Thermoelectric bonding study
Bonding process and bond failure mechanism in lead telluride thermoelectric elements
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Lox/Gox related failures during Space Shuttle Main Engine development
Specific rocket engine hardware and test facility system failures are described which were caused by high pressure liquid and/or gaseous oxygen reactions. The failures were encountered during the development and testing of the space shuttle main engine. Failure mechanisms are discussed as well as corrective actions taken to prevent or reduce the potential of future failures.
Cataldo, C. E.↗
Independent Orbiter Assessment (IOA): Analysis of the ascent thrust vector control actuator subsystem
The results of the Independent Orbiter Assessment (IOA) of the Failure Modes and Effects Analysis (FMEA) and Critical Items List (CIL) are presented. The IOA approach features a top-down analysis of the hardware to determine failure modes, criticality, and potential critical items. To preserve independence, this analysis was accomplished without reliance upon the results contained within the NASA FMEA/CIL documentation. The independent analysis results for the Ascent Thrust Vector Control (ATVC) Actuator hardware are documented. The function of the Ascent Thrust Vector Control Actuators (ATVC) is to gimbal the main engines to provide for attitude and flight path control during ascent. During first stage flight, the SRB nozzles provide nearly all the steering. After SRB separation, the Orbiter is steered by gimbaling of its main engines. There are six electrohydraulic servoactuators, one pitch and one yaw for each of the three main engines. Each servoactuator is composed of four electrohydraulic servovalve assemblies, one second stage power spool valve assembly, one primary piston assembly and a switching valve. Each level of hardware was evaluated and analyzed for possible failure modes and effects. Criticality was assigned based upon the severity of the effect for each failure mode. Critical failures resulting in loss of ATVC were mainly due to loss of hydraulic fluid, fluid contamination and mechanical failures.
Wilson, R. E.↗
Cryogenic Characterization and Testing of Magnetically-Actuated Microshutter Arrays for the James Webb Space Telescope
Two-dimensional MEMS microshutter arrays (MSA) have been fabricated at the NASA Goddard Space Flight Center (GSFC) for the James Webb Space Telescope (JWST) to enable cryogenic (approximately 35 K) spectrographic astronomy measurements in the near-infrared region. Functioning as a focal plane object selection device, the MSA is a 2-D programmable aperture mask with fine resolution, high efficiency and high contrast. The MSA are close- packed silicon nitride shutters (cell size of 100 x 200 microns) patterned with a torsion flexure to allow opening to 90 degrees. A layer of magnetic material is deposited onto each shutter to permit magnetic actuation. Two electrodes are deposited, one onto each shutter and another onto the support structure side-wall, permitting electrostatic latching and 2-D addressing. New techniques were developed to test MSA under mission-similar conditions (8 K less than or equal to T less than 300K). The magnetic rotisserie has proven to be an excellent tool for rapid characterization of MSA. Tests conducted with the magnetic rotisserie method include accelerated cryogenic lifetesting of unpackaged 128 x 64 MSA and parallel measurement of the magneto-mechanical stiffness of shutters in pathfinder test samples containing multiple MSA designs. Lifetest results indicate a logarithmic failure rate out to approximately 10(exp 6) shutter actuations. These results have increased our understanding of failure mechanisms and provide a means to predict the overall reliability of MSA devices.
King, T. T.↗
Bibliography of information on mechanics of structural failure
A bibliography of approximately 1500 reference citations related to six problem areas in the mechanics of failure in aerospace structures is presented. The bibliography represents a search of the literature published in the ten year period 1962-1972 and is largely limited to documents published in the United States. Listings are subdivided into the six problem areas: (1) life prediction of structural materials; (2) fracture toughness data; (3) fracture mechanics analysis; (4) hydrogen embrittlement; (5) protective coatings; and (6) composite materials. An author index is included.
Carpenter, J. L., Jr.↗
Particulate erosion mechanisms
Particulate damage and erosion of ductile metals are today plaguing design and field engineers in diverse fields of engineering and technology. It was found that too many models and theories were proposed leading to much speculation from debris analysis and failure mechanism postulations. Most theories of solid particle erosion are based on material removal models which do not fully represent the actual physical processes of material removal. The various mechanisms proposed thus far are: melting, low-cycle fatigue, extrusion, delamination, shear localization, adhesive material transfer, etc. The experimental data on different materials highlighting the observed failure modes of the deformation and cutting wear processes using optical and scanning electron microscopy are presented. The most important mechanisms proved from the experimental observations of the specimens exposed to both spherical and angular particles are addressed, and the validity of the earlier theories discussed. Both the initial stages of damage and advanced stages of erosion were studied to gain a fundamental understanding of the process.
