Results for “FOD” — Page 2

NASA NTRSDate not supplied

Foreign Object Damage in Ytterbium Disilicate Based Environmental Barrier Coatings Modified for Oxidation Resistance

Environmental barrier coatings (EBCs) have been developed as an enabling technology for silicon carbide based ceramic matrix composites (CMCs) in gas turbine engines. Two of the key failure mechanisms identified in EBC systems are foreign object damage (FOD) and the oxidative growth of a SiO 2 thermally grown oxide (TGO) layer that can lead to premature coating spallation. Previously the effects of FOD on NASA’s ytterbium disilicate based EBC were studied and recently it was shown that the addition of oxide modifiers resulted in improved oxidation resistance in the EBC. This work will compare FOD of the baseline ytterbium disilicate EBC to that of the modified EBC. FOD was performed at room temperature using a 1.59 mm hardened steel ball with projectile velocities of 50-300 m/s. Additionally, the effects of oxidation via cyclic steam exposure prior to impact were investigated.

foreign object damage (FOD)↗

NASA NTRSDate not supplied

Foreign Object Damage in Yb 2 Si 2 O 7 Environmental Barrier Coatings

Environmental Barrier Coatings (EBCs) have been developed as an enabling technology for silicon carbide based ceramic matrix composites in gas turbine engines. Two of the key failure mechanisms identified in EBC systems are foreign object damage (FOD) and the oxidative growth of a SiO 2 thermally grown oxide (TGO) layer that can lead to premature coating spallation. Previously the effects of FOD on NASA’s second generation Ytterbium Disilicate EBC were studied and recently it was shown that the addition of oxide modifiers resulted in improved oxidation resistance in the EBC. This work will compare FOD of the baseline Ytterbium Disilicate EBC to the that of the modified EBC. FOD was performed at room temperature using a 1.59 mm hardened steel ball with projectile velocities of 50-300 m/s. Additionally, the effects of oxidation via cyclic steam exposure prior to impact were investigated.

environmental barrier coatings (EBCs)↗

NASA NTRS2002

Foreign Object Damage Behavior of Two Gas-turbine Grade Silicon Nitrides by Steel Ball Projectiles at Ambient Temperature

Foreign object damage (FOD) behavior of two commercial gas-turbine grade silicon nitrides, AS800 and SN282, was determined at ambient temperature through strength testing of flexure test specimens impacted by steel-ball projectiles with a diameter of 1.59 mm in a velocity range from 220 to 440 m/s. AS800 silicon nitride exhibited a greater FOD resistance than SN282, primarily due to its greater value of fracture toughness (K(sub IC)). Additionally, the FOD response of an equiaxed, fine-grained silicon nitride (NC132) was also investigated to provide further insight. The NC132 silicon nitride exhibited the lowest fracture toughness of the three materials tested, providing further evidence that K(sub IC) is a key material parameter affecting FOD resistance. The observed damage generated by projectile impact was typically in the forms of well- or ill-developed ring or cone cracks with little presence of radial cracks.

Choi, Sung R.↗

NASA NTRS2004

A Foreign Object Damage Event Detector Data Fusion System for Turbofan Engines

A Data Fusion System designed to provide a reliable assessment of the occurrence of Foreign Object Damage (FOD) in a turbofan engine is presented. The FOD-event feature level fusion scheme combines knowledge of shifts in engine gas path performance obtained using a Kalman filter, with bearing accelerometer signal features extracted via wavelet analysis, to positively identify a FOD event. A fuzzy inference system provides basic probability assignments (bpa) based on features extracted from the gas path analysis and bearing accelerometers to a fusion algorithm based on the Dempster-Shafer-Yager Theory of Evidence. Details are provided on the wavelet transforms used to extract the foreign object strike features from the noisy data and on the Kalman filter-based gas path analysis. The system is demonstrated using a turbofan engine combined-effects model (CEM), providing both gas path and rotor dynamic structural response, and is suitable for rapid-prototyping of control and diagnostic systems. The fusion of the disparate data can provide significantly more reliable detection of a FOD event than the use of either method alone. The use of fuzzy inference techniques combined with Dempster-Shafer-Yager Theory of Evidence provides a theoretical justification for drawing conclusions based on imprecise or incomplete data.

