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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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All sourcesNASA NTRSDOE OSTI
NASA NTRS1977

F-8 DFBW sensor failure identification using analytic redundancy

The structure of a sensor failure detection and identification system designed for the NASA F-8 DFBW aircraft is outlined. The system is for use in a dual-redundant environment, and it takes maximal advantage of all functional relationships among the sensed variables. The identification logic uses the quality sequential probability ratio, which provides a useful on-line measure of confidence in the various forms of analytic redundancy. Preliminary simulation results indicate good behavior of the analytic decision statistic, based on the sequential probability ratio test.

Deckert, J. C.↗
NASA NTRS1996

Structures Division 1994 Annual Report

The NASA Lewis Research Center Structures Division is an international leader and pioneer in developing new structural analysis, life prediction, and failure analysis related to rotating machinery and more specifically to hot section components in air-breathing aircraft engines and spacecraft propulsion systems. The research consists of both deterministic and probabilistic methodology. Studies include, but are not limited to, high-cycle and low-cycle fatigue as well as material creep. Studies of structural failure are at both the micro- and macrolevels. Nondestructive evaluation methods related to structural reliability are developed, applied, and evaluated. Materials from which structural components are made, studied, and tested are monolithics and metal-matrix, polymer-matrix, and ceramic-matrix composites. Aeroelastic models are developed and used to determine the cyclic loading and life of fan and turbine blades. Life models are developed and tested for bearings, seals, and other mechanical components, such as magnetic suspensions. Results of these studies are published in NASA technical papers and reference publication as well as in technical society journal articles. The results of the work of the Structures Division and the bibliography of its publications for calendar year 1994 are presented.

Source record↗
NASA NTRS1997

Structures Division

The NASA Lewis Research Center Structures Division is an international leader and pioneer in developing new structural analysis, life prediction, and failure analysis related to rotating machinery and more specifically to hot section components in air-breathing aircraft engines and spacecraft propulsion systems. The research consists of both deterministic and probabilistic methodology. Studies include, but are not limited to, high-cycle and low-cycle fatigue as well as material creep. Studies of structural failure are at both the micro- and macrolevels. Nondestructive evaluation methods related to structural reliability are developed, applied, and evaluated. Materials from which structural components are made, studied, and tested are monolithics and metal-matrix, polymer-matrix, and ceramic-matrix composites. Aeroelastic models are developed and used to determine the cyclic loading and life of fan and turbine blades. Life models are developed and tested for bearings, seals, and other mechanical components, such as magnetic suspensions. Results of these studies are published in NASA technical papers and reference publication as well as in technical society journal articles. The results of the work of the Structures Division and the bibliography of its publications for calendar year 1995 are presented.

Source record↗
NASA NTRS1990

Progressive failure analysis of fibrous composite materials and structures

A brief description is given of the modifications implemented in the PAFAC finite element program for the simulation of progressive failure in fibrous composite materials and structures. Details of the memory allocation, input data, and the new subroutines are given. Also, built-in failure criteria for homogeneous and fibrous composite materials are described.

Bahei-El-din, Yehia A.↗
NASA NTRS1989

Sensor failure detection using generalized parity relations for flexible structures

Analytical redundancy may be preferable to hardware redundancy in failure detection/isolation tasks for such large-scale systems as space structures. Generalized single-sensor parity relations are presently applied to this problem; they are noted to yield a very simple isolation logic, and their generation is found to be extremely rapid, even in the case of extremely complex systems, provided only that the eigenstructure of the system be known. Their implementation is, however, extremely sensitive to modeling errors and noise.

Mercadal, Mathieu↗
NASA NTRS1991

Failure prediction of thin beryllium sheets used in spacecraft structures

The primary objective of this study is to develop a method for prediction of failure of thin beryllium sheets that undergo complex states of stress. Major components of the research include experimental evaluation of strength parameters for cross-rolled beryllium sheet, application of the Tsai-Wu failure criterion to plate bending problems, development of a high order failure criterion, application of the new criterion to a variety of structures, and incorporation of both failure criteria into a finite element code. A Tsai-Wu failure model for SR-200 sheet material is developed from available tensile data, experiments carried out by NASA on two circular plates, and compression and off-axis experiments performed in this study. The failure surface obtained from the resulting criterion forms an ellipsoid. By supplementing experimental data used in the the two-dimensional criterion and modifying previously suggested failure criteria, a multi-dimensional failure surface is proposed for thin beryllium structures. The new criterion for orthotropic material is represented by a failure surface in six-dimensional stress space. In order to determine coefficients of the governing equation, a number of uniaxial, biaxial, and triaxial experiments are required. Details of these experiments and a complementary ultrasonic investigation are described in detail. Finally, validity of the criterion and newly determined mechanical properties is established through experiments on structures composed of SR200 sheet material. These experiments include a plate-plug arrangement under a complex state of stress and a series of plates with an out-of-plane central point load. Both criteria have been incorporated into a general purpose finite element analysis code. Numerical simulation incrementally applied loads to a structural component that is being designed and checks each nodal point in the model for exceedance of a failure criterion. If stresses at all locations do not exceed the failure criterion, the load is increased and the process is repeated. Failure results for the plate-plug and clamped plate tests are accurate to within 2 percent.

