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NASA NTRS2004

Buckling and Failure of Compression-Loaded Composite Cylindrical Shells With Geometric and Material Imperfections

The results of an experimental and numerical study of the effects of initial imperfections on the buckling response and failure of unstiffened thin-walled compression-loaded graphite-epoxy cylindrical shells are presented. The shells considered in the study have six different orthotropic or quasi-isotropic shell-wall laminates and two different shell-radius-to-thickness ratios. The numerical results include the effects of geometric shell-wall mid-surface imperfections, shell-wall thickness variations, local shell-wall ply-gaps associated with the fabrication process, shell-end geometric imperfections, nonuniform end loads, and the effects of elastic boundary conditions. Selected cylinder parameter uncertainties were also considered. Results that illustrate the effects of imperfections and uncertainties on the nonlinear response characteristics, buckling loads and failure the shells are presented. In addition, a common failure analysis is used to predict material failures in the shells.

Hilburger, Mark W.↗

NASA NTRS1998

Contrasting actions of pressor agents in severe autonomic failure

BACKGROUND: Orthostatic hypotension is the most disabling symptom of autonomic failure. The choice of a pressor agent is largely empiric, and it would be of great value to define predictors of a response. PATIENTS AND METHODS: In 35 patients with severe orthostatic hypotension due to multiple system atrophy or pure autonomic failure, we determined the effect on seated systolic blood pressure (SBP) of placebo, phenylpropanolamine (12.5 mg and 25 mg), yohimbine (5.4 mg), indomethacin (50 mg), ibuprofen (600 mg), caffeine (250 mg), and methylphenidate (5 mg). In a subgroup of patients, we compared the pressor effect of midodrine (5 mg) with the effect of phenylpropanolamine (12.5 mg). RESULTS: There were no significant differences in the pressor responses between patients with multiple system atrophy or pure autonomic failure. When compared with placebo, the pressor response was significant for phenylpropanolamine, yohimbine, and indomethacin. In a subgroup of patients, we confirmed that this pressor effect of phenylpropanolamine, yohimbine, and indomethacin corresponded to a significant increase in standing SBP. The pressor responses to ibuprofen, caffeine, and methylphenidate were not significantly different from placebo. Phenylpropanolamine and midodrine elicited similar pressor responses. There were no significant associations between drug response and autonomic function testing, postprandial hypotension, or plasma catecholamine levels. CONCLUSIONS: We conclude that significant increases in systolic blood pressure can be obtained in patients with orthostatic hypotension due to primary autonomic failure with phenylpropanolamine in low doses or yohimbine or indomethacin in moderate doses. The response to a pressor agent cannot be predicted by autonomic function testing or plasma catecholamines. Therefore, empiric testing with a sequence of medications, based on the risk of side effects in the individual patient and the probability of a response, is a useful approach.

Clinical Trial↗

NASA NTRS2005

Failure Models and Criteria for FRP Under In-Plane or Three-Dimensional Stress States Including Shear Non-Linearity

A set of three-dimensional failure criteria for laminated fiber-reinforced composites, denoted LaRC04, is proposed. The criteria are based on physical models for each failure mode and take into consideration non-linear matrix shear behaviour. The model for matrix compressive failure is based on the Mohr-Coulomb criterion and it predicts the fracture angle. Fiber kinking is triggered by an initial fiber misalignment angle and by the rotation of the fibers during compressive loading. The plane of fiber kinking is predicted by the model. LaRC04 consists of 6 expressions that can be used directly for design purposes. Several applications involving a broad range of load combinations are presented and compared to experimental data and other existing criteria. Predictions using LaRC04 correlate well with the experimental data, arguably better than most existing criteria. The good correlation seems to be attributable to the physical soundness of the underlying failure models.

Pinho, Silvestre T.↗

NASA NTRS2005

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.↗

NASA NTRS1999

Modal Acoustic Emission Used at Elevated Temperatures to Detect Damage and Failure Location in Ceramic Matrix Composites

Ceramic matrix composites are being developed for elevated-temperature engine applications. A leading material system in this class of materials is silicon carbide (SiC) fiber-reinforced SiC matrix composites. Unfortunately, the nonoxide fibers, matrix, and interphase (boron nitride in this system) can react with oxygen or water vapor in the atmosphere, leading to strength degradation of the composite at elevated temperatures. For this study, constant-load stress-rupture tests were performed in air at temperatures ranging from 815 to 960 C until failure. From these data, predictions can be made for the useful life of such composites under similar stressed-oxidation conditions. During these experiments, the sounds of failure events (matrix cracking and fiber breaking) were monitored with a modal acoustic emission (AE) analyzer through transducers that were attached at the ends of the tensile bars. Such failure events, which are caused by applied stress and oxidation reactions, cause these composites to fail prematurely. Because of the nature of acoustic waveform propagation in thin tensile bars, the location of individual source events and the eventual failure event could be detected accurately.