Veerabhadrarao, P.↗
Structural Verification of the Redesigned Space Shuttle Bipod Foam Closeout
This document outlines the structural verification approach for the Space Shuttle External Tank Forward Bipod Foam Closeout. Due to the Space Shuttle Columbia accident, debris has become a major concern. The intent of the structural verification is to ensure that any debris shed from the bipod is within acceptable limits. Since cohesive failure due to internal defects was identified as the most likely cause of the STS-107 bipod ramp foam failure, verification for this failure mode receives particular emphasis. However, all failure modes for TPS are considered and appropriate verification rationale is developed for each failure mode. Figure 1 depicts the structural verification of a production design where analysis and test are the primary methods of verification. It can be seen that the successful completion of structural verification is dependent on three main areas: 1. Production process control and quality assurance must ensure that test articles and/or analytical models are representative of (or conservatively envelope) production hardware in terms of geometry, materials and processing. Variability and defects must be considered. 2. Flight environments must be sufficiently characterized to bound driving environments for all failure modes. Applied environments, either test or analytical, must be representative of flight environments and have a load factor that satisfies design requirements. 3. Structural verification must include all failure modes. A comprehensive list of failure modes and the underlying failure mechanisms has been generated based on flight and test experience. Verification tests and / or analyses must address each failure mode. ET TPS Verification is accomplished by a combination of analysis, test, and similarity.
Poole, Eric L.↗
Mechanical behavior of fiber reinforced SiC/RBSN ceramic matrix composites: Theory and experiment
The mechanical behavior of continuous fiber reinforced SiC/RBSN (Reaction Bonded Silicon Nitride) composites with various fiber contents is evaluated. Both catastrophic and noncatastrophic failures are observed in tensile specimens. Damage and failure mechanisms are identified via in-situ monitoring using NDE (nondestructive evaluation) techniques through the loading history. Effects of fiber/matrix interface debonding (splitting) parallel to fibers are discussed. Statistical failure behavior of fibers is also observed, especially when the interface is weak. Micromechanical models incorporating residual stresses to calculate the critical matrix cracking strength, ultimate strength, and work of pull-out are reviewed and used to predict composite response. For selected test problems, experimental measurements are compared to analytical predictions.
Chulya, Abhisak↗
Mechanical behavior of fiber reinforced SiC/RBSN ceramic matrix composites - Theory and experiment
The mechanical behavior of continuous fiber reinforced SiC/RBSN (Reaction Bonded Silicon Nitride) composites with various fiber contents is evaluated. Both catastrophic and noncatastrophic failures are observed in tensile specimens. Damage and failure mechanisms are identified via in-situ monitoring using NDE (nondestructive evaluation) techniques throughout the loading history. Effects of fiber/matrix interface debonding (splitting) parallel to fibers are discussed. Statistical failure behavior of fibers is also observed, especially when the interface is weak. Micromechanical models incorproating residual stresses to calculate the critical matrix cracking strength, ultimate strength, and work of pull-out are reviewed and used to predict composite response. For selected test problems, experimental measurements are compared to analytical predictions.
Chulya, Abhisak↗
Register of experts for information on mechanics of structural failure
A list of approximately 150 experts from approximately 60 organizations who have published results of theoretical and/or experimental research related to six problem areas in the mechanics of structural failure is presented. Each author included is listed by organizational affiliation, address and principal field of expertise. The initial criteria for the selection of names for the register are recent contributions to the literature, participation in or support of relevant research programs, and referral by peers. The purpose of the register is to present, in easy reference form, sources for dependable information regarding failure modes and mechanisms of aerospace structures. The Register includes two indexes: an alphabetical listing of the experts and an alphabetical listing of the organizations with whom they are affiliated.
Carpenter, J. L., Jr.↗
On the thermoelastic analysis of solar cell arrays and related material properties
Accurate prediction of failure of solar cell arrays requires accuracy in the computation of thermally induced stresses. This was accomplished by using the finite element technique. Improved procedures for stress calculation were introduced together with failure criteria capable of describing a wide range of ductile and brittle material behavior. The stress distribution and associated failure mechanisms in the N-interconnect junction of two solar cell designs were then studied. In such stress and failure analysis, it is essential to know the thermomechanical properties of the materials involved. Measurements were made of properties of materials suitable for the design of lightweight arrays: microsheet-0211 glass material for the solar cell filter, and Kapton-H, Kapton F, Teflon, Tedlar, and Mica Ply PG-402 for lightweight substrates. The temperature-dependence of the thermal coefficient of expansion for these materials was determined together with other properties such as the elastic moduli, Poisson's ratio, and the stress-strain behavior up to failure.
