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NASA NTRS2000

NASA's New Approach for Evaluating Risk Reduction Due to Space Shuttle Upgrades

As part of NASA's intensive effort to incorporate quantitative risk assessment (QRA) tools in the Agency's decision-making process concerning Space Shuttle risk, NASA has developed a powerful risk assessment tool called the Quantitative Risk Assessment System (QRAS). The QRAS is a tool designed to estimate Space Shuttle risk and evaluate Space Shuttle upgrades. This paper presents an overview of the QRAS with focus on its application for evaluating the risk reduction due to proposed Space Shuttle upgrades. The application includes a case study from the Space Shuttle main engine (SSME). The QRAS overview section of the paper includes the QRAS development process, the technical approach to model development, the QRA quantification methods and techniques, and observations concerning the complex modeling involved in QRAS. The application section of the paper describes a practical case study using QRAS models for evaluating critical Space Shuttle Program upgrades, specifically a proposed SSME nozzle upgrade. This paper presents the method for evaluating the proposed upgrade by comparing the current nozzle (old design with well-established probabilistic models) to the channel wall nozzle (new design at the preliminary design level).

Safie, Fayssal M.↗

NASA NTRS2001

Ceramic Inclusions in Powder Metallurgy Disk Alloys: Characterization and Modeling

Powder metallurgy alloys are increasingly used in gas turbine engines, especially in turbine disk applications. Although powder metallurgy materials have many advantages over conventionally cast and wrought alloys (higher strength, higher temperature capability, etc.), they suffer from the rare occurrence of ceramic defects (inclusions) that are inherent to the powder atomization process. These inclusions can have a potentially large detrimental effect on the durability of individual components. An inclusion in a high stress location can act as a site for premature crack initiation and thereby considerably reduce the fatigue life. Because these inclusions are exceedingly rare, they typically do not reveal themselves in the process of characterizing the material for a particular application (the cumulative volume of the test bars in a fatigue life characterization is typically on the order of a single actual component). Ceramic inclusions have, however, been found to be the root cause of a number of catastrophic engine failures. To investigate the effect of these inclusions in detail, we have undertaken a study where known populations of ceramic particles, whose composition and morphology are designed to mimic the "natural" inclusions, are added to the precursor powder. Surface-connected inclusions have been found to have a particularly large detrimental effect on fatigue life; therefore, the quantity of ceramic "seeds" added is calculated to ensure that a minimum number will intersect the surface of the fatigue test bars. Because the ceramic inclusions are irregularly shaped and have a tendency to break up in the process of extrusion and forging, a method of calculating the probability of occurrence and expected intercepted surface area was needed. We have developed a Monte Carlo simulation to determine the distributions of these parameters and have verified the simulated results with observations of ceramic inclusions found in macroscopic slices from extrusions and forgings. Fatigue specimens have been machined from Udimet 720 (a powder metallurgy superalloy) forgings, to determine the effects of the inclusions on fatigue life. The ultimate goal of this study will be to use probabilistic methods to determine the reliability detriment that can be attributed to these ceramic inclusions. This work has been supported by the Ultra Safe and Ultra- Efficient Engine Technologies programs.

Bonacuse, Peter J.↗

NASA NTRS2007

Reliability and Creep/Fatigue Analysis of a CMC Component

High temperature ceramic matrix composites (CMC) are being explored as viable candidate materials for hot section gas turbine components. These advanced composites can potentially lead to reduced weight and enable higher operating temperatures requiring less cooling; thus leading to increased engine efficiencies. There is a need for convenient design tools that can accommodate various loading conditions and material data with their associated uncertainties to estimate the minimum predicted life as well as the failure probabilities of a structural component. This paper presents a review of the life prediction and probabilistic analyses performed for a CMC turbine stator vane. A computer code, NASALife, is used to predict the life of a 2-D woven silicon carbide fiber reinforced silicon carbide matrix (SiC/SiC) turbine stator vane due to a mission cycle which induces low cycle fatigue and creep. The output from this program includes damage from creep loading, damage due to cyclic loading and the combined damage due to the given loading cycle. Results indicate that the trends predicted by NASALife are as expected for the loading conditions used for this study. In addition, a combination of woven composite micromechanics, finite element structural analysis and Fast Probability Integration (FPI) techniques has been used to evaluate the maximum stress and its probabilistic distribution in a CMC turbine stator vane. Input variables causing scatter are identified and ranked based upon their sensitivity magnitude. Results indicate that reducing the scatter in proportional limit strength of the vane material has the greatest effect in improving the overall reliability of the CMC vane.