Roschke, Paul N.↗
NASA NTRS1972

Reliability analysis applied to structural tests

The application of reliability theory to predict, from structural fatigue test data, the risk of failure of a structure under service conditions because its load-carrying capability is progressively reduced by the extension of a fatigue crack, is considered. The procedure is applicable to both safe-life and fail-safe structures and, for a prescribed safety level, it will enable an inspection procedure to be planned or, if inspection is not feasible, it will evaluate the life to replacement. The theory has been further developed to cope with the case of structures with initial cracks, such as can occur in modern high-strength materials which are susceptible to the formation of small flaws during the production process. The method has been applied to a structure of high-strength steel and the results are compared with those obtained by the current life estimation procedures. This has shown that the conventional methods can be unconservative in certain cases, depending on the characteristics of the structure and the design operating conditions. The suitability of the probabilistic approach to the interpretation of the results from full-scale fatigue testing of aircraft structures is discussed and the assumptions involved are examined.

Diamond, P.↗
NASA NTRS2005

Identification of Cyclically Symmetric Resonance in Experimental Data for Engine Failure Analysis

Many structural components are rotationally symmetric. For a perfectly manufactured structure, the modal wave shapes are exactly sinusoidal. These structures can be excited by similarly-shaped forcing functions such as those found frequently in or near turbomachinery. Due to orthogonality, resonance occurs only when the integer wave number of the structure equals the integer wave number of the excitation as well as when the excitation frequency is close to the natural frequency of the mode. This resonance can lead to high-cycle fatigue (HCF) cracking of the structure. To help understand this phenomenon, it is desirable to determine the modal composition of the response and excitation. Once the modal composition is known, either the excitation or the structure can be modified to reduce the response and therefore prevent HCF cracking.

Medley, Steve↗
NASA NTRS1985

Experimental Development of a Failure Detection Scheme for Large Space Structures

Large flexible spacecraft may require control systems consisting of large numbers of sensors and actuators. To assure a viable mission, the control system should tolerate failures of some of the control components. Hence, it is desirable to automate the process of failure detection, identification, and control system reconfiguration (FDI&R). Some of the opportunities to accommodate failure in the spacecraft design are reviewed. Some methods for FDI&R are presented in overview, and the method chosen for experimental testing is described. Finally, the experimental activities leading to the validation of the technique are presented.

Montgomery, R. C.↗
NASA NTRS2012

Influence of Finite Element Size in Residual Strength Prediction of Composite Structures

The sensitivity of failure load to the element size used in a progressive failure analysis (PFA) of carbon composite center notched laminates is evaluated. The sensitivity study employs a PFA methodology previously developed by the authors consisting of Hashin-Rotem intra-laminar fiber and matrix failure criteria and a complete stress degradation scheme for damage simulation. The approach is implemented with a user defined subroutine in the ABAQUS/Explicit finite element package. The effect of element size near the notch tips on residual strength predictions was assessed for a brittle failure mode with a parametric study that included three laminates of varying material system, thickness and stacking sequence. The study resulted in the selection of an element size of 0.09 in. X 0.09 in., which was later used for predicting crack paths and failure loads in sandwich panels and monolithic laminated panels. Comparison of predicted crack paths and failure loads for these panels agreed well with experimental observations. Additionally, the element size vs. normalized failure load relationship, determined in the parametric study, was used to evaluate strength-scaling factors for three different element sizes. The failure loads predicted with all three element sizes provided converged failure loads with respect to that corresponding with the 0.09 in. X 0.09 in. element size. Though preliminary in nature, the strength-scaling concept has the potential to greatly reduce the computational time required for PFA and can enable the analysis of large scale structural components where failure is dominated by fiber failure in tension.

