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NASA NTRS2005

Common Cause Case Study: An Estimated Probability of Four Solid Rocket Booster Hold-Down Post Stud Hang-ups

Until Solid Rocket Motor ignition, the Space Shuttle is mated to the Mobil Launch Platform in part via eight (8) Solid Rocket Booster (SRB) hold-down bolts. The bolts are fractured using redundant pyrotechnics, and are designed to drop through a hold-down post on the Mobile Launch Platform before the Space Shuttle begins movement. The Space Shuttle program has experienced numerous failures where a bolt has hung up. That is, it did not clear the hold-down post before liftoff and was caught by the SRBs. This places an additional structural load on the vehicle that was not included in the original certification requirements. The Space Shuttle is currently being certified to withstand the loads induced by up to three (3) of eight (8) SRB hold-down experiencing a "hang-up". The results of loads analyses performed for (4) stud hang-ups indicate that the internal vehicle loads exceed current structural certification limits at several locations. To determine the risk to the vehicle from four (4) stud hang-ups, the likelihood of the scenario occurring must first be evaluated. Prior to the analysis discussed in this paper, the likelihood of occurrence had been estimated assuming that the stud hang-ups were completely independent events. That is, it was assumed that no common causes or factors existed between the individual stud hang-up events. A review of the data associated with the hang-up events, showed that a common factor (timing skew) was present. This paper summarizes a revised likelihood evaluation performed for the four (4) stud hang-ups case considering that there are common factors associated with the stud hang-ups. The results show that explicitly (i.e. not using standard common cause methodologies such as beta factor or Multiple Greek Letter modeling) taking into account the common factor of timing skew results in an increase in the estimated likelihood of four (4) stud hang-ups of an order of magnitude over the independent failure case.

Cross, Robert↗

NASA NTRS2009

Enceladus: An Active Cryovolcanic Satellite

Enceladus is one of the most remarkable satellites in the solar system, as revealed by Cassini's detection of active plumes erupting from warm fractures near its south pole. This discovery makes Enceladus the only icy satellite known to exhibit ongoing internally driven geological activity. The activity is presumably powered by tidal heating maintained by Enceladus 2:1 mean-motion resonance with Dione, but many questions remain. For instance, it appears difficult or impossible to maintain the currently observed radiated power (probably at least 6 GW) in steady state. It is also not clear how Enceladus first entered its current self-maintaining warm and dissipative state initial heating from non-tidal sources is probably required. There are also many unanswered questions about Enceladus interior. The silicate fraction inferred from its density of 1.68 g per cubic centimeter is probably differentiated into a core, though we have only indirect evidence for differentiation. Above the core there is probably a global or regional water layer, inferred from several models of tidal heating, and an ice shell thick enough to support the ~1 kilometer amplitude topography seen on Enceladus. It is possible that dissipation is largely localized beneath the south polar region. Enceladus surface geology, ranging from moderately cratered terrain to the virtually crater-free active south polar region, is highly diverse, tectonically complex, and remarkably symmetrical about the rotation axis and the direction to Saturn. South polar activity is concentrated along the four tiger stripe fractures, which radiate heat at temperatures up to at least 167 K and are the source of multiple plumes ejecting ~200 kilograms per second of H2O vapor along with significant N2 (or C2H4), CO2, CH4, NH3, and higher-mass hydrocarbons. The escaping gas maintains Saturn's neutral gas torus, and the plumes also eject a large number of micron-sized H2O ice grains that populate Saturn's E-ring. The mechanism that powers the plumes is not well understood, and whether liquid water is involved is a subject of active debate (but likely nonetheless). Enceladus provides a promising potential habitat for life in the outer solar system, and the active plumes allow the unique opportunity for direct sampling of that zone. Enceladus is thus a prime target for Cassini's continued exploration of the Saturn system, and will be a tempting target for future missions.

Spencer, J. R.↗

NASA NTRS1997

Award-Winning CARES/Life Ceramics Durability Evaluation Software Is Making Advanced Technology Accessible

Products made from advanced ceramics show great promise for revolutionizing aerospace and terrestrial propulsion and power generation. However, ceramic components are difficult to design because brittle materials in general have widely varying strength values. The CARES/Life software developed at the NASA Lewis Research Center eases this by providing a tool that uses probabilistic reliability analysis techniques to optimize the design and manufacture of brittle material components. CARES/Life is an integrated package that predicts the probability of a monolithic ceramic component's failure as a function of its time in service. It couples commercial finite element programs--which resolve a component's temperature and stress distribution - with reliability evaluation and fracture mechanics routines for modeling strength - limiting defects. These routines are based on calculations of the probabilistic nature of the brittle material's strength.

