Results for “Failure behavior” — Page 13

NASA NTRS2008

Computational Analyses in Support of Sub-scale Diffuser Testing for the A-3 Facility: Steady Predictions - Part 1

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. Advanced numerical tools assume greater significance in supporting testing and design of high altitude testing facilities and plume induced testing environments of high thrust engines because of the greater inter-dependence and synergy in the functioning of the different sub-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. Facility designs in this case will require a complex network of diffuser ducts, steam ejector trains, fast operating valves, cooling water systems and flow diverters that need to be characterized for steady state performance. In this paper, we will demonstrate with the use of CFD analyses s advanced capability to evaluate supersonic diffuser and steam ejector performance in a sub-scale A-3 facility at NASA Stennis Space Center (SSC) where extensive testing was performed. Furthermore, the focus in this paper relates to modeling of critical sub-systems and components used in facilities such as the A-3 facility. The work here will address deficiencies in empirical models and current CFD analyses that are used for design of supersonic diffusers/turning vanes/ejectors as well as analyses for confined plumes and venting processes. The primary areas that will be addressed are: (1) supersonic diffuser performance including analyses of thermal loads (2) accurate shock capturing in the diffuser duct; (3) effect of turning duct on the performance of the facility (4) prediction of mass flow rates and performance classification for steam ejectors (5) comparisons with test data from sub-scale diffuser testing and assessment of confidence levels in CFD based flowpath modeling of the facility. The analyses tools used here expand on the multi-element unstructured CFD which has been tailored and validated for impingement dynamics of dry plumes, complex valve/feed systems, and high pressure propellant delivery systems used in engine and component test stands at NASA SSC. The analyses performed in the evaluation of the sub-scale diffuser facility explored several important factors that influence modeling and understanding of facility operation such as (a) importance of modeling the facility with Real Gas approximation, (b) approximating the cluster of steam ejector nozzles as a single annular nozzle, (c) existence of mixed subsonic/supersonic flow downstream of the turning duct, and (d) inadequacy of two-equation turbulence models in predicting the correct pressurization in the turning duct and expansion of the second stage steam ejectors. The procedure used for modeling the facility was as follows: (i) The engine, test cell and first stage ejectors were simulated with an axisymmetric approximation (ii) the turning duct, second stage ejectors and the piping downstream of the second stage ejectors were analyzed with a three-dimensional simulation utilizing a half-plane symmetry approximation. The solution i.e. primitive variables such as pressure, velocity components, temperature and turbulence quantities were passed from the first computational domain and specified as a supersonic boundary condition for the second simulation. (iii) The third domain comprised of the exit diffuser and the region in the vicinity of the facility (primary included to get the correct shock structure at the exit of the facility and entrainment characteristics). The first set of simulations comprising the engine, test cell and first stage ejectors was carried out both as a turbulent real gas calculation as well as a turbulent perfect gas calculation. A comparison for the two cases (Real Turbulent and Perfect gas turbulent) of the Ma Number distribution and temperature distributions are shown in Figures 1 and 2 respectively. The Mach Number distribution shows small yet distinct differences between the two cases such as locations of shocks/shock reflections and a slightly different impingement point on the wall of the diffuser from the expansion at the exit of the nozzle. Similarly the temperature distribution indicates different flow recirculation patterns in the test cell. Both cases capture all the essential flow phenomena such as the shock-boundary layer interaction, plume expansion, expansion of the first stage ejectors, mixing between the engine plume and the first stage ejector flow and pressurization due to the first stage ejectors. The final paper will discuss thermal loads on the walls of the diffuser and cooling mechanisms investigated.

