Search NASA⌕ Search

SEARCH · Search NASA

Results for “structural failure”

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.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 397 records · Page 22

Probability of Failure and Risk Assessment of Propulsion Structural Components

Due to increasing need to account for the uncertainties in material properties, loading conditions, or geometries, a methodology was developed to determine structural reliability and the assess the risk associated with it. The methodology consists of a probabilistic structural analysis by a probabilistic finite element computer code Nonlinear Evaluation of Stochastic Structures Under Stress (NESSUS) and a generic probabilistic material properties model. The methodology is versatile and is equally applicable to high and cryogenic temperature structures. Results obtained demonstrate that the whole issue of structural reliability and risk can be formally evaluated using the methodology developed which is inclusive of uncertainties in material properties, structural parameters and loading conditions. The methodology is described in some detail with illustrative examples.

Shiao, Michael C.↗

An improved approach for flight readiness assessment

An improved methodology for quantitatively evaluating failure risk for a spaceflight system in order to assess flight readiness is presented. This methodology is of particular value when information relevant to failure prediction, including test experience and knowledge of parameters used in engineering analyses of failure phenomena, is limited. In this approach, engineering analysis models that characterize specific failure modes based on the physics and mechanics of the failure phenomena are used in a prescribed probabilistic structure to generate a failure probability distribution that is modified by test and flight experience in a Bayesian statistical procedure. The probabilistic structure and statistical methodology are generally applicable to any failure mode for which quantitative engineering analysis can be employed to characterize the failure phenomenon and are particularly well suited for use under the constraints on information availability that are typical of such spaceflight systems as the Space Shuttle and planetary spacecraft.

Moore, N. R.↗

Probability of failure and risk assessment of propulsion structural components

The probabilistic structural analysis method (PSAM) was developed to analyze the effects of fluctuating loads, variable material properties, and uncertain analytical models especially for high performance structures such as the Space Shuttle Main Engine turbopump blades. Risk is calculated after expensive service experience. However, probabilistic structural analysis provides a rational alternative method to quantify uncertainties in the structural performance and durability. NESSUS (Numerical Evaluation of Stochastic Structures Under Stress) was developed as a probabilistic structural analysis computer code which integrates finite element methods and reliability algorithms, capable to predicting the probability distributions of structural response variables such as stress, displacement, natural frequencies, and buckling loads. This computer code is detailed.

Shiao, Michael C.↗

Probability of failure and risk assessment of propulsion structural components

Because of the increasing need to account for the uncertainties in material properties, loading conditions, geometry, etc., a methodology was developed to determine structural reliability and to assess the associated risk. The methodology consists of a probabilistic structural analysis by a probabilistic finite element computer code, numerical evaluation of stochastic structures under stress (NESSUS), and a generic probabilistic material property model. The methodology is versatile and is equally applicable to structures operating at high and cryogenic temperature environments. Results obtained demonstrate that the issues of structural reliability and risk can be formally evaluated by using the methodology developed which is inclusive of the uncertainties in material properties, structural parameters, and loading conditions. The methodology is described in some detail with illustrative examples.

Shiao, Michael C.↗

Ultrasonic Characterization of Fatigue Cracks in Composite Materials

Microcracking in composite structures due to combined fatigue and cryogenic loading can cause leakage and failure of the structure and can be difficult to detect in-service. In aerospace systems, these leaks may lead to loss of pressure/propellant, increased risk of explosion and possible cryo-pumping. The success of nondestructive evaluation to detect intra-ply microcracking in unlined pressure vessels fabricated from composite materials is critical to the use of composite structures in future space systems. The work presented herein characterizes measurements of intraply fatigue cracking through the thickness of laminated composite material by means of correlation with ultrasonic resonance. Resonant ultrasound spectroscopy provides measurements which are sensitive to both the microscopic and macroscopic properties of the test article. Elastic moduli, acoustic attenuation, and geometry can all be probed. The approach is based on the premise of half-wavelength resonance. The method injects a broadband ultrasonic wave into the test structure using a swept frequency technique. This method provides dramatically increased energy input into the test article, as compared to conventional pulsed ultrasonics. This relative energy increase improves the ability to measure finer details in the materials characterization, such as microcracking and porosity. As the microcrack density increases, more interactions occur with the higher frequency (small wavelength) components of the signal train causing the spectrum to shift toward lower frequencies. Several methods are under investigation to correlate the degree of microcracking from resonance ultrasound measurements on composite test articles including self organizing neural networks, chemometric techniques used in optical spectroscopy and other clustering algorithms.