Turso, James A.↗

NASA NTRS2006

System Would Detect Foreign-Object Damage in Turbofan Engine

A proposed data-fusion system, to be implemented mostly in software, would further process the digitized and preprocessed outputs of sensors in a turbofan engine to detect foreign-object damage (FOD) [more precisely, damage caused by impingement of such foreign objects as birds, pieces of ice, and runway debris]. The proposed system could help a flight crew to decide what, if any, response is necessary to complete a flight safely, and could aid mechanics in deciding what post-flight maintenance action might be needed. The sensory information to be utilized by the proposed system would consist of (1) the output of an accelerometer in an engine-vibration-monitoring subsystem and (2) features extracted from a gas path analysis. ["Gas path analysis" (GPA) is a term of art that denotes comprehensive analysis of engine performance derived from readings of fuel-flow meters, shaft-speed sensors, temperature sensors, and the like.] The acceleration signal would first be processed by a wavelet-transform-based algorithm, using a wavelet created for the specific purpose of finding abrupt FOD-induced changes in noisy accelerometer signals. Two additional features extracted would be the amplitude of vibration (determined via a single- frequency Fourier transform calculated at the rotational speed of the engine), and the rate of change in amplitude due to an FOD-induced rotor imbalance. This system would utilize two GPA features: the fan efficiency and the rate of change of fan efficiency with time. The selected GPA and vibrational features would be assessed by two fuzzy-logic inference engines, denoted the "Gas Path Expert" and the "Vibration Expert," respectively (see Figure 1). Each of these inference engines would generate a "possibility" distribution for occurrence of an FOD event: Each inference engine would assign, to its input information, degrees of membership, which would subsequently be transformed into basic probability assignments for the gas path and vibration components. The outputs of the inference engines would be fused by use of Dempster s combination algorithm (more precisely, an algorithm, based on the Dempster-Shafer-Yager theory of evidence, for fusing uncertain or imprecise information) to provide a reduced body of information to a human or computer decision maker. Figure 2 depicts some outputs generated in response to simulated accelerometer and GPA signals

Torso, James A.↗

NASA NTRSDate not supplied

Operating a Crewed Spacecraft in the Age of Commercial Space Using Private/Government Partnership

Fifty years after humans completed a large-scale United States government-funded and government-engineered effort of landing humans on the moon, human spaceflight has entered a new paradigm. Private companies are now investing their own money and taking on an ever-increasing role in human spaceflight, in partnership with the U.S. government. This paper will describe the development of one of these partnerships through the lens of its mission operations team. As part of the Commercial Crew Program (CCP), NASA selected Boeing’s CST-100 Starliner as one of the next generation of crewed vehicles. Boeing opted to partner with the US Government for their Starliner operations by contracting with NASA’s Mission Control teams in the Flight Operations Directorate (FOD) at the Johnson Space Center to create its own Mission Operations (MO) flight controllers. Partnering with FOD provided benefits to both Boeing and NASA while also creating new challenges. MO brought over 60 years of crewed spaceflight experience and infrastructure to Boeing’s new program. Within certain legal constraints, MO was able to work closely and efficiently with their FOD counterparts who were performing both integration duties and, under the auspices of the CCP, insight of the contractors, in this case Boeing. Involvement of NASA as the Boeing operations agent did lead to what management deemed a ‘healthy tension’ within FOD, challenging old processes and often creating better, more robust teamwork. Successful development of the framework and boundaries of both the legal aspects and the oversight tensions has been one of the keys to developing a successful corporate/government partnership. Due to the highly automated nature of the Starliner, the MO organization was designed to be much smaller than previous NASA’s flight control teams for past programs. NASA has learned through the decades that spacecraft design and operations need to be as flexible and forgiving as possible. NASA’s Commercial Crew Program was established to sponsor corporate development of economical vehicles that could get humans to and from low Earth orbit. These companies, of course, need to meet contractual obligations in providing a safe means of transporting astronauts to the International Space Station (ISS), but also need to do so in a manner that leads to the venture resulting in a profit at the same time. Through MO’s involvement in the development of this spaceflight paradigm shift, there are ample lessons to be conveyed to future teams and programs working to develop similar missions.

Robert C Dempsey↗

NASA NTRSDate not supplied

Operating a Crewed Spacecraft in the Age of Commercial Space Using Private/Government Partnership