Allgood, Daniel C.↗

NASA NTRS2010

Computational Analyses in Support of Sub-scale Diffuser Testing for the A-3 Facility: Steady Predictions - Part 1

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. Advanced numerical tools assume greater significance in supporting testing and design of high altitude testing facilities and plume induced testing environments of high thrust engines because of the greater inter-dependence and synergy in the functioning of the different sub-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. Facility designs in this case will require a complex network of diffuser ducts, steam ejector trains, fast operating valves, cooling water systems and flow diverters that need to be characterized for steady state performance. In this paper, we will demonstrate with the use of CFD analyses s advanced capability to evaluate supersonic diffuser and steam ejector performance in a sub-scale A-3 facility at NASA Stennis Space Center (SSC) where extensive testing was performed. Furthermore, the focus in this paper relates to modeling of critical sub-systems and components used in facilities such as the A-3 facility. The work here will address deficiencies in empirical models and current CFD analyses that are used for design of supersonic diffusers/turning vanes/ejectors as well as analyses for confined plumes and venting processes. The primary areas that will be addressed are: (1) supersonic diffuser performance including analyses of thermal loads (2) accurate shock capturing in the diffuser duct; (3) effect of turning duct on the performance of the facility (4) prediction of mass flow rates and performance classification for steam ejectors (5) comparisons with test data from sub-scale diffuser testing and assessment of confidence levels in CFD based flowpath modeling of the facility. The analyses tools used here expand on the multi-element unstructured CFD which has been tailored and validated for impingement dynamics of dry plumes, complex valve/feed systems, and high pressure propellant delivery systems used in engine and component test stands at NASA SSC. The analyses performed in the evaluation of the sub-scale diffuser facility explored several important factors that influence modeling and understanding of facility operation such as (a) importance of modeling the facility with Real Gas approximation, (b) approximating the cluster of steam ejector nozzles as a single annular nozzle, (c) existence of mixed subsonic/supersonic flow downstream of the turning duct, and (d) inadequacy of two-equation turbulence models in predicting the correct pressurization in the turning duct and expansion of the second stage steam ejectors. The procedure used for modeling the facility was as follows: (i) The engine, test cell and first stage ejectors were simulated with an axisymmetric approximation (ii) the turning duct, second stage ejectors and the piping downstream of the second stage ejectors were analyzed with a three-dimensional simulation utilizing a half-plane symmetry approximation. The solution i.e. primitive variables such as pressure, velocity components, temperature and turbulence quantities were passed from the first computational domain and specified as a supersonic boundary condition for the second simulation. (iii) The third domain comprised of the exit diffuser and the region in the vicinity of the facility (primary included to get the correct shock structure at the exit of the facility and entrainment characteristics). The first set of simulations comprising the engine, test cell and first stage ejectors was carried out both as a turbulent real gas calculation as well as a turbulent perfect gas calculation. A comparison for the two cases (Real Turbulent and Perfect gas turbulent) of the Ma Number distribution and temperature distributions are shown in Figures 1 and 2 respectively.

Allgood, Daniel C.↗

NASA NTRS2016

Using Tabulated Experimental Data to Drive an Orthotropic Elasto-Plastic Three-Dimensional Model for Impact Analysis

An orthotropic elasto-plastic-damage three-dimensional model with tabulated input has been developed to analyze the impact response of composite materials. The theory has been implemented as MAT 213 into a tailored version of LS-DYNA being developed under a joint effort of the FAA and NASA and has the following features: (a) the theory addresses any composite architecture that can be experimentally characterized as an orthotropic material and includes rate and temperature sensitivities, (b) the formulation is applicable for solid as well as shell element implementations and utilizes input data in a tabulated form directly from processed experimental data, (c) deformation and damage mechanics are both accounted for within the material model, (d) failure criteria are established that are functions of strain and damage parameters, and mesh size dependence is included, and (e) the theory can be efficiently implemented into a commercial code for both sequential and parallel executions. The salient features of the theory as implemented in LS-DYNA are illustrated using a widely used composite - the T800S/3900-2B[P2352W-19] BMS8-276 Rev-H-Unitape fiber/resin unidirectional composite. First, the experimental tests to characterize the deformation, damage and failure parameters in the material behavior are discussed. Second, the MAT213 input model and implementation details are presented with particular attention given to procedures that have been incorporated to ensure that the yield surfaces in the rate and temperature dependent plasticity model are convex. Finally, the paper concludes with a validation test designed to test the stability, accuracy and efficiency of the implemented model.