Workman, Gary L.↗

Full-Scale Crash Test and Finite Element Simulation of a Composite Prototype Helicopter

A full-scale crash test of a prototype composite helicopter was performed at the Impact Dynamics Research Facility at NASA Langley Research Center in 1999 to obtain data for validation of a finite element crash simulation. The helicopter was the flight test article built by Sikorsky Aircraft during the Advanced Composite Airframe Program (ACAP). The composite helicopter was designed to meet the stringent Military Standard (MIL-STD-1290A) crashworthiness criteria and was outfitted with two crew and two troop seats and four anthropomorphic dummies. The test was performed at 38-ft/s vertical and 32.5-ft/s horizontal velocity onto a rigid surface. An existing modal-vibration model of the Sikorsky ACAP helicopter was converted into a model suitable for crash simulation. A two-stage modeling approach was implemented and an external user-defined subroutine was developed to represent the complex landing gear response. The crash simulation was executed with a nonlinear, explicit transient dynamic finite element code. Predictions of structural deformation and failure, the sequence of events, and the dynamic response of the airframe structure were generated and the numerical results were correlated with the experimental data to validate the simulation. The test results, the model development, and the test-analysis correlation are described.

Jackson, Karen E.↗

Screech Tones from Rectangular Jets with Spanwise Oblique Shock-Cell Structures

Understanding screech is especially important for the design of advanced aircraft because screech can cause sonic fatigue failure of aircraft structures. Although the connection between shock-cell spacing and screech frequency is well understood, the relation between non-uniformities in the shock-cell structures and the resulting amplitude, mode, and steadiness of screech have remained unexplored. This paper addresses the above issues by intentionally producing spanwise (larger nozzle dimension) variations in the shock-cell structures and studying the resulting spanwise screech mode. The spanwise oblique shock-cell structures were produced using imperfectly expanded convergent-divergent rectangular nozzles (aspect ratio = 5) with nonuniform exit geometries. Three geometries were studied: (a) a nozzle with a spanwise uniform edge, (b) a nozzle with a spanwise oblique (single bevelled) edge, and (c) a nozzle that had two spanwise oblique (double bevelled) cuts to form an arrowhead-shaped nozzle. For all nozzles considered, the screech mode was antisymmetric in the transverse (smaller nozzle dimension) direction allowing focus on changes in the spanwise direction. Three types of spanwise modes were observed: symmetric (1), antisymmetric (2), and oblique (3). The following significant results emerged: (1) for all cases the screech mode corresponds with the spanwise shock-cell structure, (2) when multiple screech modes are present, the technique presented here makes it possible to distinguish between coexisting and mutually exclusive modes, (3) the strength of shocks 3 and 4 influences the screech source amplitude and determines whether screech is unsteady. The results presented here offer hope for a better understanding of screech and for tailoring shock-containing jets to minimize fatigue failure of aircraft components.

Raman, Ganesh↗

Compression Strength of Composite Primary Structural Components

Research conducted under NASA Grant NAG-1-537 focussed on the response and failure of advanced composite material structures for application to aircraft. Both experimental and analytical methods were utilized to study the fundamental mechanics of the response and failure of selected structural components subjected to quasi-static loads. Most of the structural components studied were thin-walled elements subject to compression, such that they exhibited buckling and postbuckling responses prior to catastrophic failure. Consequently, the analyses were geometrically nonlinear. Structural components studied were dropped-ply laminated plates, stiffener crippling, pressure pillowing of orthogonally stiffened cylindrical shells, axisymmetric response of pressure domes, and the static crush of semi-circular frames. Failure of these components motivated analytical studies on an interlaminar stress postprocessor for plate and shell finite element computer codes, and global/local modeling strategies in finite element modeling. These activities are summarized in the following section. References to literature published under the grant are listed on pages 5 to 10 by a letter followed by a number under the categories of journal publications, conference publications, presentations, and reports. These references are indicated in the text by their letter and number as a superscript.

Johnson, Eric R.↗

Establishment of design criteria for acceptable failure modes and fail safe considerations for the space shuttle structural system

The application of general design approaches for preventing failures due to repeated load cycles is briefly discussed. Program objective, mission requirements, and structural design criteria are summarized. Discrete structural elements and associated sections were selected for detailed strength, fatigue, and fracture mechanics investigations.