Source record↗

NASA NTRS1974

The detection of fatigue cracks by nondestructive testing methods

X-radiographic penetrant, ultrasonic, eddy current, holographic, and acoustic emission techniques were optimized and applied to the evaluation of 2219-T87 aluminum alloy test specimens. One hundred eighteen specimens containing a total of 328 fatigue cracks were evaluated. The cracks ranged in length from 0.500 inch (1.27 cm) to 0.007 inch (0.018 cm) and in depth from 0.178 inch (0.451 cm) and 0.001 inch (0.003 cm). Specimen thicknesses were nominally 0.060 inch (0.152 cm) and 0.210 inch (0.532 cm) and surface finishes were nominally 32 and 125 rms and 64 and 200 rms respectively. Specimens were evaluated in the as-milled surface condition, in the chemically milled surface condition and, after proof loading, in a randomized inspection sequence. Results of the nondestructive test (NDT) evaluations were compared with actual crack size obtained by measurement of the fractured specimens. Inspection data was then analyzed to provide a statistical basis for determinating the threshold crack detection sensitivity (the largest crack size that would be missed) for each of the inspection techniques at a 95% probability and 95% confidence level.

Rummel, W. D.↗

NASA NTRS1976

A reliability-based cost effective fail-safe design procedure

The authors have developed a methodology for cost-effective fatigue design of structures subject to random fatigue loading. A stochastic model for fatigue crack propagation under random loading has been discussed. Fracture mechanics is then used to estimate the parameters of the model and the residual strength of structures with cracks. The stochastic model and residual strength variations have been used to develop procedures for estimating the probability of failure and its changes with inspection frequency. This information on reliability is then used to construct an objective function in terms of either a total weight function or cost function. A procedure for selecting the design variables, subject to constraints, by optimizing the objective function has been illustrated by examples. In particular, optimum design of stiffened panel has been discussed.

Hanagud, S.↗

NASA NTRS1993

Explicit 3D continuum fracture modeling with smooth particle hydrodynamics

Impact phenomena shaped our solar system. As usual for most solar system processes, the scales are far different than we can address directly in the laboratory. Impact velocities are often much higher than we can achieve, sizes are often vastly larger, and most impacts take place in an environment where the only gravitational force is the mutual pull of the impactors. The Smooth Particle Hydrodynamics (SPH) technique has been applied in the past to the simulations of giant impacts. In these simulations, the colliding objects were so massive (at least a sizeable fraction of the Earth's mass) that material strength was negligible compared to gravity. This assumption can no longer be made when the bodies are much smaller. To this end, we have developed a 3D SPH code that includes a strength model to which we have added a von Mises yielding relation for stresses beyond the Hugoniot Elastic Limit. At the lower stresses associated with brittle failure, we use a rate-dependent strength based on the nucleation of incipient flaws whose number density is given by a Weibull distribution. Following Grady and Kipp and Melosh et al., we introduce a state variable D ('damage'), 0 less than D less than 1, which expresses the local reduction in strength due to crack growth under tensile loading. Unfortunately for the hydrodynamics, Grady and Kipp's model predicts which fragments are the most probable ones and not the ones that are really formed. This means, for example, that if a given laboratory experiment is modeled, the fragment distribution obtained from the Grady-Kipp theory would be equivalent to a ensemble average over many realizations of the experiment. On the other hand, the hydrodynamics itself is explicit and evolves not an ensemble average but very specific fragments. Hence, there is a clear incompatibility with the deterministic nature of the hydrodynamics equations and the statistical approach of the Grady-Kipp dynamical fracture model. We remedy these shortcomings by making the incipient flaw distribution explicit, i.e., particles carry activation strains which are distributed at random with a probability of occurrence given by the Weibull distribution. If the local principal axis strain exceeds this limit, damage starts to grow. By growing explicit cracks together with statistical cracks (damage) at the sub-particle scale, we ensure that material strength and fragmentation is independent of model resolution. We tested our scheme by simulating laboratory impact experiments on basalt spheres.