Polymer Matrix Composites↗

NASA NTRS2020

A Multiscale Cohesive Law for Carbon Fiber Networks

Better predictive models of mechanical failure in low-weight heat shield composites would aid material certification for missions with aggressive atmospheric entry conditions. Here, we develop such a model for the rapid engineering analysis of the failure limits of phenolic impregnated carbon ablator (PICA) - a leading heat shield material whose structural component is a carbon fiber network. We hypothesize inelastic deformation failure mechanisms and model their behavior using molecular dynamics simulations to calculate the binding energy. We then upscale this binding energy to the macroscale using a renormalization argument. The approach delivers insightful and reasonably accurate macroscale predictions that compare favorably to experiments. In application, the model is validated for a particular variety of PICA by comparison to experiment and would then be used to study design scenarios in different entry conditions.

W. SCHILL↗

NASA NTRS2018

An Abrupt Transition to an Intergranular Failure Mode in the Near-Threshold FCG Regime in Ni-Based Superalloys

Cyclic near-threshold FCG behavior of two disk superalloys was evaluated, and was shown to exhibit an unexpected sudden failure mode transition from a mostly transgranular failure mode at higher stress intensities to an almost completely intergranular failure mode in the threshold regime. The change in failure modes was associated with a crossover effect in which the conditions that produced higher FCG rates in the Paris regime resulted in lower FCG rates and increased ΔKth values in the threshold region. High resolution scanning and transmission electron microscopy was used to carefully characterize the crack tips at these near-threshold conditions. Formation of stable Al-oxide followed by Cr and Ti oxides was found to occur at the crack tip prior to formation of unstable oxides. To contrast with the threshold failure mode regime, a quantitative assessment of the role that the intergranular failure mode has on cyclic FCG behavior in the Paris regime was also performed. It was demonstrated that the even a very limited intergranular failure content dominates the FCG response under mixed mode failure conditions.

fatigue crack growth↗

NASA NTRS1978

The compressive failure of graphite/epoxy plates with circular holes

The behavior of fiber reinforced composite plates containing a circular cutout was characterized in terms of geometry (thickness, width, hole diameter), and material properties (bending/extensional stiffness). Results were incorporated in a data base for use by designers in determining the ultimate strength of such a structure. Two thicknesses, 24 plies and 48 plies were chosen to differentiate between buckling and strength failures due to the presence of a cutout. Consistent post-buckling strength was exhibited by both laminate configurations.

Knauss, J. F.↗

NASA NTRS2007

Reconfigurable Control with Neural Network Augmentation for a Modified F-15 Aircraft

This paper describes the performance of a simplified dynamic inversion controller with neural network supplementation. This 6 DOF (Degree-of-Freedom) simulation study focuses on the results with and without adaptation of neural networks using a simulation of the NASA modified F-15 which has canards. One area of interest is the performance of a simulated surface failure while attempting to minimize the inertial cross coupling effect of a [B] matrix failure (a control derivative anomaly associated with a jammed or missing control surface). Another area of interest and presented is simulated aerodynamic failures ([A] matrix) such as a canard failure. The controller uses explicit models to produce desired angular rate commands. The dynamic inversion calculates the necessary surface commands to achieve the desired rates. The simplified dynamic inversion uses approximate short period and roll axis dynamics. Initial results indicated that the transient response for a [B] matrix failure using a Neural Network (NN) improved the control behavior when compared to not using a neural network for a given failure, However, further evaluation of the controller was comparable, with objections io the cross coupling effects (after changes were made to the controller). This paper describes the methods employed to reduce the cross coupling effect and maintain adequate tracking errors. The IA] matrix failure results show that control of the aircraft without adaptation is more difficult [leas damped) than with active neural networks, Simulation results show Neural Network augmentation of the controller improves performance in terms of backing error and cross coupling reduction and improved performance with aerodynamic-type failures.