Fifty years after humans completed a large-scale United States government-funded and government-engineered effort of landing humans on the moon, human spaceflight has entered a new paradigm. Private companies are now investing their own money and taking on an ever-increasing role in human spaceflight, in partnership with the U.S. government. This paper will describe the development of one of these partnerships through the lens of its mission operations team. As part of the Commercial Crew Program (CCP), NASA selected Boeing’s CST-100 Starliner as one of the next generation of crewed vehicles. Boeing opted to partner with the US Government for their Starliner operations by contracting with NASA’s Mission Control teams in the Flight Operations Directorate (FOD) at the Johnson Space Center to create its own Mission Operations (MO) flight controllers. Partnering with FOD provided benefits to both Boeing and NASA while also creating new challenges. MO brought over 60 years of crewed spaceflight experience and infrastructure to Boeing’s new program. Within certain legal constraints, MO was able to work closely and efficiently with their FOD counterparts who were performing both integration duties and, under the auspices of the CCP, insight of the contractors, in this case Boeing. Involvement of NASA as the Boeing operations agent did lead to what management deemed a ‘healthy tension’ within FOD, challenging old processes and often creating better, more robust teamwork. Successful development of the framework and boundaries of both the legal aspects and the oversight tensions has been one of the keys to developing a successful corporate/government partnership. Due to the highly automated nature of the Starliner, the MO organization was designed to be much smaller than previous NASA’s flight control teams for past programs. NASA has learned through the decades that spacecraft design and operations need to be as flexible and forgiving as possible. NASA’s Commercial Crew Program was established to sponsor corporate development of economical vehicles that could get humans to and from low Earth orbit. These companies, of course, need to meet contractual obligations in providing a safe means of transporting astronauts to the International Space Station (ISS), but also need to do so in a manner that leads to the venture resulting in a profit at the same time. Through MO’s involvement in the development of this spaceflight paradigm shift, there are ample lessons to be conveyed to future teams and programs working to develop similar missions.

Robert C. Dempsey↗

NASA NTRSDate not supplied

Operating a Crewed Spacecraft in the Age of Commercial Space Using Private/Government Partnership

Fifty years after humans completed a large-scale United States government-funded and government-engineered effort of landing humans on the moon, human spaceflight has entered a new paradigm. Private companies are now investing their own money and taking on an ever-increasing role in human spaceflight, in partnership with the U.S. government. This paper will describe the development of one of these partnerships through the lens of its mission operations team. As part of the Commercial Crew Program (CCP), NASA selected Boeing’s CST-100 Starliner as one of the next generation of crewed vehicles. Boeing opted to partner with the US Government for their Starliner operations by contracting with NASA’s Mission Control teams in the Flight Operations Directorate (FOD) at the Johnson Space Center to create its own Mission Operations (MO) flight controllers. Partnering with FOD provided benefits to both Boeing and NASA while also creating new challenges. MO brought over 60 years of crewed spaceflight experience and infrastructure to Boeing’s new program. Within certain legal constraints, MO was able to work closely and efficiently with their FOD counterparts who were performing both integration duties and, under the auspices of the CCP, insight of the contractors, in this case Boeing. Involvement of NASA as the Boeing operations agent did lead to what management deemed a ‘healthy tension’ within FOD, challenging old processes and often creating better, more robust teamwork. Successful development of the framework and boundaries of both the legal aspects and the oversight tensions has been one of the keys to developing a successful corporate/government partnership. Due to the highly automated nature of the Starliner, the MO organization was designed to be much smaller than previous NASA’s flight control teams for past programs. NASA has learned through the decades that spacecraft design and operations need to be as flexible and forgiving as possible. NASA’s Commercial Crew Program was established to sponsor corporate development of economical vehicles that could get humans to and from low Earth orbit. These companies, of course, need to meet contractual obligations in providing a safe means of transporting astronauts to the International Space Station (ISS), but also need to do so in a manner that leads to the venture resulting in a profit at the same time. Through MO’s involvement in the development of this spaceflight paradigm shift, there are ample lessons to be conveyed to future teams and programs working to develop similar missions.

Robert C. Dempsey↗

NASA NTRS1985

Verification and performance tests of HYCAR program

The HYCAR program simulates the network protocols of HYPERchannel and Fiber Optic Demonstration System (FODS) and other related protocols. Verification tests of the program were conducted using the FODS protocol. The tests validated the operation of the program through deterministic and analytical means. Extensive experimentation with the simulator produced a set of performance characteristics for the FODS protocol under varied loading conditions. These characteristics are consistent with those expected, and are documented with the validation tests.

Bhatia, Veena↗

NASA NTRS2004

Foreign Object Damage in Flexure Bars of Two Gas-Turbine Grade Silicon Nitrides

Foreign object damage (FOD) behavior of two commercial gas-turbine grade silicon nitrides, AS800 and SN282, was determined at ambient temperature through strength testing of flexure test specimens impacted by steel ball projectiles with a diameter of 1.59 mm in a velocity range from 220 to 440 m/s. AS800 silicon nitride exhibited a greater FOD resistance than SN282, primarily due to its greater value of fracture toughness (K(sub lc)). The use of an additional equiaxed, fine-grained silicon nitride (NC132) showed that fracture toughness was a key material parameter affecting FOD resistance. The observed damages generated by projectile impact were typically in the forms of well- or ill-developed ring and cone cracks with little presence of radial cracks.

