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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 217 records · Page 12

Ejecta Management in a Safe Lithium Ion Battery Design

As lithium-ion battery energy densities continue to rise, managing the heat and pressure generated during failure events has become increasingly critical. Safety systems must effectively relieve pressure without releasing sparks, flames, or particulate matter, requiring robust filtration solutions. The challenge is compounded by the reduced free volume available for gas expansion in high-density designs, which increases the demands on these filters. While significant progress has been made through experimental studies and modeling efforts to understand the behavior of ejecta during battery failures, there remains a pressing need for practical, rule-of-thumb sizing parameters. These parameters would help correlate high-energy waste streams with appropriate filter design, ensuring reliable containment and safety. This talk will explore recent experimental findings in this area and discuss the potential pathways for developing these essential sizing guidelines.

Ejecta Management↗

Progressive Failure And Life Prediction of Ceramic and Textile Composites

An engineering approach to predict the fatigue life and progressive failure of multilayered composite and textile laminates is presented. Analytical models which account for matrix cracking, statistical fiber failures and nonlinear stress-strain behavior have been developed for both composites and textiles. The analysis method is based on a combined micromechanics, fracture mechanics and failure statistics analysis. Experimentally derived empirical coefficients are used to account for the interface of fiber and matrix, fiber strength, and fiber-matrix stiffness reductions. Similar approaches were applied to textiles using Repeating Unit Cells. In composite fatigue analysis, Walker's equation is applied for matrix fatigue cracking and Heywood's formulation is used for fiber strength fatigue degradation. The analysis has been compared with experiment with good agreement. Comparisons were made with Graphite-Epoxy, C/SiC and Nicalon/CAS composite materials. For textile materials, comparisons were made with triaxial braided and plain weave materials under biaxial or uniaxial tension. Fatigue predictions were compared with test data obtained from plain weave C/SiC materials tested at AS&M. Computer codes were developed to perform the analysis. Composite Progressive Failure Analysis for Laminates is contained in the code CPFail. Micromechanics Analysis for Textile Composites is contained in the code MicroTex. Both codes were adapted to run as subroutines for the finite element code ABAQUS and CPFail-ABAQUS and MicroTex-ABAQUS. Graphic user interface (GUI) was developed to connect CPFail and MicroTex with ABAQUS.

Xue, David Y.↗

Computational Analyses in Support of Sub-scale Diffuser Testing for the A-3 Facility: Unsteady Analyses and Risk Assessment - Part 2

Simulation technology can play an important role in rocket engine test facility design and development by assessing risks, providing analysis of dynamic pressure and thermal loads, identifying failure modes and predicting anomalous behavior of critical systems. This is especially true for facilities such as the proposed A-3 facility at NASA SSC because of a challenging operating envelope linked to variable throttle conditions at relatively low chamber pressures. Design Support of the feasibility of operating conditions and procedures is critical in such cases due to the possibility of startup/shutdown transients, moving shock structures, unsteady shock-boundary layer interactions and engine and diffuser unstart modes that can result in catastrophic failure. Analyses of such systems is difficult due to resolution requirements needed to accurately capture moving shock structures, shock-boundary layer interactions, two-phase flow regimes and engine unstart modes. In a companion paper, we will demonstrate with the use of CFD, steady analyses advanced capability to evaluate supersonic diffuser and steam ejector performance in the sub-scale A-3 facility. In this paper we will address transient issues with the operation of the facility especially at startup and shutdown, and assess risks related to afterburning due to the interaction of a fuel rich plume with oxygen that is a by-product of the steam ejectors. The primary areas that will be addressed in this paper are: (1) analyses of unstart modes due to flow transients especially during startup/ignition, (2) engine safety during the shutdown process (3) interaction of steam ejectors with the primary plume i.e. flow transients as well as probability of afterburning. In this abstract we discuss unsteady analyses of the engine shutdown process. However, the final paper will include analyses of a staged startup, drawdown of the engine test cell pressure, and risk assessment of potential afterburning in the facility. Unsteady simulations have been carried out to study the engine shutdown process in the facility and understand the physics behind the interactions between the steam ejectors, the test cell and the supersonic diffuser. As a first approximation, to understand the dominant unsteady mechanisms in the engine test cell and the supersonic diffuser, the turning duct in the facility was removed. As the engine loses power a rarefaction wave travels downstream that disrupts the shock cell structure in the supersonic diffuser. Flow from the test cell is seen to expand into the supersonic diffuser section and re-pressurizes the area around the nozzle along with a upstream traveling compression wave that emanates from near the first stage ejectors. Flow from the first stage ejector expands to the center of the duct and a new shock train is formed between the first and second stage ejectors. Both stage ejectors keep the facility pressurized and prevent any large amplitude pressure fluctuations from affecting the engine nozzle. The resultant pressure loads the nozzle experiences in the shutdown process are small.

