Studies of structural failure due to acoustic loading
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Hess, Robert W↗
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Optical inspection of space-propulsion components using an injection seeded Nd:YAG laser system
A dual-beam, injection-seeded, Nd:YAG laser has been demonstrated for detecting structural defects. This demonstration was part of an on-going project to use dual-reference-beam holographic interferometry to inspect space propulsion components for cracks, structural failures, structural changes, and gas leaks. Potential subjects for inspection include welds, duct work, casings, turbopumps, blades, composites, and ceramics. The maximum dimension of an inspected area ranges from a few centimeters to a meter. The entire optical inspection system is now ready for a demonstration application.
Decker, Arthur J.↗
Report of the NASA Ad Hoc Committee on failure of high strength structural materials
An analysis of structural failures that have occurred in NASA programs was conducted. Reports of 231 examples of structural failure were reviewed. Attempts were made to identify those factors which contributed to the failures, and recommendations were formulated for actions which would minimize their effects on future NASA programs. Two classes of factors were identified: (1) those associated with deficiencies in existing materials and structures technology and (2) those attributable to inadequate documentation or communication of that technology.
Brown, W. F., Jr.↗
Solving Component Structural Dynamic Failures Due to Extremely High Frequency Structural Response on the Space Shuttle Program
For many years, the capabilities to determine the root-cause failure of component failures have been limited to the analytical tools and the state of the art data acquisition systems. With this limited capability, many anomalies have been resolved by adding material to the design to increase robustness without the ability to determine if the design solution was satisfactory until after a series of expensive test programs were complete. The risk of failure and multiple design, test, and redesign cycles were high. During the Space Shuttle Program, many crack investigations in high energy density turbomachines, like the SSME turbopumps and high energy flows in the main propulsion system, have led to the discovery of numerous root-cause failures and anomalies due to the coexistences of acoustic forcing functions, structural natural modes, and a high energy excitation, such as an edge tone or shedding flow, leading the technical community to understand many of the primary contributors to extremely high frequency high cycle fatique fluid-structure interaction anomalies. These contributors have been identified using advanced analysis tools and verified using component and system tests during component ground tests, systems tests, and flight. The structural dynamics and fluid dynamics communities have developed a special sensitivity to the fluid-structure interaction problems and have been able to adjust and solve these problems in a time effective manner to meet budget and schedule deadlines of operational vehicle programs, such as the Space Shuttle Program over the years.
Frady, Greg↗
Stress Analysis of B-52B and B-52H Air-Launching Systems Failure-Critical Structural Components
The operational life analysis of any airborne failure-critical structural component requires the stress-load equation, which relates the applied load to the maximum tangential tensile stress at the critical stress point. The failure-critical structural components identified are the B-52B Pegasus pylon adapter shackles, B-52B Pegasus pylon hooks, B-52H airplane pylon hooks, B-52H airplane front fittings, B-52H airplane rear pylon fitting, and the B-52H airplane pylon lower sway brace. Finite-element stress analysis was performed on the said structural components, and the critical stress point was located and the stress-load equation was established for each failure-critical structural component. The ultimate load, yield load, and proof load needed for operational life analysis were established for each failure-critical structural component.
Ko, William L.↗
A Procedure for Modeling Structural Component/Attachment Failure Using Transient Finite Element Analysis
Structures often comprise smaller substructures that are connected to each other or attached to the ground by a set of finite connections. Under static loading one or more of these connections may exceed allowable limits and be deemed to fail. Of particular interest is the structural response when a connection is severed (failed) while the structure is under static load. A transient failure analysis procedure was developed by which it is possible to examine the dynamic effects that result from introducing a discrete failure while a structure is under static load. The failure is introduced by replacing a connection load history by a time-dependent load set that removes the connection load at the time of failure. The subsequent transient response is examined to determine the importance of the dynamic effects by comparing the structural response with the appropriate allowables. Additionally, this procedure utilizes a standard finite element transient analysis that is readily available in most commercial software, permitting the study of dynamic failures without the need to purchase software specifically for this purpose. The procedure is developed and explained, demonstrated on a simple cantilever box example, and finally demonstrated on a real-world example, the American Airlines Flight 587 (AA587) vertical tail plane (VTP).
