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NASA NTRS1990

Scaling effects in the static and dynamic response of graphite-epoxy beam-columns

Scale model technology represents one method of investigating the behavior of advanced, weight-efficient composite structures under a variety of loading conditions. It is necessary, however, to understand the limitations involved in testing scale model structures before the technique can be fully utilized. These limitations, or scaling effects, are characterized. in the large deflection response and failure of composite beams. Scale model beams were loaded with an eccentric axial compressive load designed to produce large bending deflections and global failure. A dimensional analysis was performed on the composite beam-column loading configuration to determine a model law governing the system response. An experimental program was developed to validate the model law under both static and dynamic loading conditions. Laminate stacking sequences including unidirectional, angle ply, cross ply, and quasi-isotropic were tested to examine a diversity of composite response and failure modes. The model beams were loaded under scaled test conditions until catastrophic failure. A large deflection beam solution was developed to compare with the static experimental results and to analyze beam failure. Also, the finite element code DYCAST (DYnamic Crash Analysis of STructure) was used to model both the static and impulsive beam response. Static test results indicate that the unidirectional and cross ply beam responses scale as predicted by the model law, even under severe deformations. In general, failure modes were consistent between scale models within a laminate family; however, a significant scale effect was observed in strength. The scale effect in strength which was evident in the static tests was also observed in the dynamic tests. Scaling of load and strain time histories between the scale model beams and the prototypes was excellent for the unidirectional beams, but inconsistent results were obtained for the angle ply, cross ply, and quasi-isotropic beams. Results show that valuable information can be obtained from testing on scale model composite structures, especially in the linear elastic response region. However, due to scaling effects in the strength behavior of composite laminates, caution must be used in extrapolating data taken from a scale model test when that test involves failure of the structure.

Jackson, Karen E.↗

NASA NTRS2006

A Comparison of Functional Models for Use in the Function-Failure Design Method

When failure analysis and prevention, guided by historical design knowledge, are coupled with product design at its conception, shorter design cycles are possible. By decreasing the design time of a product in this manner, design costs are reduced and the product will better suit the customer s needs. Prior work indicates that similar failure modes occur with products (or components) with similar functionality. To capitalize on this finding, a knowledge base of historical failure information linked to functionality is assembled for use by designers. One possible use for this knowledge base is within the Elemental Function-Failure Design Method (EFDM). This design methodology and failure analysis tool begins at conceptual design and keeps the designer cognizant of failures that are likely to occur based on the product s functionality. The EFDM offers potential improvement over current failure analysis methods, such as FMEA, FMECA, and Fault Tree Analysis, because it can be implemented hand in hand with other conceptual design steps and carried throughout a product s design cycle. These other failure analysis methods can only truly be effective after a physical design has been completed. The EFDM however is only as good as the knowledge base that it draws from, and therefore it is of utmost importance to develop a knowledge base that will be suitable for use across a wide spectrum of products. One fundamental question that arises in using the EFDM is: At what level of detail should functional descriptions of components be encoded? This paper explores two approaches to populating a knowledge base with actual failure occurrence information from Bell 206 helicopters. Functional models expressed at various levels of detail are investigated to determine the necessary detail for an applicable knowledge base that can be used by designers in both new designs as well as redesigns. High level and more detailed functional descriptions are derived for each failed component based on NTSB accident reports. To best record this data, standardized functional and failure mode vocabularies are used. Two separate function-failure knowledge bases are then created aid compared. Results indicate that encoding failure data using more detailed functional models allows for a more robust knowledge base. Interestingly however, when applying the EFDM, high level descriptions continue to produce useful results when using the knowledge base generated from the detailed functional models.

Stock, Michael E.↗

DOE OSTI2013

Enhanced Component Performance Study: Turbine-Driven Pumps 1998–2012

This report presents an enhanced performance evaluation of turbine-driven pumps (TDPs) at U.S. commercial nuclear power plants. The data used in this study are based on the operating experience failure reports from fiscal year 1998 through 2012 for the component reliability as reported in the Equipment Performance and Information Exchange (EPIX). The TDP failure modes considered are failure to start, failure to run less than or equal to 1 hour, failure to run more than 1 hour, and (for normally running systems) failure to run. The component reliability estimates and the reliability data are trended for the most recent 10-year period while yearly estimates for reliability are provided for the entire active period. No statistically significant increasing trends were identified in the TDP results. Statistically significant decreasing trends were identified for TDP run hours per reactor critical year and start demands.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2013