Ahuja, Vineet↗

Goal-Function Tree Modeling for Systems Engineering and Fault Management

The draft NASA Fault Management (FM) Handbook (2012) states that Fault Management (FM) is a "part of systems engineering", and that it "demands a system-level perspective" (NASAHDBK- 1002, 7). What, exactly, is the relationship between systems engineering and FM? To NASA, systems engineering (SE) is "the art and science of developing an operable system capable of meeting requirements within often opposed constraints" (NASA/SP-2007-6105, 3). Systems engineering starts with the elucidation and development of requirements, which set the goals that the system is to achieve. To achieve these goals, the systems engineer typically defines functions, and the functions in turn are the basis for design trades to determine the best means to perform the functions. System Health Management (SHM), by contrast, defines "the capabilities of a system that preserve the system's ability to function as intended" (Johnson et al., 2011, 3). Fault Management, in turn, is the operational subset of SHM, which detects current or future failures, and takes operational measures to prevent or respond to these failures. Failure, in turn, is the "unacceptable performance of intended function." (Johnson 2011, 605) Thus the relationship of SE to FM is that SE defines the functions and the design to perform those functions to meet system goals and requirements, while FM detects the inability to perform those functions and takes action. SHM and FM are in essence "the dark side" of SE. For every function to be performed (SE), there is the possibility that it is not successfully performed (SHM); FM defines the means to operationally detect and respond to this lack of success. We can also describe this in terms of goals: for every goal to be achieved, there is the possibility that it is not achieved; FM defines the means to operationally detect and respond to this inability to achieve the goal. This brief description of relationships between SE, SHM, and FM provide hints to a modeling approach to provide formal connectivity between the nominal (SE), and off-nominal (SHM and FM) aspects of functions and designs. This paper describes a formal modeling approach to the initial phases of the development process that integrates the nominal and off-nominal perspectives in a model that unites SE goals and functions of with the failure to achieve goals and functions (SHM/FM). This methodology and corresponding model, known as a Goal-Function Tree (GFT), provides a means to represent, decompose, and elaborate system goals and functions in a rigorous manner that connects directly to design through use of state variables that translate natural language requirements and goals into logical-physical state language. The state variable-based approach also provides the means to directly connect FM to the design, by specifying the range in which state variables must be controlled to achieve goals, and conversely, the failures that exist if system behavior go out-of-range. This in turn allows for the systems engineers and SHM/FM engineers to determine which state variables to monitor, and what action(s) to take should the system fail to achieve that goal. In sum, the GFT representation provides a unified approach to early-phase SE and FM development. This representation and methodology has been successfully developed and implemented using Systems Modeling Language (SysML) on the NASA Space Launch System (SLS) Program. It enabled early design trade studies of failure detection coverage to ensure complete detection coverage of all crew-threatening failures. The representation maps directly both to FM algorithm designs, and to failure scenario definitions needed for design analysis and testing. The GFT representation provided the basis for mapping of abort triggers into scenarios, both needed for initial, and successful quantitative analyses of abort effectiveness (detection and response to crew-threatening events).

Patterson, Jonathan D.↗

Prediction of fiber composite mechanical behavior made simple

The elastic properties and failure stresses of angleplied fiber composite laminates were determined using a pocket calculator. The procedure uses simple equations and appropriate graphs of elastic properties versus angle plies, and can handle all types of fiber composites including hybrids. The versatility and generality of the method is illustrated in several step-by-step numerical examples.

Chamis, C. C.↗

Environment assisted degradation mechanisms in advanced light metals

A multifaceted research program on the performance of advanced light metallic alloys in aggressive aerospace environments, and associated environmental failure mechanisms was initiated. The general goal is to characterize alloy behavior quantitatively and to develop predictive mechanisms for environmental failure modes. Successes in this regard will provide the basis for metallurgical optimization of alloy performance, for chemical control of aggressive environments, and for engineering life prediction with damage tolerance and long term reliability.

Gangloff, R. P.↗

Verification and Validation of Progressive Damage and Failure Analysis Methods for Intralaminar Failure Modes in Thermoplastic Composites

Current progressive damage and failure analysis (PDFA) methods were developed around thermoset material systems and their physical behavior. However, the applicability of these analysis methods has not been evaluated for use in modeling thermoplastic material systems. As part of the Hi-Rate Composite Aircraft Manufacturing (HiCAM) Project sponsored by NASA, intralaminar failure characterization was completed on a thermoplastic material system, AS4D/PEKK-FC, with off-axis tension (OAT) and off-axis compression (OAC) testing. The experiments were able to capture matrix non-linear shear behavior and the failure envelope of the material system. Two PDFA methods, LS-DYNA MAT299 and NASA’s CompDam-DGD, were then employed to simulate individual coupon behavior and simulation results were compared to published verification and validation guidelines from the CMH-17 crashworthiness working group. The results found that the two modeling methods provided suitable representation of material behavior of thermoplastics.