Choi, Sung R.↗

NASA NTRS2005

Foreign Object Damage Identification in Turbine Engines

This report summarizes the collective work of a five-person team from different organizations examining the problem of detecting foreign object damage (FOD) events in turbofan engines from gas path thermodynamic and bearing accelerometer sensors, and determining the severity of damage to each component (diagnosis). Several detection and diagnostic approaches were investigated and a software tool (FODID) was developed to assist researchers detect/diagnose FOD events. These approaches include (1) fan efficiency deviation computed from upstream and downstream temperature/ pressure measurements, (2) gas path weighted least squares estimation of component health parameter deficiencies, (3) Kalman filter estimation of component health parameters, and (4) use of structural vibration signal processing to detect both large and small FOD events. The last three of these approaches require a significant amount of computation in conjunction with a physics-based analytic model of the underlying phenomenon the NPSS thermodynamic cycle code for approaches 1 to 3 and the DyRoBeS reduced-order rotor dynamics code for approach 4. A potential application of the FODID software tool, in addition to its detection/diagnosis role, is using its sensitivity results to help identify the best types of sensors and their optimum locations within the gas path, and similarly for bearing accelerometers.

Strack, William↗

NASA NTRS2000

Development of a Methodology to Conduct Usability Evaluation for Hand Tools that May Reduce the Amount of Small Parts that are Dropped During Installation while Processing Space Flight Hardware

Foreign object debris (FOD) is an important concern while processing space flight hardware. FOD can be defined as "The debris that is left in or around flight hardware, where it could cause damage to that flight hardware," (United Space Alliance, 2000). Just one small screw left unintentionally in the wrong place could delay a launch schedule while it is retrieved, increase the cost of processing, or cause a potentially fatal accident. At this time, there is not a single solution to help reduce the number of dropped parts such as screws, bolts, nuts, and washers during installation. Most of the effort is currently focused on training employees and on capturing the parts once they are dropped. Advances in ergonomics and hand tool design suggest that a solution may be possible, in the form of specialty hand tools, which secure the small parts while they are being handled. To assist in the development of these new advances, a test methodology was developed to conduct a usability evaluation of hand tools, while performing tasks with risk of creating FOD. The methodology also includes hardware in the form of a testing board and the small parts that can be installed onto the board during a test. The usability of new hand tools was determined based on efficiency and the number of dropped parts. To validate the methodology, participants were tested while performing a task that is representative of the type of work that may be done when processing space flight hardware. Test participants installed small parts using their hands and two commercially available tools. The participants were from three groups: (1) students, (2) engineers / managers and (3) technicians. The test was conducted to evaluate the differences in performance when using the three installation methods, as well as the difference in performance of the three participant groups.

Miller, Darcy↗

NASA NTRS1974

Impact resistance of composite fan blades

Results are presented of a program to determine the impact resistance of composite fan blades subjected to foreign object damage (FOD) while operating under conditions simulating a short take-off and landing (STOL) engine at takeoff. The full-scale TF39 first-stage fan blade was chosen as the base design for the demonstration component since its configuration and operating tip speeds are similar to a typical STOL fan blade several composite configurations had already been designed and evaluated under previous programs. The first portion of the program was devoted toward fabricating and testing high impact resistant, aerodynamically acceptable composite blades which utilized only a single material system in any given blade. In order to increase the blade impact capability beyond this point, several mixed material (hybrid) designs were investigated using S-glass and Kevlar as well as boron and graphite fibers. These hybrid composite blades showed a marked improvement in resistance to bird impact over those blades made of a single composite material. The work conducted under this program has demonstrated substantial improvement in composite fan blades with respect to FOD resistance and has indicated that the hybrid design concept, which utilizes different types of fibers in various portions of a fan blade design depending on the particular requirements of the different areas and the characteristics of the different fibers involved, shows a significant improvement over those designs utilizing only one material system.

Source record↗

NASA NTRS1977

Impact resistant boron/aluminum composites for large fan blades

Blade-like specimens were subjected to static ballistic impact testing to determine their relative FOD impact resistance levels. It was determined that a plus or minus 15 deg layup exhibited good impact resistance. The design of a large solid boron/aluminum fan blade was conducted based on the FOD test results. The CF6 fan blade was used as a baseline for these design studies. The solid boron/aluminum fan blade design was used to fabricate two blades. This effort enabled the assessment of the scale up of existing blade manufacturing details for the fabrication of a large B/Al fan blade. Existing CF6 fan blade tooling was modified for use in fabricating these blades.