Murthy, Pappu L. N.↗

NASA NTRS1976

Vibroacoustic test plan evaluation: Parameter variation study

Statistical decision models are shown to provide a viable method of evaluating the cost effectiveness of alternate vibroacoustic test plans and the associated test levels. The methodology developed provides a major step toward the development of a realistic tool to quantitatively tailor test programs to specific payloads. Testing is considered at the no test, component, subassembly, or system level of assembly. Component redundancy and partial loss of flight data are considered. Most and probabilistic costs are considered, and incipient failures resulting from ground tests are treated. Optimums defining both component and assembly test levels are indicated for the modified test plans considered. modeling simplifications must be considered in interpreting the results relative to a particular payload. New parameters introduced were a no test option, flight by flight failure probabilities, and a cost to design components for higher vibration requirements. Parameters varied were the shuttle payload bay internal acoustic environment, the STS launch cost, the component retest/repair cost, and the amount of redundancy in the housekeeping section of the payload reliability model.

Stahle, C. V.↗

NASA NTRS2015

Integrated Medical Model Overview

The Integrated Medical Model (IMM) Project represents one aspect of NASA's Human Research Program (HRP) to quantitatively assess medical risks to astronauts for existing operational missions as well as missions associated with future exploration and commercial space flight ventures. The IMM takes a probabilistic approach to assessing the likelihood and specific outcomes of one hundred medical conditions within the envelope of accepted space flight standards of care over a selectable range of mission capabilities. A specially developed Integrated Medical Evidence Database (iMED) maintains evidence-based, organizational knowledge across a variety of data sources. Since becoming operational in 2011, version 3.0 of the IMM, the supporting iMED, and the expertise of the IMM project team have contributed to a wide range of decision and informational processes for the space medical and human research community. This presentation provides an overview of the IMM conceptual architecture and range of application through examples of actual space flight community questions posed to the IMM project.

Spae Adaptation Syndrome↗

NASA NTRS2002

Application of Risk Assessment Tools in the Continuous Risk Management (CRM) Process

Marshall Space Flight Center (MSFC) of the National Aeronautics and Space Administration (NASA) is currently implementing the Continuous Risk Management (CRM) Program developed by the Carnegie Mellon University and recommended by NASA as the Risk Management (RM) implementation approach. The four most frequently used risk assessment tools in the center are: (a) Failure Modes and Effects Analysis (FMEA), Hazard Analysis (HA), Fault Tree Analysis (FTA), and Probabilistic Risk Analysis (PRA). There are some guidelines for selecting the type of risk assessment tools during the project formulation phase of a project, but there is not enough guidance as to how to apply these tools in the Continuous Risk Management process (CRM). But the ways the safety and risk assessment tools are used make a significant difference in the effectiveness in the risk management function. Decisions regarding, what events are to be included in the analysis, to what level of details should the analysis be continued, make significant difference in the effectiveness of risk management program. Tools of risk analysis also depends on the phase of a project e.g. at the initial phase of a project, when not much data are available on hardware, standard FMEA cannot be applied; instead a functional FMEA may be appropriate. This study attempted to provide some directives to alleviate the difficulty in applying FTA, PRA, and FMEA in the CRM process. Hazard Analysis was not included in the scope of the study due to the short duration of the summer research project.