Lovejoy, Andrew E.↗
An application of artificial intelligence theory to reconfigurable flight control
Artificial intelligence techniques were used along with statistical hpyothesis testing and modern control theory, to help the pilot cope with the issues of information, knowledge, and capability in the event of a failure. An intelligent flight control system is being developed which utilizes knowledge of cause and effect relationships between all aircraft components. It will screen the information available to the pilots, supplement his knowledge, and most importantly, utilize the remaining flight capability of the aircraft following a failure. The list of failure types the control system will accommodate includes sensor failures, actuator failures, and structural failures.
Handelman, David A.↗
Simulation Modeling for Off-Nominal Conditions - Where Are We Today?
The modeling of aircraft flight characteris4cs in off-nominal or otherwise adverse conditions has become increasingly important for simulation in the loss-of-control arena. Adverse conditions include environmentally-induced upsets such as wind shear or wake vortex encounters; off-nominal flight conditions, such as stall or departure; on-board systems failures; and structural failures or aircraft damage. Spirited discussions in the research community are taking place as to the fidelity and data requirements for adequate representation of vehicle dynamics under such conditions for a host of research areas, including recovery training, flight controls development, trajectory guidance/planning, and envelope limiting. The increasing need for multiple sources of data (empirical, computational, experimental) for modeling across a larger flight envelope leads to challenges in developing methods of appropriately applying or combining such data, particularly in a dynamic flight environment with a physically and/or aerodynamically asymmetric vehicle. Traditional simplifications and symmetry assumptions in current modeling methodology may no longer be valid. Furthermore, once modeled, challenges abound in the validation of flight dynamics characteristics in adverse flight regimes
Shah, Gautam H.↗
Structural Health Monitoring with Fiber Bragg Grating and Piezo Arrays
Structural health monitoring (SHM) is one of the most important tools available for the maintenance, safety, and integrity of aerospace structural systems. Lightweight, electromagnetic-interference- immune, fiber-optic sensor-based SHM will play an increasing role in more secure air transportation systems. Manufacturers and maintenance personnel have pressing needs for significantly improving safety and reliability while providing for lower inspection and maintenance costs. Undetected or untreated damage may grow and lead to catastrophic structural failure. Damage can originate from the strain/stress history of the material, imperfections of domain boundaries in metals, delamination in multi-layer materials, or the impact of machine tools in the manufacturing process. Damage can likewise develop during service life from wear and tear, or under extraordinary circumstances such as with unusual forces, temperature cycling, or impact of flying objects. Monitoring and early detection are key to preventing a catastrophic failure of structures, especially when these are expected to perform near their limit conditions.
Black, Richard J.↗
Progressive failure of structures
A procedure is presented for determining the nonlinear behavior of structures subjected to extreme loading and the possibility of development of potential for progressive failure. The methodology takes into account the effect of both material and geometric nonlinearities. At a given stage of analysis, the individual components of the structure are checked against predetermined failure criteria. Subsequently, the failing components are removed and the modified structure is analyzed for overall failure. Examples, obtained from a computer program based on the proposed procedure, showing the applicability of the method are presented.
Khozeimeh, K.↗
NASA Prototype All Composite Tank Cryogenic Pressure Tests to Failure with Structural Health Monitoring
This Paper will describe the results of pressurization to failure of 100 gallon composite tanks using liquid nitrogen. Advanced methods of health monitoring will be compared as will the experimental data to a finite element model. The testing is wholly under NASA including unique PZT (Lead Zirconate Titanate) based active vibration technology. Other technologies include fiber optics strain based systems including NASA AFRC technology, Acoustic Emission, Acellent smart sensor, this work is expected to lead to a practical in-Sutu system for composite tanks.
tanks↗
Three-Dimensional Geometric Nonlinear Contact Stress Analysis of Riveted Joints
The problems associated with fatigue were brought into the forefront of research by the explosive decompression and structural failure of the Aloha Airlines Flight 243 in 1988. The structural failure of this airplane has been attributed to debonding and multiple cracking along the longitudinal lap splice riveted joint in the fuselage. This crash created what may be termed as a minor "Structural Integrity Revolution" in the commercial transport industry. Major steps have been taken by the manufacturers, operators and authorities to improve the structural airworthiness of the aging fleet of airplanes. Notwithstanding, this considerable effort there are still outstanding issues and concerns related to the formulation of Widespread Fatigue Damage which is believed to have been a contributing factor in the probable cause of the Aloha accident. The lesson from this accident was that Multiple-Site Damage (MSD) in "aging" aircraft can lead to extensive aircraft damage. A strong candidate in which MSD is highly probable to occur is the riveted lap joint.
