Mechanical reliability research in the National Aeronautics and Space Administration.
Mechanical reliability research and development for space systems, noting effect of random dynamic loading, fatigue damage, etc
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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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Growing Spaceships?
NASA currently has a program called the Space Synthetic Biology Project. Synthetic Biology or SynBio is the design and construction of new biological functions and systems not found in nature. Four NASA field centers, along with experts from industry and academia, have been partnering on the Space Synthetic Biology Project and are working on new breakthroughs in this increasingly useful pursuit, which is part a science discipline and part engineering. Led by researchers at NASA s Ames Research Center, the team is studying how this powerful new tool can help NASA now and in the future. The project was created to harness biology in reliable, robust, engineered systems to support the agency s exploration and science missions, to improve life on Earth and to help shape NASA's future. The program also is intended to contribute foundational tools to the synthetic biology research community.
Robertson, Glen A.↗
Crystalline-silicon reliability lessons for thin-film modules
Key reliability and engineering lessons learned from the 10-year history of the Jet Propulsion Laboratory's Flat-Plate Solar Array Project are presented and analyzed. Particular emphasis is placed on lessons applicable to the evolving new thin-film cell and module technologies and the organizations involved with these technologies. The user-specific demand for reliability is a strong function of the application, its location, and its expected duration. Lessons relative to effective means of specifying reliability are described, and commonly used test requirements are assessed from the standpoint of which are the most troublesome to pass, and which correlate best with field experience. Module design lessons are also summarized, including the significance of the most frequently encountered failure mechanisms and the role of encapsulant and cell reliability in determining module reliability. Lessons pertaining to research, design, and test approaches include the historical role and usefulness of qualification tests and field tests.
Ross, Ronald G., Jr.↗
Risk Reduction on X-33/RLV Engines
Risk management has received considerable attention in the X-33 and Reusable Launch Vehicle (RLV) program due to aggressive schedules, limited funding. and planned private investment to develop the commercial VentureStar vehicle. As an X-33 and RLV team member and main propulsion supplier, Boeing Rocketdyn Propulsion and Power has addressed risk through a methodical application of systems engineering in identifying, assessing, and mitigating risks. The methods employed involve rigorous risk mitigation planning early in development, continuous risk monitoring and assessment during the course of development, and the systematic verification of compliance with technical requirements prior to delivery. In addition, an engine system reliability analysis was conducted to reduce risk. In July 1996, NASA selected Lockheed Martin's "Skunk Works" (LMSW) as the lead contractor for the X-33 and RLV program. The X-33 vehicle is a half-scale pathfinder for the full-scale RLV. The LMSW RLV design is a lifting body shaped vehicle employing linear aerospike engine provided propulsion. The initial X-33 flight is planned for the summer of 2000, and the initial VentureStar flight is planned for between 2005 and 2007.
Crowley, Tim↗
An automated environment for multiple spacecraft engineering subsystem mission operations
Flight operations at the Jet Propulsion Laboratory (JPL) are now performed by teams of specialists, each team dedicated to a particular spacecraft. Certain members of each team are responsible for monitoring the performances of their respective spacecraft subsystems. Ground operations, which are very complex, are manual, labor-intensive, slow, and tedious, and therefore costly and inefficient. The challenge of the new decade is to operate a large number of spacecraft simultaneously while sharing limited human and computer resources, without compromising overall reliability. The Engineering Analysis Subsystem Environment (EASE) is an architecture that enables fewer controllers to monitor and control spacecraft engineering subsystems. A prototype of EASE has been installed in the JPL Space Flight Operations Facility for on-line testing. This article describes the underlying concept, development, testing, and benefits of the EASE prototype.
Bahrami, K. A.↗
Recent developments of the NESSUS probabilistic structural analysis computer program
The NESSUS probabilistic structural analysis computer program combines state-of-the-art probabilistic algorithms with general purpose structural analysis methods to compute the probabilistic response and the reliability of engineering structures. Uncertainty in loading, material properties, geometry, boundary conditions and initial conditions can be simulated. The structural analysis methods include nonlinear finite element and boundary element methods. Several probabilistic algorithms are available such as the advanced mean value method and the adaptive importance sampling method. The scope of the code has recently been expanded to include probabilistic life and fatigue prediction of structures in terms of component and system reliability and risk analysis of structures considering cost of failure. The code is currently being extended to structural reliability considering progressive crack propagation. Several examples are presented to demonstrate the new capabilities.