Enhanced Component Performance Study: Motor-Operated Valves 1998–2012

This report presents an enhanced performance evaluation of motor-operated valves (MOVs) at U.S. commercial nuclear power plants. The data used in this study are based on the operating experience failure reports from fiscal year 1998 through 2012 for the component reliability as reported in the Equipment Performance and Information Exchange (EPIX). The MOV failure modes considered are failure to open/close, failure to operate or control, and spurious operation. The component reliability estimates and the reliability data are trended for the most recent 10-year period while yearly estimates for reliability are provided for the entire active period. No statistically significant increasing trends were identified in the MOV results. Statistically significant decreasing trends were identified for failure to open/close and operation demands.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2013

Analysis of Loss-of-Offsite-Power Events 1998–2012

Loss of offsite power (LOOP) can have a major negative impact on a power plant’s ability to achieve and maintain safe shutdown conditions. Risk analyses performed loss of all alternating current power contributes over 70% of the overall risk at some U.S. nuclear plants. LOOP event and subsequent restoration of offsite power are important inputs to plant probabilistic risk assessments. This report presents a statistical and engineering analysis of LOOP frequencies and durations at U.S. commercial nuclear power plants. The data used in this study are based on the operating experience from fiscal year 1998 through 2012. Frequencies and durations were determined for four event categories: plant-centered, switchyard-centered, grid-related, and weather-related. The EDG failure modes considered are failure to start, failure to load and run, and failure to run more than 1 hour. The component reliability estimates and the reliability data are trended for the most recent 10-year period while yearly estimates for reliability are provided for the entire active period. A statistically significant increase in industry performance was identified for plant-centered and switchyard-centered LOOP frequencies. There is no statistically significant trend in LOOP durations.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2015

Enhanced Component Performance Study: Turbine-Driven Pumps 1998–2014

This report presents an enhanced performance evaluation of turbine-driven pumps (TDPs) at U.S. commercial nuclear power plants. The data used in this study are based on the operating experience failure reports from fiscal year 1998 through 2014 for the component reliability as reported in the Institute of Nuclear Power Operations (INPO) Consolidated Events Database (ICES). The TDP failure modes considered are failure to start (FTS), failure to run less than or equal to one hour (FTR=1H), failure to run more than one hour (FTR>1H), and normally running systems FTS and failure to run (FTR). The component reliability estimates and the reliability data are trended for the most recent 10-year period while yearly estimates for reliability are provided for the entire active period. Statistically significant increasing trends were identified for TDP unavailability, for frequency of start demands for standby TDPs, and for run hours in the first hour after start. Statistically significant decreasing trends were identified for start demands for normally running TDPs, and for run hours per reactor critical year for normally running TDPs.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2015

Enhanced Component Performance Study: Turbine-Driven Pumps 1998–2013

This report presents an enhanced performance evaluation of turbine-driven pumps (TDPs) at U.S. commercial nuclear power plants. The data used in this study are based on the operating experience failure reports from fiscal year 1998 through 2013 for the component reliability as reported in the Institute of Nuclear Power Operations Consolidated Events Database. The TDP failure modes considered are failure to start, failure to run less than or equal to 1 hour, failure to run more than 1 hour, and (for normally running systems) failure to run. The component reliability estimates and the reliability data are trended for the most recent 10-year period while yearly estimates for reliability are provided for the entire active period. Statistically significant increasing trends were identified for TDP unavailability, for frequency of start demands for standby TDPs, and for run hours in the first hour after start. Statistically significant decreasing trends were identified for start demands for normally running TDPs, and for run hours per reactor critical year for normally running TDPs.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2015

Analysis of Loss-of-Offsite-Power Events 1998–2013

Loss of offsite power (LOOP) can have a major negative impact on a power plant’s ability to achieve and maintain safe shutdown conditions. Risk analyses suggest that loss of all alternating current power contributes over 70% of the overall risk at some U.S. nuclear plants. LOOP event and subsequent restoration of offsite power are important inputs to plant probabilistic risk assessments. This report presents a statistical and engineering analysis of LOOP frequencies and durations at U.S. commercial nuclear power plants. The data used in this study are based on the operating experience during calendar years 1997 through 2013. Frequencies and durations were determined for four event categories: plant-centered, switchyard-centered, grid-related, and weather-related. The emergency diesel generator failure modes considered are failure to start, failure to load and run, and failure to run more than 1 hour. The component reliability estimates and the reliability data are trended for the most recent 10-year period while yearly estimates for reliability are provided for the entire active period. No statistically significant trends in LOOP frequencies over the 1997–2013 period are identified. There is a possibility that a significant trend in grid-related LOOP frequency exists that is not easily detected by a simple analysis. Statistically significant increases in recovery times after grid- and switchyard-related LOOPs are identified.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2015