Benz, W.↗

NASA NTRS1975

Density, chemistry, and size distribution of interplanetary dust

Depth/diameter ratios measured for 98 craters in lunar glass targets reveal a broad distribution with a single strong peaking between 0.55 and 0.8. The measured values indicate a mean meteoroid density greater than 1 g/cu cm and probably less than 4 g/cu cm. Microprobe analyses show that typical glass pit liners on silicate targets contain only approximately 0.1% or less of meteoritic material. The size-frequency distribution of meteoroids was analyzed for a fractured glass surface of 60095, and a very steep size distribution of submicron meteoroids is indicated. As in the case of 15205, a dip at approximately 5 micron in the size-frequency distribution is detected.

Brownlee, D. E.↗

DOE OSTI2026

Uncertainty quantification for competing failure mechanisms in unidirectionally reinforced carbon–carbon composites

Microstructure-informed finite element models play a key role in the carbon–carbon composite design process. Variability in manufacturing process parameters and experimental limitations introduce model parameter uncertainty. This study quantifies the effect of model parameter uncertainty on transverse tensile fracture behavior and proposes a methodology to predict the failure mode based on competing microscale damage mechanisms. Finite element simulations incorporate fiber–matrix interface debonding with cohesive zones and matrix damage with a smeared crack band approach in a unidirectional carbon–carbon composite. Results from a variance-based global sensitivity analysis identifies interfacial and matrix damage parameters as the primary source of variability in fracture behavior. Sobol’ indices indicate that matrix and cohesive zone strengths contribute 94% of the variance in the effective ultimate stress. A local analysis elucidates the relationship between these constituent strength parameters and failure mode by estimating the probability of cohesive, matrix, and mixed-mode dominated failure. Based on the results for 4000 simulations, 93% exhibit mixed-mode or interfacial dominated failure, which underscores the crucial role of fiber–matrix interface debonding in the transverse tensile failure of carbon–carbon composites. These uncertainty quantification results facilitate more efficient model calibration and provide a framework for microstructure-informed failure predictions in the face of manufacturing-induced uncertainty.

36 MATERIALS SCIENCE↗

NASA NTRS1988

Fractography of composite delamination

Studies were made of the fractography of mode 2 delamination and the impact damage of carbon fiber reinforced polymer composites. Laminates fractured under mode 2 loading were potted in a clear epoxy polymer, sectioned and polished and examined using transmission and reflection light microscopy. There were only occasional fibers bridging the mode 2 cracks. These cracks were not always visible probably because the crack opening displacement was too small as to be resolved using light microscopy. A study was made of the effect of repetitive impacts on laminates of AS4/3501-6 and IM6/3501-6. Plots of cumulative impact energy vs cumulative absorbed energy exhibited a sharp change in slope which corresponded to the damage area reaching the edges of the specimen. The initial slope was highly reproducible for both composite materials. On the other hand, the intersection point between the two slopes, where the damage area reaches the specimen edges, was highly variable between specimens. This variability is tentatively ascribed to differences in laminate quality.

Source record↗

NASA NTRS1997

Effects of Fiber Coatings on Tensile Properties of Hi-Nicalon SiC/RBSN Tow Composites

Uncoated Hi-Nicalon silicon carbide (SiC) fiber tows and those coated with a single surface layer of pyrolytic boron nitride (PBN), double layers of PBN/Si-rich PBN, and boron nitride (BN)/SiC coatings deposited by chemical vapor deposition (CVD) method were infiltrated with silicon slurry and then exposed to N2, for 4 hr at 1200 and 1400 C. Room temperature ultimate tensile fracture loads and microstructural characterization of uncoated and CVD coated Hi-Nicalon SiC fiber reinforced reaction-bonded silicon nitride (RBSN) tow composites were measured to select suitable interface coating(s) stable under RBSN processing conditions. Results indicate that room temperature ultimate fracture loads of the uncoated Hi-Nicalon SiC/RBSN tow composites nitrided at both temperatures were significantly lower than those of the uncoated Hi-Nicalon tows without slurry infiltration. In contrast, all CVD coated Hi-Nicalon SiC/RBSN tow composites retained a greater fraction of the dry tow fracture load after nitridation at 1200 C, but degraded significantly after nitridation at 1400 C. Reaction between metal impurities (Fe and Ni) present in the attrition milled silicon powder and uncoated regions of SiC fibers appears to be the probable cause for fiber degradation.