PDFA↗

Verification and Validation of Progressive Damage and Failure Analysis Methods for Intralaminar Failure Modes in Thermoplastic Composites

Current progressive damage and failure analysis (PDFA) methods were developed around thermoset material systems and their physical behavior. However, the applicability of these analysis methods has not been evaluated for use in modeling thermoplastic material systems. As part of the Hi-Rate Composite Aircraft Manufacturing (HiCAM) Project sponsored by NASA, intralaminar failure characterization was completed on a thermoplastic material system, AS4D/PEKK-FC, with off-axis tension (OAT) and off-axis compression (OAC) testing. The experiments were able to capture matrix non-linear shear behavior and the failure envelope of the material system. Two PDFA methods, LS-DYNA MAT299 and NASA’s CompDam-DGD, were then employed to simulate individual coupon behavior and simulation results were compared to published verification and validation guidelines from the CMH-17 crashworthiness working group. The results found that the two modeling methods provided suitable representation of material behavior of thermoplastics.

PDFA↗

HRMT-60- RaDIATE Material Studies

HRMT-60 experiment was performed at the CERN-HiRadMat facility in October 2022 to understand thermal shock response of conventional materials and novel materials to support the design and operation of future multi-MW accelerator beam windows and secondary particle-production targets. This experiment, organized within the framework of the RaDIATE collaboration, builds on the previous HRMT-43 (BeGrid2) experiment, where a variety of materials in both non-irradiated and previously proton-irradiated conditions were tested. The primary goal was to understand the failure mechanisms, limits and flow behavior of the various material specimens, as well as compare and contrast the thermal shock response of previously irradiated materials to their non-irradiated counterparts. A total of 120 samples were tested at different beam conditions. This poster will present the preliminary results of several materials tested during this experiments.

Ammigan, K.↗

Experimental and analytical investigation of the fracture processes of boron/aluminum laminates containing notches

Experimental results for five laminate orientations of boron/aluminum composites containing either circular holes or crack-like slits are presented. Specimen stress-strain behavior, stress at first fiber failure, and ultimate strength were determined. Radiographs were used to monitor the fracture process. The specimens were analyzed with a three-dimensional elastic-elastic finite-element model. The first fiber failures in notched specimens with laminate orientation occurred at or very near the specimen ultimate strength. For notched unidirectional specimens, the first fiber failure occurred at approximately one-half of the specimen ultimate strength. Acoustic emission events correlated with fiber breaks in unidirectional composites, but did not for other laminates. Circular holes and crack-like slits of the same characteristic length were found to produce approximately the same strength reduction. The predicted stress-strain responses and stress at first fiber failure compared very well with test data for laminates containing 0 deg fibers.

Johnson, W. S.↗

The effect of temperature on the deformation and fracture of SiC/Ti-24Al-11Nb

The effect of temperature on the stress-strain behavior in air and the failure mechanisms of Ti-24Al-11Nb alloy and of a SiC/Ti-24Al-11Nb composite with continuous SiC fibers oriented parallel to the loading direction was investigated over temperature range 23-815 C. It was found that the tensile failure process of SiC/Ti-24Al-11Nb was controlled at all temperatures by fiber fracture. Composite failure occurred at 0.8 percent strain at all temperatures. Debond and frictional stresses at the fiber-matrix interface decreased with increased temperature.

Brindley, P. K.↗

Modular Certification

Airplanes are certified as a whole: there is no established basis for separately certifying some components, particularly software-intensive ones, independently of their specific application in a given airplane. The absence of separate certification inhibits the development of modular components that could be largely "precertified" and used in several different contexts within a single airplane, or across many different airplanes. In this report, we examine the issues in modular certification of software components and propose an approach based on assume-guarantee reasoning. We extend the method from verification to certification by considering behavior in the presence of failures. This exposes the need for partitioning, and separation of assumptions and guarantees into normal and abnormal cases. We then identify three classes of property that must be verified within this framework: safe function, true guarantees, and controlled failure. We identify a particular assume-guarantee proof rule (due to McMillan) that is appropriate to the applications considered, and formally verify its soundness in PVS.

Rushby, John↗

Application of Probabilistic Analysis to Aircraft Impact Dynamics

Full-scale aircraft crash simulations performed with nonlinear, transient dynamic, finite element codes can incorporate structural complexities such as: geometrically accurate models; human occupant models; and advanced material models to include nonlinear stressstrain behaviors, laminated composites, and material failure. Validation of these crash simulations is difficult due to a lack of sufficient information to adequately determine the uncertainty in the experimental data and the appropriateness of modeling assumptions. This paper evaluates probabilistic approaches to quantify the uncertainty in the simulated responses. Several criteria are used to determine that a response surface method is the most appropriate probabilistic approach. The work is extended to compare optimization results with and without probabilistic constraints.