Westrup, R. W.↗

Modeling-Driven Damage Tolerant Design of Graphene Nanoplatelet/Carbon Fiber/Epoxy Hybrid Composite Panels for Full-Scale Aerospace Structures

The objective of this study is to design a new nano graphenecarbon fiberpolymer hybrid composite that can be used for the NASA SLS Composite Exploration Upper Stage (CEUS) forward skirt structure. The new material will improve the resistance to open-hole compression failure of the structure relative to traditional polymer fiber composites. The material is designed rapidly and with little cost using the Integrated Computational Materials Engineering (ICME) approach. Multiscale modeling and experiments are used to synergistically optimize the material design to yield improved properties and performance by controlling key processing parameters for manufacturing nano-enhanced materials. Specifically, the nanocomposite panel showed a 22 reduction in mass relative to the traditional composite panel, while both designs are equal in terms of ease of manufacture. This potential mass savings corresponds to an estimated 45 savings in materials and manufacturing costs. The multiscale ICME workflow developed for this project can be readily applied to the development of nano-enhanced composite materials and large aerospace structures. In addition, all key aspects of ICME were employed to complete this project including multiscale modeling, experimental characterization and visualization, data management, visualization, error and uncertainty quantification, and education. The results presented herein indicate a dramatic level of success, as well as the power and potential of ICME approach and multiscale modeling for composite materials.

computational mechanics↗

First-principles electronic structure in second-moment calculation of mode frequencies: Failure of quasiharmonic approximation in silicon

Using first-principles electronic structure calculations (local density approximation), we present second-moment calculations of the temperature dependence of the vibrational normal mode frequencies in Si up to 1500 K . The method is based on simple ensemble averages of displacements and forces and is easy to implement. These efficient calculations incorporate all interactions nonperturbatively, implicitly including all high order force constants, in contrast to typical perturbative approaches. Also in this work, we propose and apply to our classical calculations an estimated quantum correction that could be used for classical approaches other than the moments method. We compare our results to available experiments, including recent inelastic neutron scattering data and conclude that the second-moment gives the frequency shift to within a factor of 2 in contrast to quasiharmonic approaches that fail by an order of magnitude to predict the anharmonic shift. Noting the relative simplicity and speed of the calculations, we conclude that the second-moment approximation reasonably accounts for anharmonicity in a system that has been very closely studied experimentally and may reliably be applied in an exploratory way to more complex systems. Finally, we suggest that further improvement on the results could be obtained by incorporating the fourth moment, which can be implemented with little additional cost.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

Effect of stress concentrations in composite structures

The goal of achieving a better understanding of the failure of complex composite structure is sought. This type of structure requires a thorough understanding of the behavior under load both on a macro and micro scale if failure mechanisms are to be understood. The two problems being studied are the failure at a panel/stiffener interface and a generic problem of failure at a stress concentration.

Babcock, G. D.↗

Evaluation of control parameters for Spray-In-Air (SIA) aqueous cleaning for shuttle RSRM hardware

HD-2 grease is deliberately applied to Shuttle Redesigned Solid Rocket Motor (RSRM) D6AC steel hardware parts as a temporary protective coating for storage and shipping. This HD-2 grease is the most common form of surface contamination on RSRM hardware and must be removed prior to subsequent surface treatment. Failure to achieve an acceptable level of cleanliness (HD-2 calcium grease removal) is a common cause of defect incidence. Common failures from ineffective cleaning include poor adhesion of surface coatings, reduced bond performance of structural adhesives, and failure to pass cleanliness inspection standards. The RSRM hardware is currently cleaned and refurbished using methyl chloroform (1,1,1-trichloroethane). This chlorinated solvent is mandated for elimination due to its ozone depleting characteristics. This report describes an experimental study of an aqueous cleaning system (which uses Brulin 815 GD) as a replacement for methyl chloroform. Evaluation of process control parameters for this cleaner are discussed as well as cleaning mechanisms for a spray-in-air process.

Davis, S. J.↗

Observations, theoretical ideas and modeling of turbulent flows: Past, present and future

Turbulence was analyzed in a historical context featuring the interactions between observations, theoretical ideas, and modeling within three successive movements. These are identified as predominantly statistical, structural and deterministic. The statistical movement is criticized for its failure to deal with the structural elements observed in turbulent flows. The structural movement is criticized for its failure to embody observed structural elements within a formal theory. The deterministic movement is described as having the potential of overcoming these deficiencies by allowing structural elements to exhibit chaotic behavior that is nevertheless embodied within a theory. Four major ideas of this movement are described: bifurcation theory, strange attractors, fractals, and the renormalization group. A framework for the future study of turbulent flows is proposed, based on the premises of the deterministic movement.

Chapman, G. T.↗

Detection of lack of fusion using opaque additives

Reliable nondestructive inspection for incomplete weldment penetration and rapid oxidation of aluminum surfaces when exposed to the atmosphere are currently two major problems in welded aluminum spacecraft structure. Incomplete-penetration defects are extremely difficult to detect and can lead to catastrophic failure of the structure. The moisture absorbed by aluminum oxide on the surface can cause weldment porosity if the surface is not cleaned before welding. The approach employed in this program to solve both problems was to employ copper as a coating to prevent oxidation of the aluminum. Also, copper was used as an opaque additive in the weldment to enhance X-ray detection in the event of incomplete penetration.