Enhanced Component Performance Study: Motor-Operated Valves 1998–2013

This report presents an enhanced performance evaluation of motor-operated valves (MOVs) at U.S. commercial nuclear power plants. The data used in this study are based on the operating experience failure reports from fiscal year 1998 through 2013 for the component reliability as reported in the Institute of Nuclear Power Operations (INPO) Consolidated Events Database (ICES). The MOV failure modes considered are failure to open/close, failure to operate or control, and spurious operation. The component reliability estimates and the reliability data are trended for the most recent 10-year period while yearly estimates for reliability are provided for the entire active period. Statistically significant increasing trends were identified in the MOV spurious operation failure rate estimate (a highly statistically significant trend), and in the MOV spurious operation failure events per reactor year (a highly statistically significant trend). Statistically significant decreasing trends were identified for failure to open/close demand rates.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2020

Enhanced Component Performance Study: Turbine-Driven Pumps 1998–2018

This report presents an enhanced performance evaluation of turbine-driven pumps (TDPs) at U.S. commercial nuclear power plants. The data used in this study are based on the operating experience failure reports from calendar year 1998 through 2018 as reported in the Institute of Nuclear Power Operations (INPO) Consolidated Events Database (ICES). The TDP failure modes considered are failure to start (FTS), failure to run less than or equal to one hour (FTR≤1H), failure to run more than one hour (FTR>1H), and normally running systems FTS and failure to run (FTR). The component reliability estimates and the reliability data are trended for the most recent 10-year period while yearly estimates for reliability are provided for the entire study period. A highly statistically significant decreasing trend was identified in the standby TDP unavailability estimates.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2023

Develop and Connect TRISO Failure Analysis and Uncertainty Quantification to Fission Product Release Calculation Capability

The U.S. Department of Energy’s Nuclear Energy Advanced Modeling and Simulation (NEAMS) program aims to develop predictive capabilities by applying computational methods to the analysis and design of advanced reactor and fuel cycle systems. This program has been providing engineering-scale support for the development of BISON, a high-fidelity and high-resolution fuel performance tool. Stress-based failure probability has been developed and analyzed to assess the integrity of tri-structural isotropic (TRISO) fuel particles during fuel life cycles. While simple, stress-based approaches to failure probability leveraging the Weibull statistical distribution entails a number of drawbacks when stress concentration occurs near crack tips, including finite element mesh size dependency. In this report, we use an interaction integral approach to the computation of stress intensity factors in functionally graded materials (FGM) for axisymmetric models. The inner pyrolytic carbon (IPyC) cracking induced silicon carbide (SiC) failure is one of the dominated failure modes in TRISO failure analysis. In this study, we consider a crack in the IPyC layer perpendicular to the SiC layer. The interface between these two TRISO layers is considered to be porous, which we simulate considering a transition of mechanical properties over the porous length. These aspects are considered in the computation of stress intensity factor (SIF) from a fracture mechanics approach and compared with the known stress-based failure probability approach.

42 ENGINEERING↗

NASA NTRS1976

Flexural fatigue of hollow rolling elements

Hollow cylindrical bars were tested in the rolling-contact fatigue tester to determine the effects of material and outside diameter to inside diameter (OD/ID) ratios of 2.0, 1.6, 1.4, and 1.2 on fatigue failure mode and subsequent failure propagation. The range of applied loads with these OD/ID ratios resulted in maximum tangential tensile stresses ranging from 165 to 655 megapascals (24,000 to 95,000 psi) at the bore surface. Flexural failures of the hollow test bars occurred when this bore stress was 490 megapascals (71,000 psi) or greater with AISI 52100 hollow bars and 338 megapascals (49,000 psi) or greater with AISI M-50 hollow bars. Good correlation was obtained in relating the failures of these hollow bars with flexural failures of drilled balls from previously published full scale bearing tests.

Bamberger, E. N.↗

NASA NTRS1978

Effect of wall thickness and material on flexural fatigue of hollow rolling elements

Hollow cylindrical bars were tested in a rolling-contact fatigue tester to determine the effects of material and outside diameter to inside diameter (OD/ID) ratios on fatigue failure mode and subsequent failure propagation. The range of applied loads with OD/ID ratios of 2.0, 1.6, 1.4, and 1.2 resulted in maximum tangential tensile stresses ranging from 165 to 655 MPa at the bore surface. Flexural failures of the hollow test bars occurred when this bore stress was 490 MPa or greater with AISI 52100 hollow bars and 338 MPa or greater with AISI M-50 hollow bars. Good correlation was obtained in relating the failures of these hollow bars with flexural failures of drilled balls from full-scale bearing test published previously.

