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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 307 records · Page 17
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

HEAF Cable Fragility Testing at the Solar Furnace at the NSTTF

In order to establish a zone of influence (ZOI) due to a high energy arcing fault (HEAF) environment, the fragility of the targets must be determined. The high heat flux/short duration exposure of a HEAF is considerably different than that of a traditional hydrocarbon fire, which previous research has addressed. The previous failure metrics (e.g., internal jacket temperature of a cable exposed to a fire) were based on low heat flux/long duration exposures. Because of this, evaluation of different physics and failure modes was considered to evaluate the fragility of cables exposed to a HEAF. Tests on cable targets were performed at high heat flux/short duration exposures to gain insight on the relevant physics and failure modes. These tests yielded data on several relevant failure modes, including electrical failure and sustained ignition. Additionally, the results indicated a relationship between the total energy of exposure and the damage state of the cable target. This data can be used to inform the fragility of the targets.

42 ENGINEERING↗
NASA NTRS1987

Independent Orbiter Assessment (IOA): Analysis of the electrical power distribution and control/remote manipulator system 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 Electrical Power Distribution and Control (EPD and C)/Remote Manipulator System (RMS) hardware to determine failure modes, criticality, and potential critical items. To preserve independence, this analysis was accomplished without reliance upon the results contained in the NASA FMEA/CIL documentation. This report documents the results of the independent analysis of the EPD and C/RMS (both port and starboard) hardware. The EPD and C/RMS subsystem hardware provides the electrical power and power control circuitry required to safely deploy, operate, control, and stow or guillotine and jettison two (one port and one starboard) RMSs. The EPD and C/RMS subsystem is subdivided into the four following functional divisions: Remote Manipulator Arm; Manipulator Deploy Control; Manipulator Latch Control; Manipulator Arm Shoulder Jettison; and Retention Arm Jettison. The IOA analysis process utilized available EPD and C/RMS hardware drawings and schematics for defining hardware assemblies, components, and hardware items. Each level of hardware was evaluated and analyzed for possible failure modes and effects. Criticality was assigned based on the severity of the effect for each failure mode.

Robinson, W. W.↗
DOE OSTI2026

Uncertainty quantification for competing failure mechanisms in unidirectionally reinforced carbon–carbon composites

Microstructure-informed finite element models play a key role in the carbon–carbon composite design process. Variability in manufacturing process parameters and experimental limitations introduce model parameter uncertainty. This study quantifies the effect of model parameter uncertainty on transverse tensile fracture behavior and proposes a methodology to predict the failure mode based on competing microscale damage mechanisms. Finite element simulations incorporate fiber–matrix interface debonding with cohesive zones and matrix damage with a smeared crack band approach in a unidirectional carbon–carbon composite. Results from a variance-based global sensitivity analysis identifies interfacial and matrix damage parameters as the primary source of variability in fracture behavior. Sobol’ indices indicate that matrix and cohesive zone strengths contribute 94% of the variance in the effective ultimate stress. A local analysis elucidates the relationship between these constituent strength parameters and failure mode by estimating the probability of cohesive, matrix, and mixed-mode dominated failure. Based on the results for 4000 simulations, 93% exhibit mixed-mode or interfacial dominated failure, which underscores the crucial role of fiber–matrix interface debonding in the transverse tensile failure of carbon–carbon composites. These uncertainty quantification results facilitate more efficient model calibration and provide a framework for microstructure-informed failure predictions in the face of manufacturing-induced uncertainty.

