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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 235 records · Page 13

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NASA NTRS1976

D-1A equipment module structure test

The Centaur Equipment Module (E/M) structural test program was performed in two parts due to an unscheduled hardware failure in the first test series. The objectives of the initial test program were to define the flexibility characteristics of the E/M, verify the design load capability, and determine its ultimate strength capability by loading to structural failure. However, during the first failure test attempt, the Intelsat IV MPA failed instead of the E/M. Therefore a new adapter was fabricated to simulate the HEAO mission adapter and the second series of tests were then performed. They concluded with the failure of the E/M forward interface ring resulting in about 3.5 degrees of permanent set on the high compression side. Nevertheless, the linear or useable strength capability of the E/M is greater or equal to that which is required for the HEAO missions. The E/M is deemed structurally qualified for the HEAO missions.

Niezgoda, T. F.↗

NASA NTRS1989

Space Shuttle Orbiter main propulsion system flight safety enhancement

The Space Shuttle main propulsion system, like other major elements of the vehicle, has been part of an ongoing program to enhance the flight safety of the Space Transportation System. This activity, inherent in the basic program since its inception, has continued as part of a renewed review of failure modes and effects pertaining to flight-critical functions. Selected components were further evaluated, their potential for impacting flight safety was defined, and then the necessity for changing their design and/or operational practices was determined. Major examples of such components are the 17-inch disconnect and gaseous oxygen flow control valve. This paper summarizes that activity and provides examples of critical processes and components that have been or are being modified to enhance flight safety.

Cota, Phillip E.↗

NASA NTRS1990

Ball-Pass Cage-Modulation Detector

Ball-pass cage-modulation detector puts out signal useful in detecting incipient failure of bearing in rotating machine. Part of system of electronic equipment measuring various components of vibrations in such bearings. Bearing sensor - strain gauge or deflectometer on bearing housing - measures deflections of housing as balls pass by. Output of sensor filtered to extract ball-pass cage modulation, indicative of wear in bearing.

Randall, Richard L.↗

NASA NTRS1990

Real-time software failure characterization

A series of studies aimed at characterizing the fundamentals of the software failure process has been undertaken as part of a NASA project on the modeling of a real-time aerospace vehicle software reliability. An overview of these studies is provided, and the current study, an investigation of the reliability of aerospace vehicle guidance and control software, is examined. The study approach provides for the collection of life-cycle process data, and for the retention and evaluation of interim software life-cycle products.

Dunham, Janet R.↗

NASA NTRS1991

Thermal verification testing of commercial printed-circuit boards for spaceflight

A method is discussed developed to verify commercial printed-circuit boards for a shuttle orbital flight. The Space Acceleration Measurement System Project used this method first with great success. The test sequence is based on early fault detection, desire to test the final assembly, and integration with other verification testing. A component thermal screening test is performed first to force flaws in design, workmanship, parts, processes, and materials into observable failures. Then temperature definition tests are performed that consist of infrared scanning, thermal vacuum testing, and preliminary thermal operational testing. Only the engineering unit is used for temperature definition testing, but the preliminary thermal operational testing is performed on the flight unit after the temperature range has been defined. In the sequence of testing, vibration testing is performed next, but most vibration failures cannot be detected without subsequent temperature cycling. Finally, final assembly testing is performed to simulate the shuttle flight. An abbreviated thermal screening test is performed as a check after the vibration test, and then a complete thermal operational test is performed. The final assembly test finishes up with a burn-in of 100 hours of trouble-free operation. Verification is successful when all components and final assemblies have passed each test satisfactory. This method was very successful in verifying that commercial printed-circuit boards will survive in the shuttle environment.

Foster, William M., II↗

NASA NTRS1991

Approach to developing reliable space reactor power systems

During Phase II, the Engineering Development Phase, the SP-100 Project has defined and is pursuing a new approach to developing reliable power systems. The approach to developing such a system during the early technology phase is described along with some preliminary examples to help explain the approach. Developing reliable components to meet space reactor power system requirements is based on a top-down systems approach which includes a point design based on a detailed technical specification of a 100-kW power system. The SP-100 system requirements implicitly recognize the challenge of achieving a high system reliability for a ten-year lifetime, while at the same time using technologies that require very significant development efforts. A low-cost method for assessing reliability, based on an understanding of fundamental failure mechanisms and design margins for specific failure mechanisms, is being developed as part of the SP-100 Program.

