can be validated. The objective of the study reported here was to provide experimental data to evaluate the model under more extreme conditions, using a projectile with a more complex shape and sharp contacts, impacting flat panels at oblique angles of incidence.

Application of polymer matrix composite materials for jet engine fan blades is becoming attractive as an alternative to metallic blades; particularly for large engines where significant weight savings are recognized on moving to a composite structure. However, the weight benefit of the composite is offset by a reduction of aerodynamic efficiency resulting from a necessary increase in blade thickness; relative to the titanium blades. Blade dimensions are largely driven by resistance to damage on bird strike. Further development of the composite material is necessary to allow composite blade designs to approximate the dimensions of a metallic fan blade. The reduction in thickness over the state of the art composite blades is expected to translate into structural weight reduction, improved aerodynamic efficiency, and therefore reduced fuel consumption. This paper presents test article design, subcomponent blade leading edge fabrication, test method development, and initial results from ballistic impact of a gelatin projectile on the leading edge of composite fan blades. The simplified test article geometry was developed to realistically simulate a blade leading edge while decreasing fabrication complexity. Impact data is presented on baseline composite blades and toughened blades; where a considerable improvement to impact resistance was recorded.

Application of polymer matrix composite materials for jet engine fan blades is becoming attractive as an alternative to metallic blades; particularly for large engines where significant weight savings are recognized on moving to a composite structure. However, the weight benefit of the composite of is offset by a reduction of aerodynamic efficiency resulting from a necessary increase in blade thickness; relative to the titanium blades. Blade dimensions are largely driven by resistance to damage on bird strike. Further development of the composite material is necessary to allow composite blade designs to approximate the dimensions of a metallic fan blade. The reduction in thickness over the state of the art composite blades is expected to translate into structural weight reduction, improved aerodynamic efficiency, and therefore reduced fuel consumption. This paper presents test article design, subcomponent blade leading edge fabrication, test method development, and initial results from ballistic impact of a gelatin projectile on the leading edge of composite fan blades. The simplified test article geometry was developed to realistically simulate a blade leading edge while decreasing fabrication complexity. Impact data is presented on baseline composite blades and toughened blades; where a considerable improvement to impact resistance was recorded.

Bird strike events in commercial airliners are a fairly common occurrence. According to data collected by the US Department of Agriculture, over 80,000 bird strikes were reported in the period 1990 to 2007 in the US alone (Ref. 1). As a result, bird ingestion is an important factor in aero engine design and FAA certification. When it comes to bird impacts on engine fan blades, the FAA requires full-scale bird ingestion tests on an engine running at full speed to pass certification requirements. These rotating tests are complex and very expensive. To reduce development costs associated with new materials for fan blades, it is desirable to develop more cost effective testing procedures than full-scale rotating engine tests for material evaluation. An impact test on a nonrotating single blade that captures most of the salient physics of the rotating test would go a long way towards enabling large numbers of evaluative material screening tests. NASA Glenn Research Center has been working to identify a static blade test procedure that would be effective at reproducing similar results as seen in rotating tests. The current effort compares analytical simulations of a bird strike on various non-rotating blades to a bird strike simulation on a rotating blade as a baseline case. Several different concepts for simulating the rotating loads on a non-rotating blade were analyzed with little success in duplicating the deformation results seen in the rotating case. The rotating blade behaves as if it were stiffer than the non-rotating blade resulting in less plastic deformation from a given bird impact. The key factor limiting the success of the non-rotating blade simulations is thought to be the effect of gyroscopics. Prior to this effort, it was anticipated the difficulty would be in matching the prestress in the blade due to centrifugal forces Additional work is needed to verify this assertion, and to determine if a static test procedure can simulate the gyroscopic effects in a suitable manner. This paper describes the various non-rotating concepts analyzed, and demonstrates the effect believed to be gyroscopic in nature on the results