36 MATERIALS SCIENCE↗
NASA NTRS1988

Independent Orbiter Assessment (IOA): FMEA/CIL assessment

The McDonnell Douglas Astronautics Company (MDAC) was selected to perform an Independent Orbiter Assessment (IOA) of the Failure Modes and Effects Analysis (FMEA) and Critical Items List (CIL). Direction was given by the Orbiter and GFE Projects Office to perform the hardware analysis and assessment using the instructions and ground rules defined in NSTS 22206. The IOA analysis featured a top-down approach to determine hardware failure modes, criticality, and potential critical items. To preserve independence, the analysis was accomplished without reliance upon the results contained within the NASA and Prime Contractor FMEA/CIL documentation. The assessment process compared the independently derived failure modes and criticality assignments to the proposed NASA post 51-L FMEA/CIL documentation. When possible, assessment issues were discussed and resolved with the NASA subsystem managers. Unresolved issues were elevated to the Orbiter and GFE Projects Office manager, Configuration Control Board (CCB), or Program Requirements Control Board (PRCB) for further resolution. The most important Orbiter assessment finding was the previously unknown stuck autopilot push-button criticality 1/1 failure mode. The worst case effect could cause loss of crew/vehicle when the microwave landing system is not active. It is concluded that NASA and Prime Contractor Post 51-L FMEA/CIL documentation assessed by IOA is believed to be technically accurate and complete. All CIL issues were resolved. No FMEA issues remain that have safety implications. Consideration should be given, however, to upgrading NSTS 22206 with definitive ground rules which more clearly spell out the limits of redundancy.

Hinsdale, L. W.↗
DOE OSTI2021

Numerical and experimental evaluation of mechanical performance of the multifunctional energy storage composites

This work presents numerical simulation methods to model the mechanical behavior of the multifunctional energy storage composites (MESCs), which consist of a stack of multiple thin battery layers reinforced with through-the-hole polymer rivets and embedded inside carbon fiber composite laminates. MESC has been demonstrated through earlier experiments on its exceptional behavior as a structural element as well as a battery. However, the inherent complex infrastructure of the MESC design has created significant challenges in simulation and modeling. A novel homogenization technique was adopted to characterize the multi-layer properties of battery material using physics-based constitutive equations combined with nonlinear deformation theories to handle the interface between the battery layers. Second, mechanical damage and failure modes among battery materials, polymer reinforcements, and carbon fiber-polymer interfaces were characterized through appropriate models and experiments. The model of MESCs has been implemented in a commercial finite element code in ABAQUS. A comparison of structural response and failure modes from numerical simulations and experimental tests are presented. The results of the study showed that the predictions of elastic and damage responses of MESCs at various loading conditions agreed well with the experimental data. © 2021

Materials Science↗
NASA NTRS1984

Status of Understanding for Bearing Materials

The structural materials and potential failure modes for high technology aircraft gas turbine bearings are reviewed. Among the failure modes discussed for iron-base through-hardened bearing materials are fatigue, surface distress, and corrosion. It is shown that the sub-surface initiated rolling-contact fatigue failure mode is reasonably well understood and in most cases can be controlled by proper material selection and design. Current bearing materials provide long life and high reliability in existing applications. A new generation of materials are being developed which will provide improved fracture toughness, better corrosion resistance, and a further extension of bearing fatigue life. Bearing problems due to surface distress, caused by a variety of surface and near surface anomalies, are less well understood. This area will require the implementation of an interdisciplinary effort to improve the level of understanding of metallic surface-lubricant reactions and interactions.

E N Bamberger↗
NASA NTRS1988

Independent Orbiter Assessment (IOA): FMEA/CIL assessment

The results of the Independent Orbiter Assessment (IOA) of the Failure Modes and Effects Analysis (FMEA) and Critical Items List (CIL) are presented. Direction was given by the Orbiter and GFE Projects Office to perform the hardware analysis and assessment using the instructions and ground rules defined in NSTS 22206. The IOA analysis features a top-down approach to determine hardware failure modes, criticality, and potential critical items. To preserve independence, the anlaysis was accomplished without reliance upon the results contained within the NASA and prime contractor FMEA/CIL documentation. The assessment process compares the independently derived failure modes and criticality assignments to the proposed NASA Post 51-L FMEA/CIL documentation. When possible, assessment issues are discussed and resolved with the NASA subsystem managers. The assessment results for each subsystem are summarized. The most important Orbiter assessment finding was the previously unknown stuck autopilot push-button criticality 1/1 failure mode, having a worst case effect of loss of crew/vehicle when a microwave landing system is not active.