Salama, M. A.↗
Reliability and engineering of thin-film photovoltaic modules
Objectives were to: examine thin-film cell attributes that influence module performance and reliability, explore the lessons and applicability of crystalline-silicon module technology to thin-film modules, review the current status of thin-film module technologies, and identify problem areas and needed research. A major need is to separate the effects and resons for reversible degradatin from nonreversible degradation. Amorphous-silicon (a-Si) reliability investigations are focusing on exploratory research investigations, accelerated Arrhenius-type testing of a-Si cells, real-time outdoor exposure testing of a-Si cells, cell failure analysis, and failure mechanism research. Studies included the reduction in strength of glass by high temperature depositions on glass and laser scribing, encapsulation materials development needs, and the testing of modules. The new materials and processes in thin-film modules will require a delinquent reliability effort, including: establishment of mechanism-specific reliability goals; quantification of mechanism parameter dependencies; prediction of expected long-term degradation; identification of cost-effective solutions; and testing and failure analysis of trial solutions.
Royal, E. L.↗
Quasi-Static and Dynamic Analysis of Composite Panels: Challenges in Engineering-Level Commercial Software
In engineering applications, where analysis time and efficiency are essential, analytical models and commercially available finite element (FE) material models are the two mainstream methods used to analyze composite crush scenarios. A reliable numerical model addressing the crushing response of composite materials requires a nonlinear progressive damage analysis which includes appropriate failure mechanisms such as matrix cracking, fragmentation, delamination, and fiber breakage. One might be able to address all these interacting failure responses through implementation/validation of a user defined material model or by utilization of a commercially available model, the latter being the most efficient engineering approach. In this paper, the quasi-static and dynamic crushing response of composite specimens, consisting of a C-channel and a corrugated geometry manufactured with carbon fiber/epoxy matrix fabric, are modeled using the progressive composite damage model within ABAQUS. The novel part of this work, which has not been previously addressed in the literature, is the utilization of a detailed parametric study to optimize composite damage model parameters for a given quasi-static crush simulation in ABAQUS. C-channel experiments were used to calibrate the model and then refine/optimize a set of material parameters that best fit the experimental results. These identical parameters were then used to simulate the crush response of the corrugated channel specimens, thereby making it a pure prediction and not a double recalibration. Next, the dynamic response of both panels were predicted, further confirming the predictive capability of the developed numerical model. The effect of parameter variation on the crush response is fully documented for future use in engineering applications utilizing this specific ABAQUS damage model.
Paria Naghipour↗
Acoustic method of damage sensing in composite materials
The use of acoustic emission and acousto-ultrasonics to characterize impact damage in composite structures is being performed on both graphite epoxy and kevlar bottles. Further development of the acoustic emission methodology to include neural net analysis and/or other multivariate techniques will enhance the capability of the technique to identify failure mechanisms during fracture. The acousto-ultrasonics technique will be investigated to determine its ability to predict regions prone to failure prior to the burst tests. The combination of the two methods will allow for simple nondestructive tests to be capable of predicting the performance of a composite structure prior to being placed in service and during service.
Workman, Gary L.↗
Mechanical Behavior of a Hi-Nicalon(tm)/SiC Composite Having a Polycarbosilane Derived Matrix
Polymer infiltration of a rigidized preform, followed by pyrolysis to convert the polymer to a ceramic, potentially offers a lower cost alternative to CVD. It also offers more moderate temperature requirements than melt infiltration approaches, which should minimize potential fiber damage during processing. However, polymer infiltration and pyrolysis results in a more microcracked matrix. Preliminary mechanical property characterization, including elevated temperature (1204 C) tensile, 500 h stress rupture behavior and low cycle fatigue, was conducted on Hi-Nicalon (TM)/Si-C-(O) composites having a dual layer BN/SiC interface and a matrix derived by impregnation and pyrolysis of allylhydridopolycarbosilane (AHPCS). Microstructural evaluation of failure surfaces and of polished transverse and longitudinal cross sections of the failed specimens was used to identify predominant failure mechanisms. In stress rupture testing at 1093 C, the failure was interface dominated, while at 1204 C in both stress rupture and two hour hold/fatigue tests failure was matrix dominated, resulting in specimen delamination.