Morscher, Gregory N.↗

NASA NTRS2004

International Space Station (ISS) Low Pressure Intramodule Quick Disconnect Failures

A failure of an ISS intermodule Quick Disconnect (QD) during protoflight vibration testing of ISS regenerative Environmental Control and Life Support (ECLS) hardware led to the discovery of QD design, manufacturing, and test flaws which can yield the male QD susceptible to failure of the secondary housing seal and inadequate housing assembly locking mechanisms. Discovery of this failure had large implications when considering that currently there are 399 similar units on orbit and approximately 1100 units on the ground integrated into flight hardware. Discovery of the nature of the failure required testing and analysis and implementation of a recovery plan requiring part screening and review of element level and project hazard analysis to determine if secondary seals are required. Implementation also involves coordination with the Nodes and MPLM project offices, Regenerative ECLS Project, ISS Payloads, JAXA, ESA, and ISS Logistics and Maintenance.

Lewis, John F.↗

NASA NTRS2005

Adaptive Failure Compensation for Aircraft Flight Control Using Engine Differentials: Regulation

The problem of using engine thrust differentials to compensate for rudder and aileron failures in aircraft flight control is addressed in this paper in a new framework. A nonlinear aircraft model that incorporates engine di erentials in the dynamic equations is employed and linearized to describe the aircraft s longitudinal and lateral motion. In this model two engine thrusts of an aircraft can be adjusted independently so as to provide the control flexibility for rudder or aileron failure compensation. A direct adaptive compensation scheme for asymptotic regulation is developed to handle uncertain actuator failures in the linearized system. A design condition is specified to characterize the system redundancy needed for failure compensation. The adaptive regulation control scheme is applied to the linearized model of a large transport aircraft in which the longitudinal and lateral motions are coupled as the result of using engine thrust differentials. Simulation results are presented to demonstrate the effectiveness of the adaptive compensation scheme.

Yu, Liu↗

NASA NTRS2005

Failure Analysis of CCD Image Sensors Using SQUID and GMR Magnetic Current Imaging

During electrical testing of a Full Field CCD Image Senor, electrical shorts were detected on three of six devices. These failures occurred after the parts were soldered to the PCB. Failure analysis was performed to determine the cause and locations of these failures on the devices. After removing the fiber optic faceplate, optical inspection was performed on the CCDs to understand the design and package layout. Optical inspection revealed that the device had a light shield ringing the CCD array. This structure complicated the failure analysis. Alternate methods of analysis were considered, including liquid crystal, light and thermal emission, LT/A, TT/A SQUID, and MP. Of these, SQUID and MP techniques were pursued for further analysis. Also magnetoresistive current imaging technology is discussed and compared to SQUID.

Felt, Frederick S.↗

NASA NTRS2006

A Decohesive Constitutive Formulation for Modeling Failure of Sea Ice

One of the dominant characteristics of Arctic ice as reflected by RADARSAT Geophysical Processor System data is the development and persistence of leads. Experimental data from small specimens as well as in situ data from Arctic ice suggest that failure may occur under compression. Presented here is a decohesive constitutive model for which one of the distinguishing new features is that failure is predicted under uniaxial compression. More generally, the model specifically indicates when a lead is initiated, provides the orientation of the lead, gives the mode of failure, and allows one to numerically determine the width of leads. In addition, the approach allows multiple failure planes, a feature that is necessary to simulate crack branching. Pre-existing planes of weakness such as those formed from previous leads can be incorporated. Sample calculations indicate how such a model can be used for large-scale numerical simulations.

Schreyer, H. L.↗

NASA NTRS2007

Buckling and Failure of Compression-Loaded Composite Laminated Shells With Cutouts

Results from a numerical and experimental study that illustrate the effects of laminate orthotropy on the buckling and failure response of compression-loaded composite cylindrical shells with a cutout are presented. The effects of orthotropy on the overall response of compression-loaded shells is described. In general, preliminary numerical results appear to accurately predict the buckling and failure characteristics of the shell considered herein. In particular, some of the shells exhibit stable post-local-buckling behavior accompanied by interlaminar material failures near the free edges of the cutout. In contrast another shell with a different laminate stacking sequence appears to exhibit catastrophic interlaminar material failure at the onset of local buckling near the cutout and this behavior correlates well with corresponding experimental results.