Bhatt, Ramakrishna T.↗

NASA NTRS1994

Microstructurally based model of fatigue initiation and growth

A model to calculate fatigue life is developed based on the assumption that fatigue life is entirely composed of crack growth from an initial microstructural inhomogeneity. Specifically, growth is considered to start from either an ellipsoidal void, a cracked particle, or a debonded particle. The capability of predicting fatigue life from material microstructure is based on linear elastic fracture mechanics principles, the sizes of the crack-initiating microstructural inhomogeneities, and an initiation parameter that is proportional to the cyclic plastic zone size. A key aspect of this modeling approach is that it is linked with a general purpose probability program to analyze the effect of the distribution of controlling microstructural features within the material. This enables prediction of fatigue stress versus life curves for various specimen geometries using distributional statistics obtained from characterizations of the microstructure. Results are compared to experimental fatigue data from an aluminum alloy.

Brockenbrough, J. R.↗

NASA NTRS2019

90/95 POD Radiography Concern for COPVs and Metal Tank Welds

Radiographic inspections of welds in all-metal tanks and composite overwrapped pressure vessel (COPV) liners that are used to establish initial crack size in damage tolerance assessments are not as rigorous as previously understood. As a result, the 90/95 percent probability of detection (POD) requirements in S-080 1 and S-081 2 are not met when this inspection method is used. Development of new inspection methods will require about three years. During that time, additional review and assessment of the fracture margin may be needed to support waivers and provide a better understanding of weld cracking risk associated with an individual tank design.

90/95 POD Radiography Concern↗

NASA NTRS1982

Synthesis of regional crust and upper-mantle structure from seismic and gravity data

Analyses of regional gravity and magnetic patterns, LANDSAT images and geological information revealed two major lineaments crossing western Pennsylvania and parts of surrounding states. These lineaments are inferred to be expressions of fracture zones which penetrare deeply into the crust and possibly the upper mantle. The extensions of the Tyron-Mt. Union and the Pittsburgh-Washington lineaments bound a distinct crustal block (Lake Erie-Maryland block) over 100 km wide and probably more than 600 km in length. Evidence exists for the lateral displacement of this block at least 60 km northwestward during late Precambrian to Lower Ordovician time. Subsequent movements have been mainly vertical with respect to neighboring blocks. A possible crustal block that passes through eastern Kentucky, proposed by a TVA study on tectonics in the southern Appalachians, was also investigated. Finally, the use of regional gravity and magnetic data in identifying major crustal structures beneath western Pennsylvania is discussed.

Alexander, S. S.↗

NASA NTRS1994

Geology of the small Tharsis volcanoes: Jovis Tholus, Ulysses Patera, Biblis Patera, Mars

Jovis Tholus, Ulysses Patera, and Biblis Patera, three small volcanoes in the Tharsis area of Mars, provide important insight into the evolution of volcanism on Mars. All three are interpreted to be shield volcanoes, indicating that shield volcansim was present from the outset in Tharsis. Jovis Tholus is the least complex with simple repeated outpouring of lavas and caldera-forming events. Ulysses Patera is dominated by a giant caldera within which is a line of cinder cones or domes suggesting terminal stages of volcanism in which the magma had either significant volatiles or increased viscosity. Biblis Patera is characterized by nested calderas which have expanded by block faulting of the flank; it also exhibits lava flows erupted onto the flanks from events along concentric fractures. These shields are different from the younger Tharsis Montes shields only in terms of the volume of erupted material. The limited shield volume suggests that the magma source which fed the shields was rapidly depleted. The relatively large size ofthe calderas probably results from relatively large, shallow magma bodies rather than significant burial of the flanks by younger lavas. Eruption rates consistent with typical terrestrial basaltic eruptiuon rates suggest that these volcanoes were probably built over time spans of 10(exp 4) to 10(exp 5) years. Stratigraphic ages range from Early to Upper Hesperian; absolute ages range from 1.9 to 3.4 Ga.