Hurwitz, Frances I.↗
Analysis of a Memory Device Failure
The recent failure of a vintage memory device presented a unique challenge to failure analysts. Normally device layouts, fabrication parameters and other technical information were available to assist the analyst in the analysis. However, this device was out of production for many years and the manufacturer was no longer in business, so the information was not available. To further complicate this analysis, the package leads were all but removed making additional electrical testing difficult. Under these conditions, new and innovative methods were used to analyze the failure. The external visual exam, radiography, PIND, and leak testing were performed with nominal results. Since electrical testing was precluded by the short lead lengths, the device was delidded to expose the internal structures for microscopic examination. No failure mechanism was identified. The available electrical data suggested an ESD or low level EOS type mechanism which left no visible surface damage. Due to parallel electrical paths, electrical probing on the chip failed to locate the failure site. Two non-destructive Scanning Electron Microscopy techniques, CIVA (Charge Induced Voltage Alteration) and EBIC (Electron Beam Induced Current), and a liquid crystal decoration technique which detects localized heating were employed to aid in the analysis. CIVA and EBIC isolated two faults in the input circuitry, and the liquid crystal technique further localized two hot spots in regions on two input gates. Removal of the glassivation and metallization revealed multiple failure sites located in the gate oxide of two input transistors suggesting machine (testing) induced damage.
Nicolas, David P.↗
Testing and Analysis of Composite Skin/Stringer Debonding Under Multi-Axial Loading
A consistent step-wise approach is presented to investigate the damage mechanism in composite bonded skin/stringer constructions under uniaxial and biaxial (in-plane/out-of-plane) loading conditions. The approach uses experiments to detect the failure mechanism, computational stress analysis to determine the location of first matrix cracking and computational fracture mechanics to investigate the potential for delamination growth. In a first step, tests were performed on specimens, which consisted of a tapered composite flange, representing a stringer or frame, bonded onto a composite skin. Tests were performed under monotonic loading conditions in tension, three-point bending, and combined tension/bending to evaluate the debonding mechanisms between the skin and the bonded stringer. For combined tension/bending testing, a unique servohydraulic load frame was used that was capable of applying both in-plane tension and out-of-plane bending loads simultaneously. Specimen edges were examined on the microscope to document the damage occurrence and to identify typical damage patterns. For all three load cases, observed failure initiated in the flange, near the flange tip, causing the flange to almost fully debond from skin. In a second step, a two dimensional plane-strain finite element model was developed to analyze the different test cases using a geometrically nonlinear solution. For all three loading conditions, computed principal stresses exceeded the transverse strength of the material in those areas of the flange where the matrix cracks had developed during the tests. In a third step, delaminations of various lengths were simulated in two locations where delaminations were observed during the tests. The analyses showed that at the loads corresponding to matrix ply crack initiation computed strain energy release rates exceeded the values obtained from a mixed mode failure criterion in one location, Hence. Unstable delamination propagation is likely to occur as observed in the experiments.
Krueger, Ronald↗
Testing and Analysis of Composite Skin/Stringer Debonding under Multi-Axial Loading
A consistent step-wise approach is presented to investigate the damage mechanism in composite bonded skin/stringer constructions under uniaxial and biaxial (in-plane/out-of-plane) loading conditions. The approach uses experiments to detect the failure mechanism, computational stress analysis to determine the location of first matrix cracking and computational fracture mechanics to investigate the potential for delamination growth. In a first step, tests were performed on specimens, which consisted of a tapered composite flange, representing a stringer or frame, bonded onto a composite skin. Tests were performed under monotonic loading conditions in tension, three-point bending, and combined tension/bending to evaluate the debonding mechanisms between the skin and the bonded stringer. For combined tension/bending testing, a unique servohydraulic load frame was used that was capable of applying both in-plane tension and out-of-plane bending loads simultaneously. Specimen edges were examined on the microscope to document the damage occurrence and to identify typical damage patterns. For all three load cases, observed failure initiated in the flange, near the flange tip, causing the flange to almost fully debond from the skin. In a second step, a two-dimensional plane-strain finite element model was developed to analyze the different test cases using a geometrically nonlinear solution. For all three loading conditions, computed principal stresses exceeded the transverse strength of the material in those areas of the flange where the matrix cracks had developed during the tests. In a third step, delaminations of various lengths were simulated in two locations where delaminations were observed during the tests. The analyses showed that at the loads corresponding to matrix ply crack initiation computed strain energy release rates exceeded the values obtained from a mixed mode failure criterion in one location. Hence, unstable delamination propagation is likely to occur as observed in the experiments.
Krueger, Ronald↗