One of the difficulties with developing and verifying accurate impact models is that parameters such as high strain rate material properties, failure modes, static properties, and impact test measurements are often obtained from a variety of different sources using different materials, with little control over consistency among the different sources. In addition there is often a lack of quantitative measurements in impact tests to which the models can be compared. To alleviate some of these problems, a project is underway to develop a consistent set of material property, impact test data and failure analysis for a variety of aircraft materials that can be used to develop improved impact failure and deformation models. This project is jointly funded by the NASA Glenn Research Center and the FAA William J. Hughes Technical Center. Unique features of this set of data are that all material property data and impact test data are obtained using identical material, the test methods and procedures are extensively documented and all of the raw data is available. Four parallel efforts are currently underway: Measurement of material deformation and failure response over a wide range of strain rates and temperatures and failure analysis of material property specimens and impact test articles conducted by The Ohio State University; development of improved numerical modeling techniques for deformation and failure conducted by The George Washington University; impact testing of flat panels and substructures conducted by NASA Glenn Research Center. This report describes impact testing which has been done on aluminum (Al) 2024 and titanium (Ti) 6Al-4vanadium (V) sheet and plate samples of different thicknesses and with different types of projectiles, one a regular cylinder and one with a more complex geometry incorporating features representative of a jet engine fan blade. Data from this testing will be used in validating material models developed under this program. The material tests and the material models developed in this program will be published in separate reports.

NASA is currently developing a new crew module to replace capabilities of the retired Space Shuttles and to provide a crewed vehicle for exploring beyond low earth orbit. The crew module is a capsule-type design, which is designed to separate from the launch vehicle during launch ascent once the launch vehicle fuel is expended. The separation is achieved using pyrotechnic separation bolts, wherein a section of the bolt is propelled clear of the joint at high velocity by an explosive charge. The resulting projectile must be contained within the fairing structure by a containment plate. This paper describes an analytical effort completed to augment testing of various containment plate materials and thicknesses. The results help guide the design and have potential benefit for future similar applications.

An experimental program is underway to develop a consistent set of material property and impact test data, and failure analysis, for a variety of materials that can be used to develop improved impact failure and deformation models. Unique features of this set of data are that all material property information and impact test results are obtained using identical materials, the test methods and procedures are extensively documented and all of the raw data is available. This report describes ballistic impact testing which has been conducted on aluminum (Al) 2024 and titanium (Ti) 6Al-4vanadium (V) sheet and plate samples of different thicknesses and with different types of projectiles, one a regular cylinder and one with a more complex geometry incorporating features representative of a jet engine fan blade.

This poster summarizes 2 years of aging on E862 epoxy and E862 epoxy with triaxial braided T700s carbon fiber composite. Several test methods were used to characterize chemical, physical, and mechanical properties of both the resin and composite materials. The aging cycle that was used included varying temperature and humidity exposure. The goal was to evaluate the environmental effects on a potential jet engine fan section material. Some changes were noted in the resin which resulted in increased brittleness, though this did not significantly affect the tensile and impact test results. A potential decrease in compression strength requires additional investigation.

Composite materials are beginning to be used for structures in the fan section of commercial gas turbine engines. This paper explores the type of damage that could occur within one type of composite material after exposure to hygrothermal cycles (temperature/humidity cycles) that are representative of the environment in the fan section of an engine. The effect of this damage on composite material properties is measured. Chemical changes in the matrix material were limited to the exposed surface. Microcrack formation was identified in the composite material. This damage did not cause a significant reduction in tensile strength or impact penetration resistance of the composite material. Additional data is needed to assess the effect of damage on compressive strength.

An experimental program is underway to measure the impact and high strain rate properties of triaxial braided composite materials and to quantify any degradation in properties as a result of thermal and hygroscopic aging typically encountered during service. Impact tests are being conducted on flat panels using a projectile designed to induce high rate deformation similar to that experienced in a jet engine fan case during a fan blade-out event. The tests are being conducted on as-fabricated panels and panels subjected to various numbers of aging cycles. High strain rate properties are being measured using a unique Hopkinson bar apparatus that has a larger diameter than conventional Hopkinson bars. This larger diameter is needed to measure representative material properties because of the large unit cell size of the materials examined in this work. In this paper the experimental techniques used for impact and high strain rate testing are described and some preliminary results are presented for both as-fabricated and aged composites.

Triaxial braid composite materials are beginning to be used in fan cases for commercial gas turbine engines. The primary benefit for the use of composite materials is reduced weight and the associated reduction in fuel consumption. However, there are also cost benefits in some applications. This paper presents a description of the braided composite materials and discusses aspects of the braiding process that can be utilized for efficient fabrication of composite cases. The paper also presents an approach that was developed for evaluating the braided composite materials and composite fan cases in a ballistic impact laboratory. Impact of composite panels with a soft projectile is used for materials evaluation. Impact of composite fan cases with fan blades or blade-like projectiles is used to evaluate containment capability. A post-impact structural load test is used to evaluate the capability of the impacted fan case to survive dynamic loads during engine spool down. Validation of these new test methods is demonstrated by comparison with results of engine blade-out tests.