Burken, John J.↗

NASA NTRS1978

Progressive failure of structures

A procedure is presented for determining the nonlinear behavior of structures subjected to extreme loading and the possibility of development of potential for progressive failure. The methodology takes into account the effect of both material and geometric nonlinearities. At a given stage of analysis, the individual components of the structure are checked against predetermined failure criteria. Subsequently, the failing components are removed and the modified structure is analyzed for overall failure. Examples, obtained from a computer program based on the proposed procedure, showing the applicability of the method are presented.

Khozeimeh, K.↗

NASA NTRS1999

Effects of Heat Treatment on the Ballistic Impact Properties of Inconel 718 for Jet Engine Fan Containment Applications

The effects of heat treating Inconel 718 on the ballistic impact response and failure mechanisms were studied. Two different annealing conditions and an aged condition were considered. Large differences in the static properties were found between the annealed and the aged material, with the annealed condition having lower strength and hardness and greater elongation than the aged. High strain rate tests show similar results. Correspondingly large differences were found in the velocity required to penetrate material in the two conditions in impact tests involving 12.5 mm diameter, 25.4 mm long cylindrical Ti-6-4 projectiles impacting flat plates at velocities in the range of 150 to 300 m/sec. The annealed material was able to absorb over 25 percent more energy than the aged. This is contrary to results observed for ballistic impact response for higher velocity impacts typically encountered in military applications where it has been shown that there exists a correlation between target hardness and ballistic impact strength. Metallographic examination of impacted plates showed strong indication of failure due to adiabatic shear. In both materials localized bands of large shear deformation were apparent, and microhardness measurements indicated an increase in hardness in these bands compared to the surrounding material. These bands were more localized in the aged material than in the annealed material. In addition the annealed material underwent significantly greater overall deformation before failure. The results indicate that lower elongation and reduced strain hardening behavior lead to a transition from shear to adiabatic shear failure, while high elongation and better strain hardening capabilities reduce the tendency for shear to localize and result in an unstable adiabatic shear failure. This supports empirical containment design methods that relate containment thickness to the static toughness.

Pereira, J. Michael↗

NASA NTRS2001

Effects of Heat Treatment on the Ballistic Impact Properties of Inconel 718 for Jet Engine Fan Containment Applications

The effects of heat treating Inconel 718 on the ballistic impact response and failure mechanisms were studied. Two different annealing conditions and an aged condition were considered. Large differences in the static properties were found between the annealed and the aged material, with the annealed condition having lower strength and hardness and greater elongation than the aged. High strain rate tests show similar results. Correspondingly large differences were found in the velocity required to penetrate material in the two conditions in impact tests involving 12.5 mm diameter, 25.4 mm long cylindrical Ti-6-4 projectiles impacting flat plates at velocities in the range of 150 to 300 m/sec. The annealed material was able to absorb over 25 percent more energy than the aged. This is contrary to results observed for ballistic impact response for higher velocity impacts typically encountered in military applications where it has been shown that there exists a correlation between target hardness and ballistic impact strength. Metallographic examination of impacted plates showed strong indication of failure due to adiabatic shear. In both materials localized bands of large shear deformation were apparent, and microhardness measurements indicated an increase in hardness in these bands compared to the surrounding material. These bands were more localized in the aged material than in the annealed material. In addition the annealed material underwent significantly greater overall deformation before failure. The results indicate that lower elongation and reduced strain hardening behavior lead to a transition from shear to adiabatic shear failure, while high elongation and better strain hardening capabilities reduce the tendency for shear to localize and result in an unstable adiabatic shear failure. This supports empirical containment design methods that relate containment thickness to the static toughness.