Satyanarayana, Arunkumar↗
NASA NTRS1970

Secondary structures and mechanisms - Design trouble area for the space shuttle

The design of secondary structures and mechanisms for a reusable space shuttle can produce problems as serious as those involved in designing the primary structure and thermal protection system. Several events involving failure of secondary structures during the X-15 flight program have been selected to illustrate potential problem areas. Similar problems may be expected on future reusable vehicles until additional research provides adequate design information in these areas.

Eldon E. Kordes↗
NASA NTRS1997

Composite Interlaminar Shear Fracture Toughness, G(sub 2c): Shear Measurement of Sheer Myth?

The concept of G2c as a measure of the interlaminar shear fracture toughness of a composite material is critically examined. In particular, it is argued that the apparent G2c as typically measured is inconsistent with the original definition of shear fracture. It is shown that interlaminar shear failure actually consists of tension failures in the resin rich layers between plies followed by the coalescence of ligaments created by these failures and not the sliding of two planes relative to one another that is assumed in fracture mechanics theory. Several strain energy release rate solutions are reviewed for delamination in composite laminates and structural components where failures have been experimentally documented. Failures typically occur at a location where the mode 1 component accounts for at least one half of the total G at failure. Hence, it is the mode I and mixed-mode interlaminar fracture toughness data that will be most useful in predicting delamination failure in composite components in service. Although apparent G2c measurements may prove useful for completeness of generating mixed-mode criteria, the accuracy of these measurements may have very little influence on the prediction of mixed-mode failures in most structural components.

OBrien, T. Kevin↗
NASA NTRSDate not supplied

Component Characterization of an eVTOL Reference Model for Crashworthiness Studies

Researchers at the National Aeronautics and Space Administration (NASA) Langley Research Center (LaRC) have conducted a series of structural component and seat level tests to improve finite element model (FEM) characterization of a representative vertical take-off and landing (eVTOL) test article developed by NASA. A full-scale dynamic test was conducted on the representative eVTOL test article in November of 2022. The test article represented a high wing, six passenger eVTOL design concept and is referred to as the lift plus cruise (LPC) test article. The full-scale test identified limitations in the analytical models used to predict aircraft structural response, in particular the composite material models did not effectively capture brittle failure of the structure which were measured during dynamic loading. To better understand the mechanism behind the composite material failure mechanisms observed and to improve the FEM, intact sample specimens of the composite airframe structure were recovered from the test article post-test and used in material characterization testing. In addition, the seat configurations used in the LPC test article were further studied using isolated seat and anthropomorphic test device (ATD) drop tower testing. Dynamic compression tests and three-point bend tests, conducted at varied impact speeds, were performed on the recovered frame section specimens. Additional testing was conducted to characterize the material properties of the forming foam, which remained in the frames after fabrication. These tests were used to improve characterization of the damage and failure parameters of the composite material model used in the FE model of the LPC test article. Seat level tests were conducted on the seats used in the LPC test article using acceleration pulses inclusive of current general aviation and rotorcraft certification load levels as well as conditions representative of those measured at the seat base during the LPC test. The structural material models and seat environment models of the LPC test article FEM were calibrated using the generated component test data. The updates made to these models were then integrated into the LPC FEM and simulated in the full-scale test condition. Results demonstrated the effectiveness of component testing to improve predictive capability of composite aerospace structural models within the crash and dynamic loading environments. Demonstration of the LPC FEM response across an accumulation of coupon, component, seat environment, and full-scale test levels provides confidence in the predictive capability of this model for future use in the study of occupant safety within eVTOL relevant crash environments.

Craswhorthiness↗
NASA NTRSDate not supplied

Component Characterization of an eVTOL Reference Model for Crashworthiness Studies