Shivakumar, Kunigal N.↗
Reliability assessment of thrust chamber cooling concepts using probabilistic analysis techniques
The reliability of OFHC (Oxygen Free High Conductivity) copper and NARloy-Z thrust chambers is assessed by applying probabilistic structural analysis techniques to incorporate design parameter variability and uncertainty. Thrust chambers specifically evaluated are the cylindrical test fixtures employed in a plug-nozzle configuration at the NASA Lewis Research Center. Direct sampling Monte Carlo simulations based on a simplified life prediction methodology established probability densities of firing cycles to structural failure. Simulated cyclic lives demonstrated modest agreement to experiment. Similarly, regions of high structural failure probability were determined using a limit state approach employing calculated cumulative distribution functions for effective stress response and an assumed material strength distribution. A probability of failure of 0.012 was calculated at the center of the coolant channel hot-gas-side wall for an OFHC milled channel. Structural response was found to be sensitive to the uncertainties in the thrust chamber thermal environment and the material's thermal expansion coefficient.
Rapp, Douglas C.↗
Reliability assessment of thrust chamber cooling concepts using probabilistic analysis techniques
The reliability of OFHC (Oxygen Free High Conductivity) copper and NARloy-Z thrust chambers is assessed by applying probabilistic structural analysis techniques to incorporate design parameter variability and uncertainty. Thrust chambers specifically evaluated are the cylindrical test fixtures employed in a plug-nozzle configuration at the NASA Lewis Research Center. Direct sampling Monte Carlo simulations based on a simplified life prediction methodology established probability densities of firing cycles to structural failure. Simulated cyclic lives demonstrated modest agreement to experiment. Similarly, regions of high structural failure probability were determined using a limit state approach employing calculated cumulative distribution functions for effective stress response and an assumed material strength distribution. A probability of failure of 0.012 was calculated at the center of the coolant channel hot-gas-side wall for an OFHC milled channel. Structural response was found to be sensitive to the uncertainties in the thrust chamber thermal environment and the material's thermal expansion coefficient.
Rapp, Douglas C.↗
Boundary-Layer Flow Simulations Over Ablating Woven Thermal Protection System Material
Spallation is the mechanical removal of small chunks of material gets removed typically due to high shear conditions of the flow field. This reduces the ability of the thermal protection system (TPS) material to protect the spacecraft as well as cause turbulence in the flow causing higher heating rates. In this work, we focus on the material removal through ablation and high shear flow within the boundary layer region of woven TPS material. Woven TPS (WTPS) material is the latest class of material developed by NASA, to be used within the next generation of space flights. They are complex interlocked weaves designed to create a rigid structure that is highly resistant to heat and can be easily designed and tailored for a wide variety of entry environments. Due to material removal resulting from chemical degradation, the structural integrity of TPS material is affected. Spallation occurs when this structurally compromised material is exposed to the high shear flow conditions within the boundary layer. In order to understand the spallation mechanism within WTPS material, we first perform the material removal simulations which occur primarily through oxidation to obtain the microstructure at various stages of degradation. These simulations are performed using the Porous Microstructure Analysis (PuMA) software developed at NASA Ames. The micro-structure geometry used within these simulations were generated artificially to be similar to the 3D weave architecture of MSR-EEV (Mars Sample Return - Earth Entry Vehicle). The various eroded TPS micro-structures are then subjected to the boundary layer flow conditions to obtain critical surface quantities which contribute to the structural failure mechanism such as heat flux, pressure, and shear stress. The direct simulation Monte Carlo (DSMC) methodology is used to perform these simulations in order to accurately capture the strong gradients within the high-temperature boundary layer flow over the intricate geometry of WTPS material. The boundary layer profile is directly taken from the Computational Fluid Dynamics (CFD) simulation and provided as boundary conditions to the DSMC inlet and outlet. Further, the variation of these properties as the microstructure undergoes changes due to oxidation is also investigated. Finally, these quantities are used as input in PuMA to understand the material expansion/compression and strain within the woven TPS geometry and help in developing a comprehensive spallation and structure failure model.