Paul S. Ray↗

NASA NTRS1983

Validation methods for flight crucial systems

Research to develop techniques that can aid in determining the reliability and performance of digital electronic fault-tolerant systems, that have probability of catastrophic system failure on the order of 10 to the -9th at 10 hours, is reviewed. The computer-aided reliability estimation program (CARE III) provides general-purpose reliability analysis and a design tool for fault-tolerant systems; large reduction of state size; and a fault-handling model based on probabilistic description of detection, isolation, and recovery mechanisms. The application of design proof techniques as part of the design and development of the software implemented fault-tolerance computer is mentioned. Emulation techniques and experimental procedures are verified using specimens of fault-tolerant computers and the capabilities of the validation research laboratory, AIRLAB.

Holt, H. M.↗

NASA NTRS2020

MEDPRAT-SEL: Medical Resource Set Selector Searching High-Dimensionality Space

NASA Human Research Program's (HRP) next generation risk model closes the loop on medical risk and resource evaluation, providing researchers with a tool to assess and choose capabilities scientifically. The Medical Extensible Dynamic Probabilistic Risk Assessment Tool (MEDPRAT) simulator (SIM) evaluates resources in terms of medical benefit, such as reduced crew quality time lost (QTL), vs. cost, in mass or volume. The MEDPRAT resource set selector (SEL) searches the space of resource benefits v. cost, closing a feedback loop around the simulator, thus selecting resource sets with best benefit for cost. We discuss the design and results of the resource set selector. NASA HRP's emphasis on scientific assessment of risk, PRA, has led to the Cross-cutting Computational Modeling Project (CCMP).

Leinweber, Lawrence↗

NASA NTRS2001

Probabilistic Risk-Based Approach to Aeropropulsion System Assessment Developed

In an era of shrinking development budgets and resources, where there is also an emphasis on reducing the product development cycle, the role of system assessment, performed in the early stages of an engine development program, becomes very critical to the successful development of new aeropropulsion systems. A reliable system assessment not only helps to identify the best propulsion system concept among several candidates, it can also identify which technologies are worth pursuing. This is particularly important for advanced aeropropulsion technology development programs, which require an enormous amount of resources. In the current practice of deterministic, or point-design, approaches, the uncertainties of design variables are either unaccounted for or accounted for by safety factors. This could often result in an assessment with unknown and unquantifiable reliability. Consequently, it would fail to provide additional insight into the risks associated with the new technologies, which are often needed by decisionmakers to determine the feasibility and return-on-investment of a new aircraft engine.

Tong, Michael T.↗

NASA NTRS2019

Calibration of a Structural Finite Element Model for a Representative Inflatable Space Structure Utilizing Probabilistic Methods and Surrogate Models

A structural finite element model representing a novel inflatable airlock concept has been calibrated using full‐scale test data. The concept, denoted as the Non‐Axisymmetric Inflatable Pressure Structure (NAIPS), was developed under NASA’s Minimalistic Advanced Softgoods Hatch (MASH) Program. The current studies extended previous numerical efforts by incorporating the midbody section of the NAIPS to the dome section and calibrating the model with test data using a process that included surrogate models. Brief overviews of the finite element model and calibration process are provided. The completion of the calibration process provided a model that adequately replicated the test data. The successful demonstration of calibration of a finite element model representing an inflatable habitat provides confidence in the ability to use numerical simulations and associated surrogate models to support design and certification of inflatable space habitats.

Lyle, Karen H.↗

NASA NTRS1998

CARES/Life Ceramics Durability Evaluation Software Used for Mars Microprobe Aeroshell

The CARES/Life computer program, which was developed at the NASA Lewis Research Center, predicts the probability of a monolithic ceramic component's failure as a function of time in service. The program has many features and options for materials evaluation and component design. It couples commercial finite element programs-which resolve a component's temperature and stress distribution-to-reliability evaluation and fracture mechanics routines for modeling strength-limiting defects. These routines are based on calculations of the probabilistic nature of the brittle material's strength. The capability, flexibility, and uniqueness of CARES/Life has attracted many users representing a broad range of interests and has resulted in numerous awards for technological achievements and technology transfer.