Researchers at the National Aeronautics and Space Administration (NASA) Langley Research Center (LaRC) have conducted a series of structural component and seat level tests to improve finite element model (FEM) characterization of a representative vertical take-off and landing (eVTOL) test article developed by NASA. A full-scale dynamic test was conducted on the representative eVTOL test article in November of 2022. The test article represented a high wing, six passenger eVTOL design concept and is referred to as the lift plus cruise (LPC) test article. The full-scale test identified limitations in the analytical models used to predict aircraft structural response, in particular the composite material models did not effectively capture brittle failure of the structure which were measured during dynamic loading. To better understand the mechanism behind the composite material failure mechanisms observed and to improve the FEM, intact sample specimens of the composite airframe structure were recovered from the test article post-test and used in material characterization testing. In addition, the seat configurations used in the LPC test article were further studied using isolated seat and anthropomorphic test device (ATD) drop tower testing. Dynamic compression tests and three-point bend tests, conducted at varied impact speeds, were performed on the recovered frame section specimens. Additional testing was conducted to characterize the material properties of the forming foam, which remained in the frames after fabrication. These tests were used to improve characterization of the damage and failure parameters of the composite material model used in the FE model of the LPC test article. Seat level tests were conducted on the seats used in the LPC test article using acceleration pulses inclusive of current general aviation and rotorcraft certification load levels as well as conditions representative of those measured at the seat base during the LPC test. The structural material models and seat environment models of the LPC test article FEM were calibrated using the generated component test data. The updates made to these models were then integrated into the LPC FEM and simulated in the full-scale test condition. Results demonstrated the effectiveness of component testing to improve predictive capability of composite aerospace structural models within the crash and dynamic loading environments. Demonstration of the LPC FEM response across an accumulation of coupon, component, seat environment, and full-scale test levels provides confidence in the predictive capability of this model for future use in the study of occupant safety within eVTOL relevant crash environments.

Craswhorthiness↗
NASA NTRS2021

Damage Tolerance of Candidate Sandwich Structure for the Space Launch System (SLS) Payload Adapter Fitting (PAF)

This Technical Memorandum presents results from a damage tolerance study undertaken in support of the payload adapter fitting (PAF) for the Space Launch System (SLS) program at NASA’s Marshall Space Flight Center (MSFC). The study consisted of determining the compression-after-impact (CAI) strength of candidate carbon/epoxy face sheet sandwich structure that has been identified for potential use to manufacture the PAF hardware. Two types of core material that have been considered for use on the PAF structure were used in this study. One was an aluminum honeycomb and the other was a Rohacell foam. Levels of barely visible impact damage (BVID) were determined for the types of sandwich structure tested in this study and this level of damage was used for CAI strength testing. It was found that the honeycomb core sandwich structure failed by face sheet failure and the foam core sandwich structure failed by core shear failure. CAI strength values were normalized by weight of the sandwich structure since lower mass is desirable for this structure.

sandwich structure↗
NASA NTRS1992

An improved approach for flight readiness certification: Probabilistic models for flaw propagation and turbine blade failure. Volume 1: Methodology and applications

An improved methodology for quantitatively evaluating failure risk of spaceflight systems to assess flight readiness and identify risk control measures is presented. This methodology, called Probabilistic Failure Assessment (PFA), combines operating experience from tests and flights with analytical modeling of failure phenomena to estimate failure risk. The PFA methodology is of particular value when information on which to base an assessment of failure risk, including test experience and knowledge of parameters used in analytical modeling, is expensive or difficult to acquire. The PFA methodology is a prescribed statistical structure in which analytical models that characterize failure phenomena are used conjointly with uncertainties about analysis parameters and/or modeling accuracy to estimate failure probability distributions for specific failure modes. These distributions can then be modified, by means of statistical procedures of the PFA methodology, to reflect any test or flight experience. State-of-the-art analytical models currently employed for designs failure prediction, or performance analysis are used in this methodology. The rationale for the statistical approach taken in the PFA methodology is discussed, the PFA methodology is described, and examples of its application to structural failure modes are presented. The engineering models and computer software used in fatigue crack growth and fatigue crack initiation applications are thoroughly documented.

Moore, N. R.↗
NASA NTRS1992

An improved approach for flight readiness certification: Probabilistic models for flaw propagation and turbine blade failure. Volume 2: Software documentation

An improved methodology for quantitatively evaluating failure risk of spaceflights systems to assess flight readiness and identify risk control measures is presented. This methodology, called Probabilistic Failure Assessment (PFA), combines operating experience from tests and flights with analytical modeling of failure phenomena to estimate failure risk. The PFA methodology is of particular value when information on which to base an assessment of failure risk, including test experience and knowledge of parameters used in analytical modeling, is expensive or difficult to acquire. The PFA methodology is a prescribed statistical structure in which analytical models that characterize failure phenomena are used conjointly with uncertainties about analysis parameters and/or modeling accuracy to estimate failure probability distributions for specific failure modes. These distributions can then be modified, by means of statistical procedures of the PFA methodology, to reflect any test or flight experience. State-of-the-art analytical models currently employed for design, failure prediction, or performance analysis are used in this methodology. The rationale for the statistical approach taken in the PFA methodology is discussed, the PFA methodology is described, and examples of its application to structural failure modes are presented. The engineering models and computer software used in fatigue crack growth and fatigue crack initiation applications are thoroughly documented.

Moore, N. R.↗