Plescia, J. B.↗

NASA NTRS1994

NASA/CARES dual-use ceramic technology spinoff applications

NASA has developed software that enables American industry to establish the reliability and life of ceramic structures in a wide variety of 21st Century applications. Designing ceramic components to survive at higher temperatures than the capability of most metals and in severe loading environments involves the disciplines of statistics and fracture mechanics. Successful application of advanced ceramics material properties and the use of a probabilistic brittle material design methodology. The NASA program, known as CARES (Ceramics Analysis and Reliability Evaluation of Structures), is a comprehensive general purpose design tool that predicts the probability of failure of a ceramic component as a function of its time in service. The latest version of this software, CARESALIFE, is coupled to several commercially available finite element analysis programs (ANSYS, MSC/NASTRAN, ABAQUS, COSMOS/N4, MARC), resulting in an advanced integrated design tool which is adapted to the computing environment of the user. The NASA-developed CARES software has been successfully used by industrial, government, and academic organizations to design and optimize ceramic components for many demanding applications. Industrial sectors impacted by this program include aerospace, automotive, electronic, medical, and energy applications. Dual-use applications include engine components, graphite and ceramic high temperature valves, TV picture tubes, ceramic bearings, electronic chips, glass building panels, infrared windows, radiant heater tubes, heat exchangers, and artificial hips, knee caps, and teeth.

Powers, Lynn M.↗

NASA NTRS1975

Fractography of the high temperature hydrogen attack of a medium carbon steel

Microscopic fracture processes were studied which are associated with hydrogen attack of a medium carbon steel in a well-controlled, high-temperature, high-purity hydrogen environment. Exposure to a hydrogen pressure and temperature of 3.5 MN/m2 and 575 C was found to degrade room temperature tensile properties with increasing exposure time. After 408 hr, yield and ultimate strengths were reduced by more than 40 percent and elongation was reduced to less than 2 percent. Initial fissure formation was found to be associated with manganese rich particles, most probably manganese oxide, aligned in the microstructure during the rolling operation. Fissure growth was found to be associated with a reduction in carbide content of the microstructure and was inhibited by the depletion of carbon. The interior surfaces of sectioned fissures or bubbles exhibit both primary and secondary cracking by intergranular separation. The grain surfaces were rough and rounded, suggesting a diffusion-associated separation process. Specimens that failed at room temperature after exposure to hydrogen were found to exhibit mixed mode fracture having varying amounts of intergranular separation, dimple formation, and cleavage, depending on exposure time.

Melson, H. G.↗

NASA NTRS1961

Spontaneous Cracking in Unfired Magnesia Compacts Upon Standing in Air

Analytical-grade magnesium oxide powder without binder was compressed hydrostatically to 50,000 lb. per sq. in. to form compacts. When exposed to moist air immediately after pressing, these compacts developed irregularly shaped cracks. Controlled tests, in which these compacts were exposed for various lengths of time to various atmospheres, indicated that in general water vapor, carbon dioxide, and residual stresses had to be present if cracking was to occur. The probable cause of the cracking was the formation of a less dense and mechanically weak basic carbonate of magnesium at crystallite surface points of high stress concentration which developed during the compacting. The adsorption of dry CO2 at such sites prevented subsequent delayed fracture.

Davies, Myron O.↗

NASA NTRS1985

The relationship of extensional and compressional tectonics to a Precambrian fracture system in the eastern overthrust belt, USA

The central and southern Appalachians have a long history of interrelated extensional and compressional tectonics. It is proposed that each episode was controlled by a reactivation of a fracture system in the Precambrian basement. Proprietary seismic-reflection profiles show a system of down-to-the-east Precambrian extensional faults. When under renewed extension, these faults produce features such as the western border faults of Mesozoic basins, and when under compression, probably produce tectonic ramps in the overlying sedimentary cover rocks as well as the spatially and genetically related Alleghenian folds. This system, which parallels the Appalachian trend, is cut by a system of cross-strike hinge or scissors faults that have probable strike-slip movements. Reactivation of this cross-strike system appears to have produced lateral ramps that connect decollements at different stratigraphic levels and caused abrupt changes in fold wavelength along strikes. Continued reactivation of this cross-strike system is suggested by east-west border faults and Precambrian highs between Mesozoic basins. The present activity of this system is suggested by the fact that more than 35% of recent earthquakes are coincident with cross-strike faults and lateral ramps.

Pohn, H.↗