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Competition of fracture and hydrodynamic effects in aerospace composites and ceramics under hypervelocity impact, The
Morton, Joseph Galen
Morton, Joseph Galen
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2025
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Abstract
With the commercialization of space and the global development of hypersonic vehicles for defense and potential commercial use, hypervelocity impact (HVI) has become a critical concern. Two materials that have become essential in the aerospace and defense industries due to their versatility and strength-to-weight ratio under extreme conditions are composites and ceramics. Composites, like carbon-fiber-reinforced polymer (CFRP), provide a lightweight yet strong material that can be customized for specific applications by modifying the composite layup. Ceramics have become the material of choice for thermal protection systems (TPS) of both hypersonic and reentry vehicles due to their high strength-to-weight and heat-resistance-to-weight ratio. Thus, understanding the failure mechanisms present after a hypervelocity impact of both low-impedance composites and ceramics is of high interest. This study aims to further the understanding of the failure mechanisms in play during impacts on both material systems, highlighting the similarities and differences in their response.
The first component of this research focused on CFRP composite truss members subjected to hypervelocity impact, designed to replicate the types of structural elements used in deployable space assets. Using a two-stage light-gas gun, a series of impact experiments were conducted on roll-wrapped CFRP tubes, with damage morphology tracked through shadowgraph imaging, X-ray computed tomography, and compression-after-impact testing. The results demonstrated localized damage and a strong correlation between delamination area and residual strength reduction. Finite element models by collaborators incorporating cohesive zone elements and LS-DYNA smooth particle hydrodynamics (SPH) provided additional insight into ejecta cloud formation and damage propagation across impact orientations and velocities.
The second component investigated dense, hot-pressed silicon carbide (SiC-N) plates to capture the brittle fracture and fragmentation mechanisms under HVI conditions. This work combined ultra-high-speed imaging, strain gauge diagnostics, holographic interferometry, and numerical modeling to assess the onset and evolution of damage. The results show a transition from bulk fracture to an increase in microcracking and shock amorphization at higher impact energies. Together, these findings contribute new experimental and modeling insights toward the design and validation of advanced aerospace materials for extreme environments.
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