Bamberger, E. N.↗

NASA NTRS1989

Scaling effects in the static large deflection response of graphite-epoxy composite beams

Scaling effects in the large deflection response of graphite-epoxy composite beams was investigated. Eight different scale model beams ranging from 1/6 to full-scale were subjected to an eccentric axial compressive load to promote large bending deformations and failures. Beams having laminate stacking sequences including unidirectional, angle ply, cross ply, and quasi-isotropic were tested to examine a wide variety of composite response and failure modes. The model beams were loaded under scaled test conditions until catastrophic failure. Data acquired included load, end displacement, and strain measurements, and qualitative failure measurements. The experimental data is compared to a large rotation beam analysis and a finite element model analysis. Results from the tests indicate that the beam response becomes nonlinear. Failure modes are consistent between scale models within a laminate family, however, a significant scale effect is observed in strength of the scaled beams.

Jackson, Karen E.↗

NASA NTRS1989

Characterization of failure processes in tungsten copper composites under fatigue loading conditions

A fractographic and metallographic investigation was performed on specimens of a tungsten fiber reinforced copper matrix composite (9 vol percent), which had experienced fatigue failures at elevated temperatures. Major failure modes and possible failure mechanisms, with an emphasis placed on characterizing fatigue damage accumulation, were determined. Metallography of specimens fatigued under isothermal cyclic loading suggested that fatigue damage initiates in the matrix. Cracks nucleated within the copper matrix at grain boundaries, and they propagated through cavity coalescence. The growing cracks subsequently interacted with the reinforcing tungsten fibers, producing a localized ductile fiber failure. Examinations of interrupted tests before final failure confirmed the suggested fatigue damage processes.

Kim, Yong-Suk↗

NASA NTRS1989

MEVTV Workshop on Tectonic Features on Mars

The state of knowledge of tectonic features on Mars was determined and kinematic and mechanical models were assessed for their origin. Three sessions were held: wrinkle ridges and compressional structure; strike-slip faults; and extensional structures. Each session began with an overview of the features under discussion. In the case of wrinkle ridges and extensional structures, the overview was followed by keynote addresses by specialists working on similar structures on the Earth. The first session of the workshop focused on the controversy over the relative importance of folding, faulting, and intrusive volcanism in the origin of wrinkle ridges. The session ended with discussions of the origin of compressional flank structures associated with Martian volcanoes and the relationship between the volcanic complexes and the inferred regional stress field. The second day of the workshop began with the presentation and discussion of evidence for strike-slip faults on Mars at various scales. In the last session, the discussion of extensional structures ranged from the origin of grabens, tension cracks, and pit-crater chains to the origin of Valles Marineris canyons. Shear and tensile modes of brittle failure in the formation of extensional features and the role of these failure modes in the formation of pit-crater chains and the canyons of Valles Marineris were debated. The relationship of extensional features to other surface processes, such as carbonate dissolution (karst) were also discussed.

Watters, Thomas R.↗

NASA NTRS1992

Experimental validation of clock synchronization algorithms

The objective of this work is to validate mathematically derived clock synchronization theories and their associated algorithms through experiment. Two theories are considered, the Interactive Convergence Clock Synchronization Algorithm and the Midpoint Algorithm. Special clock circuitry was designed and built so that several operating conditions and failure modes (including malicious failures) could be tested. Both theories are shown to predict conservative upper bounds (i.e., measured values of clock skew were always less than the theory prediction). Insight gained during experimentation led to alternative derivations of the theories. These new theories accurately predict the behavior of the clock system. It is found that a 100 percent penalty is paid to tolerate worst-case failures. It is also shown that under optimal conditions (with minimum error and no failures) the clock skew can be as much as three clock ticks. Clock skew grows to six clock ticks when failures are present. Finally, it is concluded that one cannot rely solely on test procedures or theoretical analysis to predict worst-case conditions.

Palumbo, Daniel L.↗

NASA NTRS1990

Postbuckling behavior of curved panels under combined compression and shear loads

A validated semiempirical design procedure and fatigue data were developed for curved, stiffened composite panels operating in the postbuckled regime under the action of combined compression and shear loading. A previously developed design methodology for composite panels under pure shear or pure compression loading was used as the starting point for the program. Initially, the well established interaction rules for metal panels were adopted to predict buckling under combined loading. Test data were then developed to verify these rules and suggest modifications where necessary. Postbuckling failure envelopes were developed by accounting for the failure modes possible under shear loading only, and under pure compression loading. Static failure predictions under combined loading were based on test verified interaction criteria. Fatigue tests were conducted under combined loading to determine strength degradation and the possible failure modes.

Deo, Ravi B.↗