Saiidi, Mo J.↗
NASA NTRS1980

Orbiter subsystem hardware/software interaction analysis. Volume 8: AFT reaction control system, part 2

The orbiter subsystems and interfacing program elements which interact with the orbiter computer flight software are analyzed. The failure modes identified in the subsystem/element failure mode and effects analysis are examined. Potential interaction with the software is examined through an evaluation of the software requirements. The analysis is restricted to flight software requirements and excludes utility/checkout software. The results of the hardware/software interaction analysis for the forward reaction control system are presented.

Becker, D. D.↗
NASA NTRS1991

Reusable rocket engine intelligent control system framework design, phase 2

Elements of an advanced functional framework for reusable rocket engine propulsion system control are presented for the Space Shuttle Main Engine (SSME) demonstration case. Functional elements of the baseline functional framework are defined in detail. The SSME failure modes are evaluated and specific failure modes identified for inclusion in the advanced functional framework diagnostic system. Active control of the SSME start transient is investigated, leading to the identification of a promising approach to mitigating start transient excursions. Key elements of the functional framework are simulated and demonstration cases are provided. Finally, the advanced function framework for control of reusable rocket engines is presented.

Nemeth, ED↗
DOE OSTI2020

A Quantitative Failure Analysis on Capacity Fade in Rechargeable Lithium Metal Cells

Rechargeable lithium battery (RLB) technology is transforming portable devices, vehicle electrification, and grid modernization. To make RLB durable, reliable and safe, conducting failure mode and effect analysis (FMEA) to identify failure mechanism under the operating conditions is very desirable. However, this ability is often overlooked or even lacking. The failure analysis (FA) is often conducted by laboratory testing and postmortem analysis, and the knowledge typically empirical. Here we present a quantitative approach for FMEA that can reveal how failure modes and effects reduce the capacity of a RLB. This approach is based on the state of the battery for FMEA, contrary to the conventional approach based on operating or testing conditions. The key aspect of this FMEA method is to convert the experimental results to a state-of-charge (SOC)-based analytic methodology. Such a conversion can separate the thermodynamic and kinetic attributes of capacity fade based on compositional correspondence in the electrode, so the loss and the decreased utilization of the active materials can be determined respectively.

25 ENERGY STORAGE↗
NASA NTRS1990

A methodology for probabilistic prediction of structural failures of launch vehicle propulsion systems

A quantitative methodology for estimating the probability of occurrence of critical structural failure modes of launch vehicle propulsion systems during mission operation is presented. In this approach, engineering analysis models that characterize specific failure modes based on the physics and mechanics of the failure phenomenon are used in a prescribed probabalistic structure in which quantified uncertainty in the information used in the analysis and quantified uncertainty of the engineering analysis models themselves are both considered in estimating failure risk. The methodology is applicable to high cycle fatigue, low cycle fatigue, flaw propagation stress rupture, and other failure modes of launch vehicle propulsion systems and other space-flight systems. The probabalistic failure assessment presented provides the capability of performing quantitative analyses to rank options to improve reliability, thereby enabling limited financial resources of development and improvement programs to be more effectively allocated.

Moore, N.↗
NASA NTRSDate not supplied

Simulation of Dynamic Crushing Behavior of Simulated Carbon/Epoxy Stanchions Using MAT58 and MAT213 in LS-DYNA