Cook, J. L.↗

Research on computer aided testing of pilot response to critical in-flight events

Experiments on pilot decision making are described. The development of models of pilot decision making in critical in flight events (CIFE) are emphasized. The following tests are reported on the development of: (1) a frame system representation describing how pilots use their knowledge in a fault diagnosis task; (2) assessment of script norms, distance measures, and Markov models developed from computer aided testing (CAT) data; and (3) performance ranking of subject data. It is demonstrated that interactive computer aided testing either by touch CRT's or personal computers is a useful research and training device for measuring pilot information management in diagnosing system failures in simulated flight situations. Performance is dictated by knowledge of aircraft sybsystems, initial pilot structuring of the failure symptoms and efficient testing of plausible causal hypotheses.

Giffin, W. C.↗

Structural Reliability Analysis and Optimization: Use of Approximations

This report is intended for the demonstration of function approximation concepts and their applicability in reliability analysis and design. Particularly, approximations in the calculation of the safety index, failure probability and structural optimization (modification of design variables) are developed. With this scope in mind, extensive details on probability theory are avoided. Definitions relevant to the stated objectives have been taken from standard text books. The idea of function approximations is to minimize the repetitive use of computationally intensive calculations by replacing them with simpler closed-form equations, which could be nonlinear. Typically, the approximations provide good accuracy around the points where they are constructed, and they need to be periodically updated to extend their utility. There are approximations in calculating the failure probability of a limit state function. The first one, which is most commonly discussed, is how the limit state is approximated at the design point. Most of the time this could be a first-order Taylor series expansion, also known as the First Order Reliability Method (FORM), or a second-order Taylor series expansion (paraboloid), also known as the Second Order Reliability Method (SORM). From the computational procedure point of view, this step comes after the design point identification; however, the order of approximation for the probability of failure calculation is discussed first, and it is denoted by either FORM or SORM. The other approximation of interest is how the design point, or the most probable failure point (MPP), is identified. For iteratively finding this point, again the limit state is approximated. The accuracy and efficiency of the approximations make the search process quite practical for analysis intensive approaches such as the finite element methods; therefore, the crux of this research is to develop excellent approximations for MPP identification and also different approximations including the higher-order reliability methods (HORM) for representing the failure surface. This report is divided into several parts to emphasize different segments of the structural reliability analysis and design. Broadly, it consists of mathematical foundations, methods and applications. Chapter I discusses the fundamental definitions of the probability theory, which are mostly available in standard text books. Probability density function descriptions relevant to this work are addressed. In Chapter 2, the concept and utility of function approximation are discussed for a general application in engineering analysis. Various forms of function representations and the latest developments in nonlinear adaptive approximations are presented with comparison studies. Research work accomplished in reliability analysis is presented in Chapter 3. First, the definition of safety index and most probable point of failure are introduced. Efficient ways of computing the safety index with a fewer number of iterations is emphasized. In chapter 4, the probability of failure prediction is presented using first-order, second-order and higher-order methods. System reliability methods are discussed in chapter 5. Chapter 6 presents optimization techniques for the modification and redistribution of structural sizes for improving the structural reliability. The report also contains several appendices on probability parameters.

Grandhi, Ramana V.↗

Mechanics of pore array collapse and interaction in shock-compressed polymethyl methacrylate (PMMA)

Recent studies on dynamic pore collapse have revealed significant development of shear localization, which can lead to material failure in porous structures and hot spot generation in energetic materials. These findings have dramatically improved the understanding of failure mechanisms during pore collapse but also prompt further investigation of realistic porous materials. In particular, porous media consist of many pores and porous networks. Even in low-porosity materials, pores can form in close proximity during the manufacturing process, leading to the critical question of pore–pore interaction during collapse under dynamic loading conditions. This study investigates, via plate impact experiments coupled with high-speed internal digital image correlation and shadowgraphy techniques, the collapse of two pores in shock-compressed PMMA at stresses between 0.4 and 1 GPa. The results of these experiments provide new insights into shear localization in pore collapse, in addition to distinct interactions between pores. Shadowgraphy measurements reveal novel, direct visualization of shear band development and crack evolution from pore surfaces. Spacing between adiabatic shear bands is measured over a range of impact stresses and is predicted accurately by the Grady–Kipp model. Pore interactions are found to effect a transition in the impact stress threshold at which different failure mechanisms initiate and are also found to possibly influence preferential sites for shear cracking. Throughout the study, numerical and theoretical models are leveraged to understand shear localization behavior. The role of baroclinicity and wave interactions between the pores is used to elucidate interaction mechanisms between pores.

Lawlor, Barry P. [California Institute of Technolo↗