Pereira, J. Michael↗

NASA NTRS1998

Analyses of Buckling and Stable Tearing in Thin-Sheet Materials

This paper was to verify the STAGS (general shell, geometric and material nonlinear) code and the critical crack tip opening angle (CTOA) fracture criterion for predicting stable tearing in cracked panels that fail with severe out of plane buckling. Materials considered ranged from brittle to ductile behavior. Test data used in this study are reported elsewhere. The STAGS code was used to model stable tearing using a critical CTOA value that was determined from a cracked panel that was 'restrained' from buckling. ne analysis methodology was then used to predict the influence of buckling on stable tearing and failure loads. Parameters like crack length to specimen width ratio, crack configuration, thickness, and material tensile properties had a significant influence on the buckling behavior of cracked thin sheet materials. Experimental and predicted results showed a varied buckling response for different crack length to sheet thickness ratios because different buckling modes were activated. Effects of material tensile properties and fracture toughness on buckling response were presented. The STAGS code and the CTOA fracture criterion were able to predict the influence of buckling on stable tearing behavior and failure loads on a variety of materials and crack configurations.

Seshadri, B. R.↗

DOE OSTI2026

ACT University Collaboration Proposal: Role of manufacturing defects on material failure under dynamic loading for developing enhanced failure models and theories (Final Report)

Research on the tensile behavior of additively manufactured 316L stainless steel coupon specimens at increasing strain rates was conducted over the past year at Penn State. Dynamic loading rates into the 1000 1/s loading rates were performed on specimens with nearly 1.32” gage lengths. Stress-strain plots show ductile and plastic behavior well beyond 12% strain with necked specimens, having smaller effective gage lengths showing up to 56% ultimate strain. Additional tests performed on compact tension specimens helped with simulation work to understand the deformation behavior. Using finite elements, it was possible to determine the feasibility of a comprehensive experimental validation study towards an improved model for AM material failure – specifically, the Bai-Wierzbicki approach which accounts for lode angle and triaxiality. A non-significant number of tests are projected for eight specific failure nodes, with additional replicates to provide strain-rate capabilities to the existing formulation. One such correction factor is explored for quasi-static, notched specimens. Finally, stress intensity factor was explored using a set of compact-tension specimens which would also provide useful validation data for any simulation work.

36 MATERIALS SCIENCE↗

NASA NTRS1988

Characterization of elastic-plastic properties of AS4/APC-2 thermoplastic composite

Elastic and inelastic properties of AS4/APC-2 composites were characterized with respect to temperature variation by using a one-parameter orthotropic plasticity model and a one parameter failure criterion. Simple uniaxial off-axis tension tests were performed on coupon specimens of unidirectional AS4/APC-2 thermoplastic composite at various temperatures. To avoid the complication caused by the extension-shear coupling effect in off-axis testing, new tabs were designed and used on the test specimens. The experimental results showed that the nonlinear behavior of constitutive relations and the failure strengths can be characterized quite well using the one parameter plasticity model and the failure criterion, respectively.

Sun, C. T.↗

NASA NTRS2014

Adaptive Controller Effects on Pilot Behavior

Adaptive control provides robustness and resilience for highly uncertain, and potentially unpredictable, flight dynamics characteristic. Some of the recent flight experiences of pilot-in-the-loop with an adaptive controller have exhibited unpredicted interactions. In retrospect, this is not surprising once it is realized that there are now two adaptive controllers interacting, the software adaptive control system and the pilot. An experiment was conducted to categorize these interactions on the pilot with an adaptive controller during control surface failures. One of the objectives of this experiment was to determine how the adaptation time of the controller affects pilots. The pitch and roll errors, and stick input increased for increasing adaptation time and during the segment when the adaptive controller was adapting. Not surprisingly, altitude, cross track and angle deviations, and vertical velocity also increase during the failure and then slowly return to pre-failure levels. Subjects may change their behavior even as an adaptive controller is adapting with additional stick inputs. Therefore, the adaptive controller should adapt as fast as possible to minimize flight track errors. This will minimize undesirable interactions between the pilot and the adaptive controller and maintain maneuvering precision.