Carbon fiber-reinforced polymer (CFRP) composites have shown promise as a material for structures designed to absorb energy in crush-style impact loading. In complementing the lightweight and tailorable characteristics of CFRP structures, the benefits of impact energy absorption are particularly interesting in aerospace vehicles that require excellent crashworthiness performance. However, simulating the behavior of CFRP structures in dynamic, crushing-style impact loading is challenging because of the many damage and failure modes that are essential to capture in the model. For the present investigation, CFRP stanchions were tested using a crash sled experimental test rig. The stanchions were designed by the Composite Materials Handbook-17 (CMH-17) Crashworthiness Working Group for the purpose of comparing experimental crash sled tests to corresponding simulations of the tests. The stanchions are C-channel shaped and represent a geometry common in the interior of aerospace vehicle structures. Explicit simulations in LSDYNA were performed using a well-established composite material model (MAT58) and a next-generation material model (MAT213). Fully integrated shell elements were utilized instead of 3D solid elements to limit computation time. In all models, each of the sixteen plies were represented with individual layers of shell elements with tiebreak contact between each adjacent ply pair to simulate interlaminar fracture. Simulating the crushing of the stanchions occurred in two phases. First, the material models were calibrated using flat specimens that were manufactured with the same layup as the stanchions. While the original goal was calibration of material-related properties, meshdependent behavior was observed in simulations with either material model, and an unstructured mesh was selected to remediate undesirable mesh-dependent failure modes. Additionally, for both the MAT58 and MAT213 models, it was found that either the crush force or the failure mode could be modeled accurately, but no set of parameters could be identified to attain both results in the same model. Once satisfactory calibration was achieved, the same material parameters were applied to the stanchion crush simulations. The stanchion simulations showed that MAT213 more accurately predicted the experimentally determined crush force, and both material models predicted key aspects of the experimentally observed failure modes.

Composite Materials↗
NASA NTRS1980

Orbiter subsystem hardware/software interaction analysis. Volume 8: Forward reaction control system

The results of the orbiter hardware/software interaction analysis for the AFT reaction control system are presented. The interaction between hardware failure modes and software are examined in order to identify associated issues and risks. All orbiter subsystems and interfacing program elements which interact with the orbiter computer flight software are analyzed. The failure modes identified in the subsystem/element failure mode and effects analysis are discussed.

Becker, D. D.↗
NASA NTRS1979

Testing of containers made of glass-fiber reinforced plastic with the aid of acoustic emission analysis

Acoustic emission analysis as a quasi-nondestructive test method makes it possible to differentiate clearly, in judging the total behavior of fiber-reinforced plastic composites, between critical failure modes (in the case of unidirectional composites fiber fractures) and non-critical failure modes (delamination processes or matrix fractures). A particular advantage is that, for varying pressure demands on the composites, the emitted acoustic pulses can be analyzed with regard to their amplitude distribution. In addition, definite indications as to how the damages occurred can be obtained from the time curves of the emitted acoustic pulses as well as from the particular frequency spectrum. Distinct analogies can be drawn between the various analytical methods with respect to whether the failure modes can be classified as critical or non-critical.

Wolitz, K.↗
NASA NTRS1986

Independent Orbiter Assessment (IOA): Analysis of the rudder/speed brake 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 Orbiter Rudder/Speedbrake Actuation Mechanism is documented. The function of the Rudder/Speedbrake (RSB) is to provide directional control and to provide a means of energy control during entry. The system consists of two panels on a vertical hinge mounted on the aft part of the vertical stabilizer. These two panels move together to form a rudder but split apart to make a speedbrake. The Rudder/Speedbrake Actuation Mechanism consists of the following elements: (1) Power Drive Unit (PDU) which is composed of hydraulic valve module and a hydraulic motor-powered gearbox which contains differentials and mixer gears to provide PDU torque output; (2) four geared rotary actuators which apply the PDU generated torque to the rudder/speedbrake panels; and (3) ten torque shafts which join the PDU to the rotary actuators and interconnect the four rotary actuators. Each level of hardware was evaluated and analyzed for possible failures and causes. Criticality was assigned based upon the severity of the effect for each failure mode. Critical RSB failures which result in potential loss of vehicle control were mainly due to loss of hydraulic fluid, fluid contaminators, and mechanical failures in gears and shafts.