Lyle, Karen H.↗

Automated fault-management in a simulated spaceflight micro-world

BACKGROUND: As human spaceflight missions extend in duration and distance from Earth, a self-sufficient crew will bear far greater onboard responsibility and authority for mission success. This will increase the need for automated fault management (FM). Human factors issues in the use of such systems include maintenance of cognitive skill, situational awareness (SA), trust in automation, and workload. This study examine the human performance consequences of operator use of intelligent FM support in interaction with an autonomous, space-related, atmospheric control system. METHODS: An expert system representing a model-base reasoning agent supported operators at a low level of automation (LOA) by a computerized fault finding guide, at a medium LOA by an automated diagnosis and recovery advisory, and at a high LOA by automate diagnosis and recovery implementation, subject to operator approval or veto. Ten percent of the experimental trials involved complete failure of FM support. RESULTS: Benefits of automation were reflected in more accurate diagnoses, shorter fault identification time, and reduced subjective operator workload. Unexpectedly, fault identification times deteriorated more at the medium than at the high LOA during automation failure. Analyses of information sampling behavior showed that offloading operators from recovery implementation during reliable automation enabled operators at high LOA to engage in fault assessment activities CONCLUSIONS: The potential threat to SA imposed by high-level automation, in which decision advisories are automatically generated, need not inevitably be counteracted by choosing a lower LOA. Instead, freeing operator cognitive resources by automatic implementation of recover plans at a higher LOA can promote better fault comprehension, so long as the automation interface is designed to support efficient information sampling.

NASA Discipline Space Human Factors↗

Reliability-Based Life Assessment of Stirling Convertor Heater Head

Onboard radioisotope power systems being developed and planned for NASA's deep-space missions require reliable design lifetimes of up to 14 yr. The structurally critical heater head of the high-efficiency Stirling power convertor has undergone extensive computational analysis of operating temperatures, stresses, and creep resistance of the thin-walled Inconel 718 bill of material. A preliminary assessment of the effect of uncertainties in the material behavior was also performed. Creep failure resistance of the thin-walled heater head could show variation due to small deviations in the manufactured thickness and in uncertainties in operating temperature and pressure. Durability prediction and reliability of the heater head are affected by these deviations from nominal design conditions. Therefore, it is important to include the effects of these uncertainties in predicting the probability of survival of the heater head under mission loads. Furthermore, it may be possible for the heater head to experience rare incidences of small temperature excursions of short duration. These rare incidences would affect the creep strain rate and, therefore, the life. This paper addresses the effects of such rare incidences on the reliability. In addition, the sensitivities of variables affecting the reliability are quantified, and guidelines developed to improve the reliability are outlined. Heater head reliability is being quantified with data from NASA Glenn Research Center's accelerated benchmark testing program.

Shah, Ashwin R.↗

Variable Stiffness Panel Structural Analyses With Material Nonlinearity and Correlation With Tests

Results from structural analyses of three tow-placed AS4/977-3 composite panels with both geometric and material nonlinearities are presented. Two of the panels have variable stiffness layups where the fiber orientation angle varies as a continuous function of location on the panel planform. One variable stiffness panel has overlapping tow bands of varying thickness, while the other has a theoretically uniform thickness. The third panel has a conventional uniform-thickness [plus or minus 45](sub 5s) layup with straight fibers, providing a baseline for comparing the performance of the variable stiffness panels. Parametric finite element analyses including nonlinear material shear are first compared with material characterization test results for two orthotropic layups. This nonlinear material model is incorporated into structural analysis models of the variable stiffness and baseline panels with applied end shortenings. Measured geometric imperfections and mechanical prestresses, generated by forcing the variable stiffness panels from their cured anticlastic shapes into their flatter test configurations, are also modeled. Results of these structural analyses are then compared to the measured panel structural response. Good correlation is observed between the analysis results and displacement test data throughout deep postbuckling up to global failure, suggesting that nonlinear material behavior is an important component of the actual panel structural response.

Wu, K. Chauncey↗

Metal Whiskers: Failure Modes and Mitigation Strategies

Metal coatings especially tin, zinc and cadmium are unpredictably susceptible to the formation of electrically conductive, crystalline filaments referred to as metal whiskers. The use of such coatings in and around electrical systems presents a risk of electrical shorting. Examples of metal whisker formation are shown with emphasis on optical inspection techniques to improve probability of detection. The failure modes (i.e., electrical shorting behavior) associated with metal whiskers are described. Based on an almost 9- year long study, the benefits of polyurethane conformal coat (namely, Arathane 5750) to protect electrical conductors from whisker-induced short circuit anomalies is discussed.

Brusse, Jay A.↗