Nemeth, Noel N.↗

NASA NTRS2007

Design for Reliability and Safety Approach for the New NASA Launch Vehicle

The United States National Aeronautics and Space Administration (NASA) is in the midst of a space exploration program intended for sending crew and cargo to the international Space Station (ISS), to the moon, and beyond. This program is called Constellation. As part of the Constellation program, NASA is developing new launch vehicles aimed at significantly increase safety and reliability, reduce the cost of accessing space, and provide a growth path for manned space exploration. Achieving these goals requires a rigorous process that addresses reliability, safety, and cost upfront and throughout all the phases of the life cycle of the program. This paper discusses the "Design for Reliability and Safety" approach for the NASA new launch vehicles, the ARES I and ARES V. Specifically, the paper addresses the use of an integrated probabilistic functional analysis to support the design analysis cycle and a probabilistic risk assessment (PRA) to support the preliminary design and beyond.

Safie, Fayssal M.↗

NASA NTRS1988

Probabilistic constitutive relationships for cyclic material strength models

A methodology is developed that provides a probabilistic treatment for the lifetime of structural components of aerospace propulsion systems subjected to fatigue. Material strength degradation models, based on primitive variables, include both a fatigue strength reduction model and a fatigue crack growth model. Probabilistic analysis is based on simulation, and both maximum entropy and maximum penalized likelihood methods are used for the generation of probability density functions. The resulting constitutive relationships are included in several computer programs.

Boyce, L.↗

NASA NTRS1995

Probabilistic risk assessment of the Space Shuttle. Phase 3: A study of the potential of losing the vehicle during nominal operation. Volume 2: Integrated loss of vehicle model

The application of the probabilistic risk assessment methodology to a Space Shuttle environment, particularly to the potential of losing the Shuttle during nominal operation is addressed. The different related concerns are identified and combined to determine overall program risks. A fault tree model is used to allocate system probabilities to the subsystem level. The loss of the vehicle due to failure to contain energetic gas and debris, to maintain proper propulsion and configuration is analyzed, along with the loss due to Orbiter, external tank failure, and landing failure or error.

Fragola, Joseph R.↗

NASA NTRSDate not supplied

Accounting for Point Estimate Uncertainty in Space Systems Reliability and Risk Analysis

Understanding and accounting for uncertainty in risk analysis is a critical step in the management and communication of risk in engineered systems. The component and system-level analysis to determine the probability of a negative outcome and its consequence is often quantified by a point estimate. Many Program and Enterprise decisions involving technical concerns and issues rely on reliability engineering activities to produce quantified risk analysis to inform the decision making process. At NASA, it is common to use a Probabilistic Risk Analysis (PRA) to inform the overall risk to Loss of Mission or Loss of Crew that involves integration across all spacecraft subsystem fault trees to produce an overall probability of mission failure. The point estimate is an estimate of this overall probability and is an immediate result of a fault tree model. It is the result of a model where the probability of each event is taken to be equal to its mean. The value provides an approximation of the overall mean without running any uncertainty calculations (e.g., no sampling). Using only the point estimate can lead to a false sense of precision and the point estimate may not match the resulting mean when uncertainty is taken into consideration. This paper will explore five conditions that can cause the PRA model mean to diverge from the point estimate and will provide engineers and managers insight into the importance of understanding uncertainty in the elements of PRA models.