microstructure↗
Boundary-Layer Flow Simulations Over Ablating Woven Thermal Protection System Material
Spallation is the mechanical removal of small chunks of material gets removed typically due to high shear conditions of the flow field. This reduces the ability of the thermal protection system (TPS) material to protect the spacecraft as well as cause turbulence in the flow causing higher heating rates. In this work, we focus on the material removal through ablation and high shear flow within the boundary layer region of woven TPS material. Woven TPS (WTPS) material is the latest class of material developed by NASA, to be used within the next generation of space flights. They are complex interlocked weaves designed to create a rigid structure that is highly resistant to heat and can be easily designed and tailored for a wide variety of entry environments. Due to material removal resulting from chemical degradation, the structural integrity of TPS material is affected. Spallation occurs when this structurally compromised material is exposed to the high shear flow conditions within the boundary layer. In order to understand the spallation mechanism within WTPS material, we first perform the material removal simulations which occur primarily through oxidation to obtain the microstructure at various stages of degradation. These simulations are performed using the Porous Microstructure Analysis (PuMA) software developed at NASA Ames. The micro-structure geometry used within these simulations were generated artificially to be similar to the 3D weave architecture of MSR-EEV (Mars Sample Return - Earth Entry Vehicle). The various eroded TPS micro-structures are then subjected to the boundary layer flow conditions to obtain critical surface quantities which contribute to the structural failure mechanism such as heat flux, pressure, and shear stress. The direct simulation Monte Carlo (DSMC) methodology is used to perform these simulations in order to accurately capture the strong gradients within the high-temperature boundary layer flow over the intricate geometry of WTPS material. The boundary layer profile is directly taken from the Computational Fluid Dynamics (CFD) simulation and provided as boundary conditions to the DSMC inlet and outlet. Further, the variation of these properties as the microstructure undergoes changes due to oxidation is also investigated. Finally, these quantities are used as input in PuMA to understand the material expansion/compression and strain within the woven TPS geometry and help in developing a comprehensive spallation and structure failure model.
microstructure↗
Dynamic Structural Fault Detection and Identification
Aircraft structures are designed to guarantee safety of flight in some required operational envelope. When the aircraft becomes structurally impaired, safety of flight may not be guaranteed within that previously safe operational envelope. In this case the safe operational envelope must be redefined in-flight and a means to prevent excursion from this new envelope must be implemented. A specific structural failure mode that may result in a reduced safe operating envelope, the exceedance of which could lead to catastrophic structural failure of the aircraft, will be addressed. The goal of the DFEAP program is the detection of this failure mode coupled with flight controls adaptation to limit critical loads in the damaged aircraft structure. The DFEAP program is working with an F/A-18 aircraft model. The composite wing skins are bonded to metallic spars in the wing substructure. Over time, it is possible that this bonding can deteriorate due to fatigue. In this case, the ability of the wing spar to transfer loading between the wing skins is reduced. This failure mode can translate to a reduced allowable compressive strain on the wing skin and could lead to catastrophic wing buckling if load limiting of the wing structure is not applied. The DFEAP program will make use of a simplified wing strain model for the healthy aircraft. The outputs of this model will be compared in real-time to onboard strain measurements at several locations on the aircraft wing. A damage condition is declared at a given location when the strain measurements differ sufficiently from the strain model. Parameter identification of the damaged structure wing strain parameters will be employed to provide load limiting control adaptation for the aircraft. This paper will discuss the simplified strain models used in the implementation and their interaction with the strain sensor measurements. Also discussed will be the damage detection and identification schemes employed and the means by which the damaged aircraft parameters will be used to provide load limiting that keeps the aircraft within the safe operational envelope.
Smith, Timothy↗
A load factor formula
The ultimate test of a load factor formula is experience. The chief advantages of a semi rational formula over arbitrary factors are that it fairs in between points of experience and it differentiates according to variables within a type. Structural failure of an airplane apparently safe according to the formula would call for a specific change in the formula. The best class of airplanes with which to check a load factor formula seems to be those which have experienced structural failure. Table I comprises a list of the airplanes which have experienced failure in flight traceable to the wing structure. The load factor by formula is observed to be greater than the designed strength in each case, without a single exception. Table II comprises the load factor by formula with the designed strength of a number of well-known service types. The formula indicates that by far the majority of these have ample structural strength. One case considered here in deriving a suitable formula is that of a heavy load carrier of large size and practically no reserve power.
Miller, Roy G↗