A test methodology currently employed for large engines was extended to quantify the ballistic containment capability of a small turboshaft engine compressor case. The approach involved impacting the inside of a compressor case with a compressor blade. A gas gun propelled the blade into the case at energy levels representative of failed compressor blades. The test target was a full compressor case. The aft flange was rigidly attached to a test stand and the forward flange was attached to a main frame to provide accurate boundary conditions. A window machined in the case allowed the projectile to pass through and impact the case wall from the inside with the orientation, direction and speed that would occur in a blade-out event. High-peed, digital-video cameras provided accurate velocity and orientation data. Calibrated cameras and digital image correlation software generated full field displacement and strain information at the back side of the impact point.

This report summarizes the ballistic impact testing that was conducted to provide validation data for the development of numerical models of blade out events in fabric containment systems. The ballistic impact response of two different fiber materials - Kevlar 49 (E.I. DuPont Nemours and Company) and Zylon AS (Toyobo Co., Ltd.) was studied by firing metal projectiles into dry woven fabric specimens using a gas gun. The shape, mass, orientation and velocity of the projectile were varied and recorded. In most cases the tests were designed such that the projectile would perforate the specimen, allowing measurement of the energy absorbed by the fabric. The results for both Zylon and Kevlar presented here represent a useful set of data for the purposes of establishing and validating numerical models for predicting the response of fabrics under conditions simulating those of a jet engine blade release situations. In addition some useful empirical observations were made regarding the effects of projectile orientation and the relative performance of the different materials.

A set of experimental data is being generated under the Fundamental Aeronautics Program Supersonics project to help create and validate accurate computational impact models of jet engine impact events. The data generated will include material property data generated at a range of different strain rates, from 1x10(exp -4)/sec to 5x10(exp 4)/sec, over a range of temperatures. In addition, carefully instrumented ballistic impact tests will be conducted on flat plates and curved structures to provide material and structural response information to help validate the computational models. The material property data and the ballistic impact data will be generated using materials from the same lot, as far as possible. It was found in preliminary testing that the surface finish of test specimens has an effect on measured high strain rate tension response of AL2024. Both the maximum stress and maximum elongation are greater on specimens with a smoother finish. This report gives an overview of the testing that is being conducted and presents results of preliminary testing of the surface finish study.

Following the tragedy of the Space Shuttle Columbia on February 1, 2003, a major effort commenced to develop a better understanding of debris impacts and their effect on the Space Shuttle subsystems. An initiative to develop and validate physics-based computer models to predict damage from such impacts was a fundamental component of this effort. To develop the models it was necessary to physically characterize Reinforced Carbon-Carbon (RCC) and various debris materials which could potentially shed on ascent and impact the Orbiter RCC leading edges. The validated models enabled the launch system community to use the impact analysis software LS DYNA to predict damage by potential and actual impact events on the Orbiter leading edge and nose cap thermal protection systems. Validation of the material models was done through a three-level approach: fundamental tests to obtain independent static and dynamic material model properties of materials of interest, sub-component impact tests to provide highly controlled impact test data for the correlation and validation of the models, and full-scale impact tests to establish the final level of confidence for the analysis methodology. This paper discusses the second level subcomponent test program in detail and its application to the LS DYNA model validation process. The level two testing consisted of over one hundred impact tests in the NASA Glenn Research Center Ballistic Impact Lab on 6 by 6 in. and 6 by 12 in. flat plates of RCC and evaluated three types of debris projectiles: BX 265 External Tank foam, ice, and PDL 1034 External Tank foam. These impact tests helped determine the level of damage generated in the RCC flat plates by each projectile. The information obtained from this testing validated the LS DYNA damage prediction models and provided a certain level of confidence to begin performing analysis for full-size RCC test articles for returning NASA to flight with STS 114 and beyond.

A ballistic impact test program was conducted to provide validation data for the development of numerical models of blade out events in fabric containment systems. The impact response of two different fiber materials - Kevlar 49 (E.I. DuPont Nemours and Company) and Zylon AS (Toyobo Co., Ltd.) was studied by firing metal projectiles into dry woven fabric specimens using a gas gun. The shape, mass, orientation and velocity of the projectile were varied and recorded. In most cases the tests were designed such that the projectile would perforate the specimen, allowing measurement of the energy absorbed by the fabric. The results for both Zylon and Kevlar presented here represent a useful set of data for the purposes of establishing and validating numerical models for predicting the response of fabrics under conditions simulating those of a jet engine blade release situation. In addition some useful empirical observations were made regarding the effects of projectile orientation and the relative performance of the different materials.