Millwater, H.↗
Reliability Analysis of Complex NASA Systems with Model-Based Engineering
The emergence of model-based engineering, with Model- Based Systems Engineering (MBSE) leading the way, is transforming design and analysis methodologies. The recognized benefits to systems development include moving from document-centric information systems and document-centric project communication to a model-centric environment in which control of design changes in the life cycles is facilitated. In addition, a “single source of truth” about the system, that is up-to-date in all respects of the design, becomes the authoritative source of data and information about the system. This promotes consistency and efficiency in regard to integration of the system elements as the design emerges and thereby may further optimize the design. Therefore Reliability Engineers (REs) supporting NASA missions must be integrated into model-based engineering to ensure the outputs of their analyses are relevant and value-needed to the design, development, and operational processes for failure risks assessment and communication.
FMEA/FMECA↗
Investigation and Demonstration of Reliability Target Allocation to Support Reliability and Integrity Management Program
Nuclear energy is the most reliable and environmentally sustainable energy source available today. In the United States (U.S.), nuclear-generated power accounts for approximately 20% of total electricity and over 55% of clean energy. New advanced reactors have enormous potential to help further decarbonize the energy market, enhance grid resiliency, create new jobs, and build a stronger economy. More than 50 new reactors are being developed in the U.S., and the federal government realizes an urgent need to deploy nuclear technologies to meet the country’s energy, environmental, and national security goals. As such, the U.S. Department of Energy (DOE) launched multiple programs to support advanced reactor deployment. The research described in this report explores implementation strategies for the Reliability and Integrity Management Program that directly supports the DOE goal to enable the near-term deployment of the advanced reactor technologies. The project is conducted under the Regulatory Development Program for advanced reactors sponsored by the DOE.
22 GENERAL STUDIES OF NUCLEAR REACTORS↗
Characterization of Side Load Phenomena Using Measurement of Fluid/Structure Interaction
During ground-tests of most production rocket engines over the last 30 years, large asymmetric transient side loads coming from the nozzle and related steady-state vibrational loads within the nozzle have been measured. The widely varying magnitude of these loads has been large enough to fail interfacing components as well as nozzles in these engines. This paper will discuss a comprehensive test and analysis program that has been undertaken to develop a methodology to accurately predict the character and magnitude of this loading. The project to-date has incorporated analytical modeling of both the fluid flow and the nozzle structure and testing of both full-scale and sub-scale rocket nodes. Examination of the test data indicates that one of the two-nodal diameter structural modes may be interacting with flow separation from the nozzle inside-wall in a self-excited or aeroelastic vibration phenomenon. If verified, this observation will be used to develop a methodology for design and analysis. A fuller understanding of the characteristics of this vibration will provide an increase in the accuracy and confidence of side load predictions, which will be critical for the successful construction of the next generation of low-cost, reliable rocket engines.
Brown, Andrew M.↗
A Compact, Single Stage, >1 kV Medium-Voltage Line Impedance Stabilization Network
This paper presents the design of a single-phase, single-stage line impedance stabilization network (LISN) for medium-voltage (MV) applications. More than 1 kV rated widebandgap (WBG) power semiconductor switches are increasingly utilized in new, emerging power electronics energy systems to improve power density and efficiency. However, due to inherently fast-switching speeds, WBG switch modules emit considerable electromagnetic interference (EMI) (e.g., common mode (CM) or differential mode (DM)). State-of-the-art offers standardized LISN solutions to validate and certify the new energy system for electromagnetic compatibility (EMC). However, most are for low voltage applications (i.e., < 1 kV). MV LISNs (i.e., > 1 kV) are rare until recently and literature does not provide sufficient guidelines for designing and characterizing such devices. It has been a critical challenge for many scientists and engineers to reliably certify the emerging MV energy systems (e.g., electric ships and aircraft). This paper addresses such a technology gap. Specifically, a CISPR 16-1-2 compliant 50Ω/50μH LISN with 1.5kV, 75A and 30MHz measurement capability has been proposed. Detailed performance study versus non-linear parasitic parameters variations in MV inductors and capacitors have been done. Based on new understandings, novel techniques to intuitively mitigate unwanted parasitic have been proposed to develop the proposed LISN successfully. Thorough characterization of important LISN parameters are presented and factors influencing them are analyzed. A rigorous analysis, experimental tests, and in-depth comparisons over state-of-the-art have been made to validate the effectiveness. This is done through the state-of-the-art 300kVA MV EMI testbed.
