SAMPE Journal - May/June 2020 - 21

nal bonded joint design significantly exceeds the
joint design loads with a 2.0 factor of safety for the
pristine coupons. The joint tests showed repeatable test failure loads and failure mechanisms leading to joint failure. The analysis pre-test failure load
predictions were +8.8% of the average test failure
load for the AEWC coupons, -3.0% of the average
test failure load for the HEWC coupons, and within
1% of the average test coupon failure load for the
HEWT coupons. Post-test analyses were performed
on the AEWC coupons to improve the analysis failure load prediction to be +3.3% of the average test
failure load. The PFA also accurately predicted the
dominant failure mode for each sub-element joint
test. This testing and analysis provides confidence
in the potential use of composite bonded joints for
future launch vehicle structures.

AIAA/ASME/ASCE/AHS/ ASC Structures, Structural Dynamics, and Materials Conference, Boston, MA, April 2013.
3. Fikes, J. C., Jackson, J. R., Richardson, S. W., Thomas, A. S., and, T. O., and Miller, S.
G., "Composites for Exploration Upper Stage," NASA/TM-2016-219433, December 2016.
4. Sleight, David. W., Rosario, S., Johnson, T. F., and Shular, D. A., "Composite Cryotank
Technology Demonstration 5.5-Meter Diameter Pre-Test, Analysis and Test Readiness,"
NASA/TM-2016-219325.
5. Mann, T., Smeltzer, S., Grenoble, R. W., Mason, B. H., Rosario, S., & Fairbairn, R., "Sizing
and Lifecycle Cost Analysis of an Ares V Composite Interstage", AIAA 2012-1770, 53rd
AIAA/ASME/ASCE/AHS/ASC Structures, Structural Dynamics, and Materials Conference, Honolulu, HI, April 2012.
6. Sleight, D. W., Segal, K. N., Guin, W. E., McDougal, M. R., Wolfe, C. C., Johnston, M. M.,
and Miller, S. G., "Development of Composite Sandwich Bonded Longitudinal Joints for
Space Launch Vehicle Structures", AIAA Sci-Tech 2019.
7. NX Nastran, Software Package, Ver. 10, Siemens PLM Software, Inc., Plano, TX, 2014
8. Satyanarayana, A., Bogert, P., Karayev, Z. K., Nordman, S. P., Hamid, "Influence of Finite
Element Size in Residual Strength Prediction of Composite Structures," Proceedings

REFERENCES
1. Kirsch, Michael, T. "Composite Crew Module: Primary
Structure," NASA/TM-2011-217185.
2. Johnson, T. F., Sleight, D. W., and Martin, R. A., "Struc-

of the 53rd AIAA/ASME/ASCE/AHS/ASC Structures, Structural Dynamics and Materials
Conference, Honolulu, Hawaii, April 2012, AIAA-2012-1619.
9. Abaqus, Software Package, Ver. 6.13, Dassault Systèmes, Waltham, MA, 2013.

tures and Design Phase I Summary for the NASA Com-

10. Mason, B. H., Satyanarayana, A., and Sleight, D. W., "Test and Analysis Correlation for

posite Cryotank Technology Demonstration Project," 54th

Sandwich Composite Longitudinal Joint Specimens," AIAA Sci-Tech 2019.

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