Tests were conducted to measure the impact forces generated by cylindrical ice projectiles striking a relatively rigid target. Two types of ice projectiles were used, solid clear ice and lower density fabricated ice. Three forms of solid clear ice were tested: single crystal, poly-crystal, and "rejected" poly-crystal (poly-crystal ice in which defects were detected during inspection.) The solid ice had a density of approximately 56 lb/cu ft (0.9 gm/cu cm). A second set of test specimens, termed "low density ice" was manufactured by molding shaved ice into a cylindrical die to produce ice with a density of approximately 40 lb/cu ft (0.65 gm/cu cm). Both the static mechanical characteristics and the crystalline structure of the ice were found to have little effect on the observed transient response. The impact forces generated by low density ice projectiles, which had very low mechanical strength, were comparable to those of full density solid ice. This supports the hypothesis that at a velocity significantly greater than that required to produce fracture in the ice, the mechanical properties become relatively insignificant, and the impact forces are governed by the shape and mass of the projectile.

An integrated team of NASA personnel, Government contractors, industry partners, and university staff have developed an innovative new technology for commercial fan cases that will substantially influence the safety and efficiency of future turbine engines. This effective team, under the direction of the NASA Glenn Research Center and with the support of the Federal Aviation Administration, has matured a new class of carbon/polymer composites and demonstrated a 30- to 50-percent improvement in specific containment capacity (blade fragment kinetic energy/containment system weight). As the heaviest engine component, the engine case/containment system greatly affects both the safety and efficiency of aircraft engines. The ballistic impact research team has developed unique test facilities and methods for screening numerous candidate material systems to replace the traditional heavy, metallic engine cases. This research has culminated in the selection of a polymer matrix composite reinforced with triaxially braided carbon fibers and technology demonstration through the fabrication of prototype engine cases for three major commercial engine manufacturing companies.

Impact tests using a soft gelatin projectile were performed to identify failure modes that occur at high strain energy density during impact loading. Use of a soft projectile allows a large amount of kinetic energy to be transferred into strain energy in the target before penetration occurs. Failure modes were identified for flat aluminum plates and for flat composite plates made from a triaxial braid having a quasi-isotropic fiber architecture with fibers in the 0 and +/- 60 deg. directions. For the aluminum plates, a large hole formed as a result of crack propagation from the initiation site at the center of the plate to the fixed boundaries. For the composite plates, fiber tensile failure occurred in the back ply at the center of the plate. Cracks then propagated from this site along the +/- 60 deg. fiber directions until triangular flaps opened to allow the projectile to pass through the plate. The damage size was only slightly larger than the initial impact area. It was difficult to avoid slipping of the fixed edges of the plates during impact, and slipping was shown to have a large effect on the penetration threshold. Failure modes were also identified for composite half-rings fabricated with the 0 deg. fibers aligned circumferentially. Slipping of the edges was not a problem in the half-ring tests. For the composite half-rings, fiber tensile failure also occurred in the back ply. However, cracks initially propagated from this site in a direction transverse to the 0 deg. fibers. The cracks then turned to follow the +/- 60 deg. fibers for a short distance before turning again to follow 0 deg. fibers until two approximately rectangular flaps opened to allow the projectile to pass through the plate. The damage size in the composite half-rings was also only slightly larger than the initial impact area. Cracks did not propagate to the boundaries, and no delamination was observed. The damage tolerance demonstrated by the quasi-isotropic triaxial braid composites indicate that composites of this type can reasonably be considered as a lightweight alternative to metals for fan cases in commercial jet engines.

Gamma TiAl was evaluated as a candidate alloy for low-pressure turbine blades in aeroengines. The durability of g-TiAl was studied by examining the effects of impact or fretting on its fatigue strength. Cast-to-size Ti-48Al-2Cr-2Nb was studied in impact testing with different size projectiles at various impact energies as the reference alloy and subsequently fatigue tested. Impacting degraded the residual fatigue life. However, under the ballistic impact conditions studied, it was concluded that the impacts expected in an aeroengine would not result in catastrophic damage, nor would the damage be severe enough to result in a fatigue failure under the anticipated design loads. In addition, other gamma alloys were investigated including another cast-to-size alloy, several cast and machined specimens, and a forged alloy. Within this Ti-48-2-2 family of alloys aluminum content was also varied. The cracking patterns as a result of impacting were documented and correlated with impact variables. The cracking type and severity was reasonably predicted using finite element models. Mean stress affects were also studied on impact-damaged fatigue samples. The fatigue strength was accurately predicted based on the flaw size using a threshold-based, fracture mechanics approach. To study the effects of wear due to potential applications in a blade-disk dovetail arrangement, the machined Ti-47-2-2 alloy was fretted against In-718 using pin-on-disk experiments. Wear mechanisms were documented and compared to those of Ti-6Al-4V. A few fatigue samples were also fretted and subsequently fatigue tested. It was found that under the conditions studied, the fretting was not severe enough to affect the fatigue strength of g-TiAl.