Mondt, Jack F.↗

NASA NTRS1992

Thermal verification testing of commercial printed-circuit boards for spaceflight

A method developed to verify commercial printed-circuit boards for a Shuttle orbital flight is discussed. The test sequence is based on early fault detection, desire to test the final assembly, and integration with other verification testing. A component thermal screening test is performed first to force flaws in design, workmanship, parts, processes, and materials into observable failures. Temperature definition and vibration tests are performed next. Final assembly testing is performed to simulate the Shuttle flight. An abbreviated thermal screening test is performed as a check after the vibration test, and then a complete thermal operational test is performed. The final assembly test finishes up with a burn-in of 100 h of trouble-free operation. Verification is successful when all components and final assemblies have passed each test. This method was very successful in verifying that commercial printed-circuit boards will survive in the Shuttle environment.

Foster, William M., II↗

NASA NTRS1998

Spacecraft Compartment Venting

At various time concerns have been expressed that rapid decompressions of compartments of gas pockets and thermal blankets during spacecraft launches may have caused pressure differentials across their walls sufficient to cause minor structural failures, separations of adhesively-joined parts, ballooning, and flapping of blankets. This paper presents a close form equation expressing the expected pressure differentials across the walls of a compartment as a function of the external to the volume pressure drops, the pressure at which the rates occur and the vent capability of the compartment. The pressure profiles measured inside the shrouds of several spacecraft propelled by several vehicles and some profiles obtained from ground vacuum systems have been included. The equation can be used to design the appropriate vent, which will preclude excessive pressure differentials. Precautions and needed approaches for the evaluations of the expected pressures have been indicated. Methods to make a rapid assessment of the response of the compartment to rapid external pressure drops have been discussed. These are based on the evaluation of the compartment vent flow conductance, the volume and the length of time during which the rapid pressure drop occurs.

Scialdone, John J.↗

NASA NTRS2005

Experiences issues with plastic parts at cold temperatures

Missions to MARS/planets/asteroids require electronic parts to operate and survive at extreme cold conditions. At extreme cold temperatures many types of cold related failures can occur. Office 514 is currently evaluating plastic parts under various cold temperature conditions and applications. Evaluations, screens, and qualifications are conducted on flight parts.

cold temperatures↗

NASA NTRS2010

Reliability Demonstration Approach for Advanced Stirling Radioisotope Generator

Developed for future space missions as a high-efficiency power system, the Advanced Stirling Radioisotope Generator (ASRG) has a design life requirement of 14 yr in space following a potential storage of 3 yr after fueling. In general, the demonstration of long-life dynamic systems remains difficult in part due to the perception that the wearout of moving parts cannot be minimized, and associated failures are unpredictable. This paper shows a combination of systematic analytical methods, extensive experience gained from technology development, and well-planned tests can be used to ensure a high level reliability of ASRG. With this approach, all potential risks from each life phase of the system are evaluated and the mitigation adequately addressed. This paper also provides a summary of important test results obtained to date for ASRG and the planned effort for system-level extended operation.

Ha, CHuong↗

NASA NTRS2012

Managing Space System Faults: Coalescing NASA's Views

Managing faults and their resultant failures is a fundamental and critical part of developing and operating aerospace systems. Yet, recent studies have shown that the engineering "discipline" required to manage faults is not widely recognized nor evenly practiced within the NASA community. Attempts to simply name this discipline in recent years has been fraught with controversy among members of the Integrated Systems Health Management (ISHM), Fault Management (FM), Fault Protection (FP), Hazard Analysis (HA), and Aborts communities. Approaches to managing space system faults typically are unique to each organization, with little commonality in the architectures, processes and practices across the industry.

Muirhead, Brian↗

NASA NTRS2016

Simulation of Malfunctions for the ISS Double-Gimbal Control Moment Gyroscope

This paper presents a simplified approach to simulation of malfunctions of the Control Moment Gyroscope (CMG) on board the International Space Station (ISS). These malfunctions will be used as part of flight training of CMG failure scenarios in the guidance navigation control (GNC) subsystem of the Training Systems for 21st Century (TS21) simulator. The CMG malfunctions are grouped under mechanical, thermal and electrical categories. A malfunction can be as simple as one which only affects the telemetry or a complex one that changes the state and behavior of the CMG model. In both cases, the ISS GNC flight software will read the telemetry and respond accordingly. The user executes these malfunctions by supplying conditional data which modify internal model states and then elicit a response as seen on the user displays. Ground operators and crew on board the ISS use CMG malfunction procedures to better understand and respond to anomalies observed within the CMG subsystem.