Trujillo, Anna C.↗

NASA NTRS2007

Flight Test Results from the NF-15B Intelligent Flight Control System (IFCS) Project with Adaptation to a Simulated Stabilator Failure

Adaptive flight control systems have the potential to be more resilient to extreme changes in airplane behavior. Extreme changes could be a result of a system failure or of damage to the airplane. A direct adaptive neural-network-based flight control system was developed for the National Aeronautics and Space Administration NF-15B Intelligent Flight Control System airplane and subjected to an inflight simulation of a failed (frozen) (unmovable) stabilator. Formation flight handling qualities evaluations were performed with and without neural network adaptation. The results of these flight tests are presented. Comparison with simulation predictions and analysis of the performance of the adaptation system are discussed. The performance of the adaptation system is assessed in terms of its ability to decouple the roll and pitch response and reestablish good onboard model tracking. Flight evaluation with the simulated stabilator failure and adaptation engaged showed that there was generally improvement in the pitch response; however, a tendency for roll pilot-induced oscillation was experienced. A detailed discussion of the cause of the mixed results is presented.

Bosworth, John T.↗

NASA NTRS2007

Flight Test Results from the NF-15B Intelligent Flight Control System (IFCS) Project with Adaptation to a Simulated Stabilator Failure

Adaptive flight control systems have the potential to be more resilient to extreme changes in airplane behavior. Extreme changes could be a result of a system failure or of damage to the airplane. A direct adaptive neural-network-based flight control system was developed for the National Aeronautics and Space Administration NF-15B Intelligent Flight Control System airplane and subjected to an inflight simulation of a failed (frozen) (unmovable) stabilator. Formation flight handling qualities evaluations were performed with and without neural network adaptation. The results of these flight tests are presented. Comparison with simulation predictions and analysis of the performance of the adaptation system are discussed. The performance of the adaptation system is assessed in terms of its ability to decouple the roll and pitch response and reestablish good onboard model tracking. Flight evaluation with the simulated stabilator failure and adaptation engaged showed that there was generally improvement in the pitch response; however, a tendency for roll pilot-induced oscillation was experienced. A detailed discussion of the cause of the mixed results is presented.

Bosworth, John T.↗

NASA NTRS2010

Flight Test Results from the NF-15B Intelligent Flight Control System (IFCS) Project with Adaptation to a Simulated Stabilator Failure

Adaptive flight control systems have the potential to be more resilient to extreme changes in airplane behavior. Extreme changes could be a result of a system failure or of damage to the airplane. A direct adaptive neural-network-based flight control system was developed for the National Aeronautics and Space Administration NF-15B Intelligent Flight Control System airplane and subjected to an inflight simulation of a failed (frozen) (unmovable) stabilator. Formation flight handling qualities evaluations were performed with and without neural network adaptation. The results of these flight tests are presented. Comparison with simulation predictions and analysis of the performance of the adaptation system are discussed. The performance of the adaptation system is assessed in terms of its ability to decouple the roll and pitch response and reestablish good onboard model tracking. Flight evaluation with the simulated stabilator failure and adaptation engaged showed that there was generally improvement in the pitch response; however, a tendency for roll pilot-induced oscillation was experienced. A detailed discussion of the cause of the mixed results is presented.

Bosworth, John T.↗

NASA NTRS1990

High-temperature tensile properties of fiber reinforced reaction bonded silicon nitride

Measurements of tensile properties of unidirectional silicon carbide fiber-reinforced reaction-bonded silicon nitride (SiC/RBSN) composite specimens were carried out in air at 25, 1300, and 1500 C, using a new testing technique and a specially designed gripping system that minimizes bending moment and assures that failure always occurred in the gage section. The material was found to display metallike stress-strain behavior at all temperatures tested, and a noncatastrophic failure beyond the matrix fracture. The tensile properties were found to be temperature dependent, with the values of the ultimate tensile strength decreasing with temperature, from 543 MPa at 25 C to 169 at 1500 C.

Jablonski, David A.↗