Foreign object damage (FOD) behavior of a gas-turbine grade SiC/SiC ceramic matrix composite (CMC) was determined at 25 and 1316 C, employing impact velocities from 115 to 440 meters per second by 1.59-mm diameter stell-ball projectiles. Two different types of specimen support were used at each temperature: fully supported and partially supported. For a given temperature, the degree of post-impact strength degradation increased with increasing impact velocity, and was greater in a partially supported configuration than in a fully supported one. The elevated-temperature FOD resistance of the composite, particularly under partially supported loading at higher impact velocities greater than or equal to 350 meters per second, was significantly less than the ambient-temperature counterpart, attributed to a weakening effect of the composite. For fully supported loading, frontal contact stress played a major role in generating composite damage; whereas, for partially supported loading, both frontal contact and backside bending stresses were combined sources of damage generation. The SiC/SiC composite was able to survive higher energy impacts without complete structural failure but suffered more strength affecting damage from low energy impacts than AS800 and SN282 silicon nitrides.

Foreign object damage (FOD) behavior of two commercial gas-turbine grade silicon nitrides, AS800 and SN282, was determined at ambient temperature through strength testing of flexure test specimens impacted by steel ball projectiles with a diameter of 1.59 mm in a velocity range from 220 to 440 m/s. AS800 silicon nitride exhibited a greater FOD resistance than SN282, primarily due to its greater value of fracture toughness (K(sub lc)). The use of an additional equiaxed, fine-grained silicon nitride (NC132) showed that fracture toughness was a key material parameter affecting FOD resistance. The observed damages generated by projectile impact were typically in the forms of well- or ill-developed ring and cone cracks with little presence of radial cracks.

Foreign object damage (FOD) behavior of two commercial gas-turbine-grade silicon nitrides, AS800 and SN282, was determined at ambient temperature through postimpact strength testing of disks impacted by steel ball projectiles with a diameter of 1.59 mm in a velocity range from 115 to 440 m/s. AS800 silicon nitride exhibited a greater FOD resistance than SN282, primarily due to its greater value of fracture toughness (k(sub Ic)). The critical impact velocity V(sub c) for which the corresponding postimpact strength was the lowest was V(sub c) approximately equal to 440 and 300 m/s AS800 and SN282, respectively. A unique lower strength regime was typified for both silicon nitrides depending on impact velocity and was attributed to significant radial cracking. The damage generated by projectile impact was typically in the form of ring, radial, and cone cracks with their severity and combination being dependent on impact velocity. Unlike the thick (4 millimeters) flexure bar specimens used in our previous studies, the thin (2 millimeter) disk target specimen exhibited a unique back-side radial cracking on the reverse side just beneath the impact sites at and above impact velocities of 160 meters per second for SN282 and 220 meters per second AS800.

Foreign object damage (FOD) behavior of two commercial gas-turbine grade silicon nitrides, AS800 and SN282, was determined at ambient temperature through post-impact strength testing for thin disks impacted by steel-ball projectiles with a diameter of 1.59 mm in a velocity range from 115 to 440 m/s. AS800 silicon nitride exhibited a greater FOD resistance than SN282, primarily due to its greater value of fracture toughness (K(sub IC)). The critical impact velocity in which the corresponding post-impact strength yielded the lowest value was V(sub c) approx. 440 and 300 m/s for AS800 and SN282, respectively. A unique lower-strength regime was typified for both silicon nitrides depending on impact velocity, attributed to significant radial cracking. The damages generated by projectile impact were typically in the forms of ring, radial, and cone cracks with their severity and combination being dependent on impact velocity. Unlike thick (3 mm) flexure bar specimens used in the previous studies, thin (2 mm) disk target specimens exhibited a unique backside radial cracking occurring on the reverse side just beneath the impact sites at and above impact velocity of 160 and 220 m/s for SN282 and AS800, respectively.