Inampudi, Ravi↗

NASA NTRS2016

Failure Simulation Testing of the Z-1 Spacesuit Titanium Bearing Assemblies

The Z-2 is a candidate for NASA's next generation spacesuit, designed for a range of possible missions with enhanced mobility for spacewalks both on planetary surfaces and in microgravity. Increased mobility was accomplished through innovations in shoulder and hip joints, using a number of new bearings to allow spacesuit wearers to dip, walk, and bend with ease; all important tasks for a planetary explorer collecting samples or traveling over rough terrain. The Advanced Spacesuit Development Team of NASA Johnson Space Center requested that the NASA White Sands Test Facility (WSTF) perform a series failure simulation tests on three titanium bearing assemblies, an elemental part of the joint construction used in new spacesuit designs. This testing simulated two undetected failures within the bearings and as a result the objective of this test program was to evaluate whether a failed or failing bearing could result in ignition of the titanium race material due to friction. The first failure was an inner seal leak sufficient to pressurize the race with +99 percent oxygen. The second failure was an improperly installed or mismatched ball port that created a protrusion in the ball bearing race, partially obstructing the nominal rolling path of each ball bearing. When the spacesuit bearings are assembled, bearing balls are loaded into the assembly via a ball port. The ball port is specific and unique to each bearing assembly (matched pair). The simulated mismatched ball port is a significant source of friction, which would be caused by an assembly error. To evaluate this risk, the bearings were cycled in a simulated worst-case scenario environment, with operational loads, and potential flaw conditions. During test the amount of actuation torque required and heat generated through continuous operation were measured and the bearings were observed for sparks or burning events. This paper provides detailed descriptions of the test hardware, methodology, and results.

de Baca, Richard C.↗

NASA NTRS2018

Coupled Thermomechanical Micromechanics Modeling of the Influence of Thermally Grown Oxide Layer in an Environmental Barrier Coating System

Environmental Barrier Coatings (EBCs) have emerged as a promising means of protecting critical components for high temperature applications (e.g., aircraft engines). EBCs are often used to protect an underlying material (substrate) from extreme thermal/chemical environments. However, systems that utilize EBCs are susceptible to a number of failure modes including oxidation/delamination. Environmental Barrier Coatings (EBCs) have emerged as a promising means of protecting silicon based ceramic matrix composite (CMC) components for high temperature applications (e.g., aircraft engines). EBCs are often used to protect an underlying material (substrate) such as silicon carbide from extreme thermal/chemical environments. In a typical CMC/EBC system, an EBC may or may not be adhered to an underlying substrate with a bond coat (e.g., silicon). Irrespective, systems that utilize EBCs are susceptible to a number of failure modes including oxidation/delamination, recession, chemical attack and dissolution, thermo-mechanical degradation, erosion, and foreign object damage. Current work at NASA Glenn Research Center is aimed at addressing these failure modes in EBC systems and developing robust analysis tools to aid in the design process. The Higher-Order Theory for Functionally Graded Materials (HOTFGM), a precursor to the High-Fidelity Generalized Method of Cells micromechanics approach, was developed to investigate the coupled thermo-mechanical behavior of functionally graded composites and will be used herein to assess the development and growth of a low-stiffness thermally grown oxide (TGO) layer in EBC/CMC systems without a silicon bond coat. To accomplish this a sensitivity study is conducted to examine the influence of uniformly and non-uniformly grown oxide layer on the associated driving forces leading to mechanical failure (spallation) of EBC layer when subjected to isothermal loading, recession, chemical attack and dissolution, thermomechanical degradation, erosion, and foreign object damage. Current work at NASA Glenn Research Center is aimed at addressing these failure modes in EBC systems and developing robust analysis tools to aid in the design process. The Higher-Order Theory for Functionally Graded Materials (HOTFGM), a precursor to the High-Fidelity Generalized Method of Cells micromechanics approach, was developed to investigate the coupled thermo-mechanical behavior of functionally graded composites (Aboudi et al., 1999, Composites B). For example, HOTFGM was previously used (Arnold et al, 1995, NASA CP 10178, paper 34), to assess interlaminar stresses (including free edge effects) in a substrate with a thermal barrier coating (TBC). In this study, HOTFGM micromechanics analyses will be used to assess the development and growth of a low-stiffness thermally grown oxide (TGO) layer between a silicon carbide substrate and a ytterbium disilicate EBC. In order to realistically simulate TGO growth, an evolution law will be incorporated into HOTFGM. In addition, the effect of TGO roughness will be explored consistent with previous TBC work (Pindera et al., 2000. Material Science and Engineering, A284, pp. 158-175). This model represents a first step in developing a robust analysis tool that can ultimately be used to design durable EBC systems. Additional failure modes will be considered as part of a future work.