Wilson, R. E.↗
NASA NTRS1980

Failure analyses of composite bolted joints

The complex failure behavior exhibited by bolted joints of graphite epoxy (Hercules AS/3501) was investigated for the net tension, bearing and shearout failure modes using combined analytical and experimental techniques. Plane stress, linear elastic, finite element methods were employed to determine the two dimensional state of stress resulting from a loaded hole in a finite width, semiinfinite strip. The stresses predicted by the finite element method were verified by experiment to lend credence to the analysis. The influence of joint geometric parameters on the state of stress and resultant strength of the joint was also studied. The resulting functional relationships found to exist between bolted joint strength and the geometric parameters, were applied in the formulation of semiempirical strength models for the basic failure modes. A point stress failure criterion was successfully applied as the failure criterion for the net tension and shearout failure modes.

Wilson, D. W.↗
NASA NTRS1992

User's guide to the Reliability Estimation System Testbed (REST)

The Reliability Estimation System Testbed is an X-window based reliability modeling tool that was created to explore the use of the Reliability Modeling Language (RML). RML was defined to support several reliability analysis techniques including modularization, graphical representation, Failure Mode Effects Simulation (FMES), and parallel processing. These techniques are most useful in modeling large systems. Using modularization, an analyst can create reliability models for individual system components. The modules can be tested separately and then combined to compute the total system reliability. Because a one-to-one relationship can be established between system components and the reliability modules, a graphical user interface may be used to describe the system model. RML was designed to permit message passing between modules. This feature enables reliability modeling based on a run time simulation of the system wide effects of a component's failure modes. The use of failure modes effects simulation enhances the analyst's ability to correctly express system behavior when using the modularization approach to reliability modeling. To alleviate the computation bottleneck often found in large reliability models, REST was designed to take advantage of parallel processing on hypercube processors.

Nicol, David M.↗
DOE OSTI2026

Facilitating Data Collection of Maintenance Events to Populate the Hydrogen Component Reliability Database (HyCReD)

The Hydrogen Component Reliability Database (HyCReD) is a collaborative project between the National Renewable Energy Laboratory, the University of Maryland, and hydrogen stakeholders to improve safety and reliability for hydrogen facilities by implementing component reliability data taxonomies that support hydrogen infrastructure failure rate analysis. The project aims to quantify failure rates of hydrogen components through high-quality data collection and analysis on root causes and maintenance needed. HyCReD provides a common database for cataloging hydrogen component failures which exists for reliability research in many other mature industries [2]. The database fills a gap for the hydrogen community by providing a scientifically rigorous approach to quantitative risk assessment (QRA), prognostic health management (PHM), and reliability-centered maintenance (RCM) analysis. High level results will be aggregated and anonymized to protect company sensitive information; detailed results will be used to help address issues of hydrogen components. These advanced analytics will support accelerated deployment of hydrogen infrastructure by enabling better: design and safety of projects (safety codes and standards development), infrastructure reliability and cost (component failure rates, maintenance protocols), and component R&D needs (robust supply chain). A key to a successful HyCReD implementation is facilitating the ease of reporting and data quality in the database that can be used for analysis. Maintenance data was a previously identified gap in initial efforts to populate and validate the database taxonomies [3]. Collection of maintenance data will be instrumental in identifying failure modes and rates, identifying incipient component failures or reduced performance, cataloging best practices for maintenance routines and methods for prognostic health management, and quantifying the risk and effect of different failure modes. Several key priorities are identified for streamlined data collection to achieve quality and detailed failure data: Applicability, Ease of Use, Accessibility, and Information Security. The HyCReD team has now begun deployment of the database to several companies and groups that have signed non-disclosure agreements to facilitate the data collection of failures in industry hydrogen refueling station infrastructure. This paper will provide an update into the process of HyCReD deployment including the development of a coding guide for facility personnel to reference and ensure data quality and consistency from one station to another as well as implementation of contextually dependent data fields of system taxonomy and formatted entries to provide ease of use. The goal is to communicate the lessons learned from the roll-out to technicians and engineers in the field, and the addition of need for high level of security to protect all stakeholders.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