Paul J Collier↗

NASA NTRS2011

Methodology for Developing a Probabilistic Risk Assessment Model of Spacecraft Rendezvous and Dockings

In 2007 NASA was preparing to send two new visiting vehicles carrying logistics and propellant to the International Space Station (ISS). These new vehicles were the European Space Agency s (ESA) Automated Transfer Vehicle (ATV), the Jules Verne, and the Japanese Aerospace and Explorations Agency s (JAXA) H-II Transfer Vehicle (HTV). The ISS Program wanted to quantify the increased risk to the ISS from these visiting vehicles. At the time, only the Shuttle, the Soyuz, and the Progress vehicles rendezvoused and docked to the ISS. The increased risk to the ISS was from an increase in vehicle traffic, thereby, increasing the potential catastrophic collision during the rendezvous and the docking or berthing of the spacecraft to the ISS. A universal method of evaluating the risk of rendezvous and docking or berthing was created by the ISS s Risk Team to accommodate the increasing number of rendezvous and docking or berthing operations due to the increasing number of different spacecraft, as well as the future arrival of commercial spacecraft. Before the first docking attempt of ESA's ATV and JAXA's HTV to the ISS, a probabilistic risk model was developed to quantitatively calculate the risk of collision of each spacecraft with the ISS. The 5 rendezvous and docking risk models (Soyuz, Progress, Shuttle, ATV, and HTV) have been used to build and refine the modeling methodology for rendezvous and docking of spacecrafts. This risk modeling methodology will be NASA s basis for evaluating the addition of future ISS visiting spacecrafts hazards, including SpaceX s Dragon, Orbital Science s Cygnus, and NASA s own Orion spacecraft. This paper will describe the methodology used for developing a visiting vehicle risk model.

Farnham, Steven J., II↗

NASA NTRS2010

Orion Entry Performance-Based Center-of-Gravity Box

The Orion capsule has many performance requirements for its atmospheric entry trajectory. Requirements on landing accuracy, maximum heating rate, total heat load, propellant usage, and sensed acceleration must all be satised. It is desired to define a methodology to translate the many performance requirements for an atmospheric entry trajectory into language easily understood by vehicle designers in terms of an allowable center-of-gravity box. This is possible by noting that most entry performance parameters for a capsule vehicle are mainly determined by the lift-to-drag ratio of the vehicle. However, the lift-to- drag ratio should be considered a probabilistic quantity rather than deterministic, where variations in the lift-to-drag are caused by both aerodynamic and center-of-gravity un- certainties. This paper discusses the technique used by the Orion program to define the allowable dispersions in center-of-gravity to achieve the desired entry performance while accounting for aerodynamic uncertainty.

Rea, Jeremy R.↗

NASA NTRS2017

A Compilation of MATLAB Scripts and Functions for MACGMC Analyses

The primary aim of the current effort is to provide scripts that automate many of the repetitive pre- and post-processing tasks associated with composite materials analyses using the Micromechanics Analysis Code with the Generalized Method of Cells. This document consists of a compilation of hundreds of scripts that were developed in MATLAB (The Mathworks, Inc., Natick, MA) programming language and consolidated into 16 MATLAB functions. (MACGMC). MACGMC is a composite material and laminate analysis software code developed at NASA Glenn Research Center. The software package has been built around the generalized method of cells (GMC) family of micromechanics theories. The computer code is developed with a user-friendly framework, along with a library of local inelastic, damage, and failure models. Further, application of simulated thermo-mechanical loading, generation of output results, and selection of architectures to represent the composite material have been automated to increase the user friendliness, as well as to make it more robust in terms of input preparation and code execution. Finally, classical lamination theory has been implemented within the software, wherein GMC is used to model the composite material response of each ply. Thus, the full range of GMC composite material capabilities is available for analysis of arbitrary laminate configurations as well. The pre-processing tasks include generation of a multitude of different repeating unit cells (RUCs) for CMCs and PMCs, visualization of RUCs from MACGMC input and output files and generation of the RUC section of a MACGMC input file. The post-processing tasks include visualization of the predicted composite response, such as local stress and strain contours, damage initiation and progression, stress-strain behavior, and fatigue response. In addition to the above, several miscellaneous scripts have been developed that can be used to perform repeated Monte-Carlo simulations to enable probabilistic simulations with minimal manual intervention. This document is formatted to provide MATLAB source files and descriptions of how to utilize them. It is assumed that the user has a basic understanding of how MATLAB scripts work and some MATLAB programming experience.

Materials Engineering↗