environmental barrier coating↗

DOE OSTI2023

Passive Safety System Reliability Analysis: Lessons Learned and Open Items

Passive safety systems have multiple benefits, largely stemming from their high functional reliability due to their simplicity and lack of dependencies. However, accurately assessing the reliability of passive systems can be challenging due in large part to the possibility of functional failures. Argonne National Laboratory (Argonne) has been involved in several recent efforts concerning the reliability assessment of passive safety systems for advanced, non-light water reactors (non-LWRs). These efforts have focused on the development and application of mechanistic methods for the evaluation of passive system reliability, which rely on system modelling and uncertainty analyses to derive reliability values for use in probabilistic safety assessments (PSAs). Further information on these efforts is provided in ref [1]. The current paper reviews key lessons learned through these projects, along with outstanding open items regarding the reliability assessment of passive systems.

Grabaskas, David↗

NASA NTRSDate not supplied

Composite Technologies for Science Missions

ASTROLAB, Lunar Geophysical Network, Mars Icebreaker and Mars PLACER Net missions propose use of various types of vehicles – such as rovers, landers and flying probes - to accomplish their scientific objectives. Although designs for such vehicles are myriad, many structural components can be made using composite manufacturing technologies. Composite materials are also myriad, by nature, but carbon fiber reinforced polymers (CFRP) in particular are sought after for their high specific strength and specific stiffness. CFRP components could be especially beneficial in vehicle designs for Moon or Mars missions due to their nearly negligible coefficient of thermal expansion (CTE). CTE is a critical design characteristics in environments where significant thermal swings are prevalent, such as those of atmosphere-less Moon and Mars.MSFC/EM42 houses several relevant composites technologies. Strong and rigid struts can be filament-wound. Shells and platforms can be laid-up using automated fiber placement (for repeatability) or by hand (for small features). Monolithic structures can even be designed to reduce part count and therefore reduce the risk of joint failures. Composites are also tailorable, allowing the incorporation of different material types or formats through the thickness of a part. This includes materials which shield from radiation or electrostatic discharge. Finally, the rigidity of composite parts minimizes overall vibration and compliance within a design.Additionally, missions such as Triton Ocean World Surveyor anticipate use of traditional, metallic fuel tanks. Composite overwrapped pressure vessels (COPVs) are suitable for use in this application as well. The Triton mission even cites a concern for heat retention, for which CFRP also offers improved characteristics over traditional metallic tanks.

Lightweight↗

NASA NTRS2009

Developing Ultra Reliable Life Support for the Moon and Mars

Recycling life support systems can achieve ultra reliability by using spares to replace failed components. The added mass for spares is approximately equal to the original system mass, provided the original system reliability is not very low. Acceptable reliability can be achieved for the space shuttle and space station by preventive maintenance and by replacing failed units, However, this maintenance and repair depends on a logistics supply chain that provides the needed spares. The Mars mission must take all the needed spares at launch. The Mars mission also must achieve ultra reliability, a very low failure rate per hour, since it requires years rather than weeks and cannot be cut short if a failure occurs. Also, the Mars mission has a much higher mass launch cost per kilogram than shuttle or station. Achieving ultra reliable space life support with acceptable mass will require a well-planned and extensive development effort. Analysis must define the reliability requirement and allocate it to subsystems and components. Technologies, components, and materials must be designed and selected for high reliability. Extensive testing is needed to ascertain very low failure rates. Systems design should segregate the failure causes in the smallest, most easily replaceable parts. The systems must be designed, produced, integrated, and tested without impairing system reliability. Maintenance and failed unit replacement should not introduce any additional probability of failure. The overall system must be tested sufficiently to identify any design errors. A program to develop ultra reliable space life support systems with acceptable mass must start soon if it is to produce timely results for the moon and Mars.

Jones, Harry W.↗

NASA NTRS1978

Quantitative ultrasonic evaluation of mechanical properties of engineering materials

Current progress in the application of ultrasonic techniques to nondestructive measurement of mechanical strength properties of engineering materials is reviewed. Even where conventional NDE techniques have shown that a part is free of overt defects, advanced NDE techniques should be available to confirm the material properties assumed in the part's design. There are many instances where metallic, composite, or ceramic parts may be free of critical defects while still being susceptible to failure under design loads due to inadequate or degraded mechanical strength. This must be considered in any failure prevention scheme that relies on fracture analysis. This review will discuss the availability of ultrasonic methods that can be applied to actual parts to assess their potential susceptibility to failure under design conditions.

Vary, A.↗