42 ENGINEERING↗
Vibration-Based Data Used to Detect Cracks in Rotating Disks
Rotor health monitoring and online damage detection are increasingly gaining the interest of aircraft engine manufacturers. This is primarily due to the fact that there is a necessity for improved safety during operation as well as a need for lower maintenance costs. Applied techniques for the damage detection and health monitoring of rotors are essential for engine safety, reliability, and life prediction. Recently, the United States set the ambitious goal of reducing the fatal accident rate for commercial aviation by 80 percent within 10 years. In turn, NASA, in collaboration with the Federal Aviation Administration, other Federal agencies, universities, and the airline and aircraft industries, responded by developing the Aviation Safety Program. This program provides research and technology products needed to help the aerospace industry achieve their aviation safety goal. The Nondestructive Evaluation (NDE) Group of the Optical Instrumentation Technology Branch at the NASA Glenn Research Center is currently developing propulsion-system-specific technologies to detect damage prior to catastrophe under the propulsion health management task. Currently, the NDE group is assessing the feasibility of utilizing real-time vibration data to detect cracks in turbine disks. The data are obtained from radial blade-tip clearance and shaft-clearance measurements made using capacitive or eddy-current probes. The concept is based on the fact that disk cracks distort the strain field within the component. This, in turn, causes a small deformation in the disk's geometry as well as a possible change in the system's center of mass. The geometric change and the center of mass shift can be indirectly characterized by monitoring the amplitude and phase of the first harmonic (i.e., the 1 component) of the vibration data. Spin pit experiments and full-scale engine tests have been conducted while monitoring for crack growth with this detection methodology. Even so, published data are extremely limited, and the basic foundation of the methodology has not been fully studied. The NDE group is working on developing this foundation on the basis of theoretical modeling as well as experimental data by using the newly constructed subscale spin system shown in the preceding photograph. This, in turn, involved designing an optimal sub-scale disk that was meant to represent a full-scale turbine disk; conducting finite element analyses of undamaged and damaged disks to define the disk's deformation and the resulting shift in center of mass; and creating a rotordynamic model of the complete disk and shaft assembly to confirm operation beyond the first critical concerning the subscale experimental setup. The finite element analysis data, defining the center of mass shift due to disk damage, are shown. As an example, the change in the center of mass for a disk spinning at 8000 rpm with a 0.963-in. notch was 1.3 x 10(exp -4) in. The actual vibration response of an undamaged disk as well as the theoretical response of a cracked disk is shown. Experiments with cracked disks are continuing, and new approaches for analyzing the captured vibration data are being developed to better detect damage in a rotor. In addition, the subscale spin system is being used to test the durability and sensitivity of new NDE sensors that focus on detecting localized damage. This is designed to supplement the global response of the crack-detection methodology described here.
Gyekenyesi, Andrew L.↗
Observation and Modeling of Dynamic Fracture Behaviors of Battery Cell Under Impact Loading Using Enhanced Representative Volume Element Concept
The burgeoning electric automobile industry has increased interest in battery safety. Battery cells experience significant mechanical stress during operation, including the impact of accidents and vibrations from driving. The potential for thermal runaway reactions in battery cells raises safety concerns. Although numerous researchers have defined the dynamic behavior of battery cells and proposed numerical models to describe it, few studies have focused on the high-strain rate mechanical impact phase correlated with the onset of fracture. In this study, we describe the dynamic behavior of pouch battery cells and propose a modeling method to study their mechanical failure under impact situations. Impact tests are conducted at various velocities and heights. To overcome numerical issues commonly encountered under rapid deformation scenarios, a new finite element model is developed based on the representative volume element model. The proposed approach efficiently simulates continuous crack propagation and brittleness behavior during impact by permitting the individual behavior of the cell components. Therefore, engineers can reliably design safer electric vehicle battery cells by measuring the properties of the cell components.
ENERGY STORAGE↗
Electricity Market of the Future: Potential North American Designs Without Fuel Costs
Electricity markets across the United States and Canada have evolved since their inception in the late 1990s and early 2000s. Not all states and provinces moved toward restructured organized electricity markets, but rather those that have belonged to markets operated by independent system operators (ISOs) and regional transmission organizations, with designs developed through stakeholder processes and approved through state, provincial, or federal agencies, such as the Federal Energy Regulatory Commission (FERC).