Oller, T. L.↗

NASA NTRS1985

Finite element engine blade structural optimization

The Structural Tailoring of Engine Blades (STAEBL) computer program was developed to perform engine fan blade numerical optimizations. These blade optimizations seek a minimum weight or cost design that satisfies realistic blade design constraints, by tuning one to twenty design variables. The STAEBL system has been generalized to include both fan and compressor blade numerical optimizations. The system analyses have been significantly improved through the inclusion of an efficient plate finite element analysis for blade stress and frequency determinations. Additionally, a finite element based approximate severe foreign object damage (FOD) analysis has been included. The new FOD analysis gives very accurate estimates of the full nonlinear bird ingestion solution. Optimizations of fan and compressor blades have been performed using the system, showing significant cost and weight reductions, while comparing very favorably with refined design validation procedures.

Brown, K. W.↗

NASA NTRS2003

Foreign Object Damage in Disks of Two Gas-turbine-grade Silicon Nitrides by Steel Ball Projectiles at Ambient Temperature

Foreign object damage (FOD) behavior of two commercial gas-turbine-grade silicon nitrides, AS800 and SN282, was determined at ambient temperature through postimpact strength testing of disks impacted by steel ball projectiles with a diameter of 1.59 mm in a velocity range from 115 to 440 m/s. AS800 silicon nitride exhibited a greater FOD resistance than SN282, primarily due to its greater value of fracture toughness (k(sub Ic)). The critical impact velocity V(sub c) for which the corresponding postimpact strength was the lowest was V(sub c) approximately equal to 440 and 300 m/s AS800 and SN282, respectively. A unique lower strength regime was typified for both silicon nitrides depending on impact velocity and was attributed to significant radial cracking. The damage generated by projectile impact was typically in the form of ring, radial, and cone cracks with their severity and combination being dependent on impact velocity. Unlike the thick (4 millimeters) flexure bar specimens used in our previous studies, the thin (2 millimeter) disk target specimen exhibited a unique back-side radial cracking on the reverse side just beneath the impact sites at and above impact velocities of 160 meters per second for SN282 and 220 meters per second AS800.

Choi, Sung R.↗

NASA NTRS2003

Foreign Object Damage of Two Gas-Turbine Grade Silicon Nitrides in a Thin Disk Configuration

Foreign object damage (FOD) behavior of two commercial gas-turbine grade silicon nitrides, AS800 and SN282, was determined at ambient temperature through post-impact strength testing for thin disks impacted by steel-ball projectiles with a diameter of 1.59 mm in a velocity range from 115 to 440 m/s. AS800 silicon nitride exhibited a greater FOD resistance than SN282, primarily due to its greater value of fracture toughness (K(sub IC)). The critical impact velocity in which the corresponding post-impact strength yielded the lowest value was V(sub c) approx. 440 and 300 m/s for AS800 and SN282, respectively. A unique lower-strength regime was typified for both silicon nitrides depending on impact velocity, attributed to significant radial cracking. The damages generated by projectile impact were typically in the forms of ring, radial, and cone cracks with their severity and combination being dependent on impact velocity. Unlike thick (3 mm) flexure bar specimens used in the previous studies, thin (2 mm) disk target specimens exhibited a unique backside radial cracking occurring on the reverse side just beneath the impact sites at and above impact velocity of 160 and 220 m/s for SN282 and AS800, respectively.

Choi, Sung R.↗

NASA NTRS2004

Foreign Object Damage Behavior of a SiC/SiC Composite at Ambient and Elevated Temperatures

Foreign object damage (FOD) behavior of a gas-turbine grade SiC/SiC ceramic matrix composite (CMC) was determined at 25 and 1316 C, employing impact velocities from 115 to 440 meters per second by 1.59-mm diameter stell-ball projectiles. Two different types of specimen support were used at each temperature: fully supported and partially supported. For a given temperature, the degree of post-impact strength degradation increased with increasing impact velocity, and was greater in a partially supported configuration than in a fully supported one. The elevated-temperature FOD resistance of the composite, particularly under partially supported loading at higher impact velocities greater than or equal to 350 meters per second, was significantly less than the ambient-temperature counterpart, attributed to a weakening effect of the composite. For fully supported loading, frontal contact stress played a major role in generating composite damage; whereas, for partially supported loading, both frontal contact and backside bending stresses were combined sources of damage generation. The SiC/SiC composite was able to survive higher energy impacts without complete structural failure but suffered more strength affecting damage from low energy impacts than AS800 and SN282 silicon nitrides.

Bhatt, Ramakrishna T.↗