29 ENERGY PLANNING, POLICY, AND ECONOMY↗
Hybrid Resources: Challenges, Implications, Opportunities, and Innovation
The electric power system has historically been designed to provide reliable energy to loads by using a relatively small number of well-understood generators. The distinction between load, generation, and transmission resources has been quite clear. Most of the responsibility for planning and operating a system - building a highly reliable network from less reliable parts - has been with the system manager, whether that be a utility, a regional market operator, or some similar entity. Given this historical context, many experts were initially perplexed by the rapidly growing popularity of hybrid resources, which combine multiple technologies into a single entity. Rather than depending on a system operator to provide instructions to individual technologies, hybrid resources intentionally take on more operational responsibility by optimizing and scheduling their combined functions. Interconnection queues in many regions reveal a large and growing interest in hybrids, suggesting that project developers and investors see them as providing advantages.
generators↗
Foundations for the Future Power System: Inverter-Based Resource Interconnection Standards
As power systems evolve to become reliant on solar, wind, batteries, and other inverter-based resources (IBRs), it is essential that those resources meet certain minimum performance and capability criteria designed to ensure the power system operates stably and reliably. Because those criteria, as enshrined in interconnection standards, take years to develop and are very long lived, they need to account for not only the present state of the power system but also its expected future state over the lifetime of the power plants to which they will apply. In addition, they need to be specific enough to ensure reliability without over specifying and, thereby, impeding innovation. Because power systems are shifting rapidly from a state where IBRs make up a small to medium portion of generation to one where the generation will, at times, come predominantly from IBRs, interconnection standards are especially challenging to develop today. Good interconnection standards can make the power system more reliable and less costly to operate, whereas poorly designed standards can lead to major problems, like the famous German 50.2-Hz problem, which introduced a risk of losing many gigawatts of solar on a frequency excursion and resulted in many IBRs being retrofitted at great cost to mitigate a major system reliability risk. Readying the power system by specifying forward-looking technical minimum functional capabilities for IBRs can be an effective approach to avoid future retrofits.
data models↗
Design Advancement of an Indoor Soil Deposition Chamber: A Road to Standardization
An indoor soil deposition chamber has been designed and constructed at the Arizona State University Photovoltaic Reliability Lab (ASU-PRL) to simulate photovoltaic (PV) module soiling in the field. This paper discusses the next set of revisions to the design, which are organized into three categories: design improvements, cost reduction, and new features. The design process was carried out with the intention of working toward the development of a national or international soiling standard. The improvements made to the chamber are described in detail to provide a guide for other laboratories or research facilities who wish to study photovoltaic (PV) soiling.
14 SOLAR ENERGY↗
A Theoretical Approach for Reliability Within Information Supply Chains With Cycles and Negations
Complex networks of information processing systems, or information supply chains, present challenges for performance analysis. Here, we establish a mathematical setting, in which a process within an information supply chain can be analyzed in terms of the functionality of the system’s components. Principles of this methodology are rigorously defended and induce a model for determining the reliability for the various products in these networks. Our model does not limit us from having cycles in the network, as long as the cycles do not contain negation. It is shown that our approach to reliability resolves the nonuniqueness caused by cycles in a probabilistic Boolean network. An iterative algorithm is given to find the reliability values of the model, using a process that can be fully automated. This automated method of discerning reliability is beneficial for systems managers. As a systems manager considers systems modification, such as the replacement of owned and maintained hardware systems with cloud computing resources, the need for comparative analysis of system reliability is paramount. The model is extended to handle conditional knowledge about the network, allowing one to make predictions of weaknesses in the system. Finally, to illustrate the model’s flexibility over different forms, it is demonstrated on a system of components and subcomponents.
97 MATHEMATICS AND COMPUTING↗
Distribution of nickel(II) ions adsorbed at the muscovite mica (001)-water interface determined by in-situ resonant anomalous X-ray reflectivity
Mineral-water interfaces mediate adsorption, ion exchange, and secondary mineral formation that control element mobility in natural and engineered systems. Reliable prediction and control of these processes require a fundamental understanding of the interfacial structure that links adsorbed ion speciation to macroscopic sorption capacity and strength. Here, we determine atomic-scale changes in hydration and distribution of Ni(II) at the muscovite mica (001)-water interface using in situ high-resolution X-ray reflectivity (XR) and resonant anomalous X-ray reflectivity (RAXR) at 1 mM NiCl2 and pH 5.7. XR reveals reorganization of the primary hydration structure relative to that in deionized water: the water layer adsorbed in the cavity sites at a height of ~1.3 Å disappears, while distinct solution layers emerge at ~2.3, ~4.1, and ~5.6 Å above the basal oxygen plane. RAXR resolves three interfacial Ni(II) species: a dominant outer-sphere complex at 3.65 Å (~80% of the total coverage), a minor inner-sphere complex at 0.75 Å, and a low-coverage, more distant outer-sphere species at 5.63 Å. These three adsorbed Ni(II) species account for a total Ni(II) coverage of 0.54 ± 0.02 ion per unit cell area that compensates for the surface charge. These results highlight the role of interfacial hydration in controlling the speciation and stability of adsorbate cations on the negatively charged mica surface, providing quantitative insight into predicting the geochemical behavior of divalent metal cations in the aqueous environments.
Lee, Sang Soo↗