Hilburger, Mark W.↗

NASA NTRS2006

Explosive Event in MON-3 Oxidizer System Resulting from Pressure Transducer Failure

In 2003, a Druck(Registered Trademark) pressure transducer failed catastrophically in a test system circulating nitrogen tetroxide at NASA Johnson Space Center White Sands Test Facility. The cause of the explosion was not immediately obvious since the wetted areas of the pressure transducer were constructed of materials compatible with nitrogen tetroxide. Chemical analysis of the resulting residue and a materials analysis of the diaphragm and its weld zones were used to determine the chain of events that led to the catastrophic failure. Due to excessive dynamic pressure loading in the test system, the diaphragm in the pressure transducer suffered cyclic failure and allowed the silicon oil located behind the isolation diaphragm to mix with the nitrogen tetroxide. The reaction between these two chemicals formed a combination of 2,4-di and 2,4,6-trinitrophenol, which are shock sensitive explosives that caused the failure of the pressure transducer. Further research indicated numerous manufacturers offer similar pressure transducers with silicone oil separated from the test fluid by a thin stainless steel isolation diaphragm. Caution must be exercised when purchasing a pressure transducer for a particular system to avoid costly failures and test system contamination.

Baker, David L.↗

NASA NTRS2008

Solder Reflow Failures in Electronic Components During Manual Soldering

This viewgraph presentation reviews the solder reflow failures in electronic components that occur during manual soldering. It discusses the specifics of manual-soldering-induced failures in plastic devices with internal solder joints. The failure analysis turned up that molten solder had squeezed up to the die surface along the die molding compound interface, and the dice were not protected with glassivation allowing solder to short gate and source to the drain contact. The failure analysis concluded that the parts failed due to overheating during manual soldering.

Teverovsky, Alexander↗

NASA NTRS2008

Full-Field Strain Methods for Investigating Failure Mechanisms in Triaxial Braided Composites

Recent advancements in braiding technology have led to commercially viable manufacturing approaches for making large structures with complex shape out of triaxial braided composite materials. In some cases, the static load capability of structures made using these materials has been higher than expected based on material strength properties measured using standard coupon tests. A more detailed investigation of deformation and failure processes in large-unit-cell-size triaxial braid composites is needed to evaluate the applicability of standard test methods for these materials and to develop alternative testing approaches. This report presents some new techniques that have been developed to investigate local deformation and failure using digital image correlation techniques. The methods were used to measure both local and global strains during standard straight-sided coupon tensile tests on composite materials made with 12- and 24-k yarns and a 0 /+60 /-60 triaxial braid architecture. Local deformation and failure within fiber bundles was observed and correlations were made between these local failures and global composite deformation and strength.

Littell, Justin D.↗

NASA NTRS2008

A Novel Multiscale Physics Based Progressive Failure Methodology for Laminated Composite Structures

A variable fidelity, multiscale, physics based finite element procedure for predicting progressive damage and failure of laminated continuous fiber reinforced composites is introduced. At every integration point in a finite element model, progressive damage is accounted for at the lamina-level using thermodynamically based Schapery Theory. Separate failure criteria are applied at either the global-scale or the microscale in two different FEM models. A micromechanics model, the Generalized Method of Cells, is used to evaluate failure criteria at the micro-level. The stress-strain behavior and observed failure mechanisms are compared with experimental results for both models.

Pineda, Evan J.↗

NASA NTRS2009

Improving the Estimates of International Space Station (ISS) Induced K-Factor Failure Rates for On-Orbit Replacement Unit (ORU) Supportability Analyses

This is a case study on revised estimates of induced failure for International Space Station (ISS) on-orbit replacement units (ORUs). We devise a heuristic to leverage operational experience data by aggregating ORU, associated function (vehicle sub -system), and vehicle effective' k-factors using actual failure experience. With this input, we determine a significant failure threshold and minimize the difference between the actual and predicted failure rates. We conclude with a discussion on both qualitative and quantitative improvements the heuristic methods and potential benefits to ISS supportability engineering analysis.

Anderson, Leif F.↗

NASA NTRS2010

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↗

NASA NTRS2010

SAW Sensor for Fastener Failure Detection

The proof of concept for using surface acoustic wave (SAW) strain sensors in the detection of aircraft fastener failures is demonstrated. SAW sensors were investigated because they have the potential for the development of passive wireless systems. The SAW devices employed four orthogonal frequency coding (OFC) spread spectrum reflectors in two banks on a high temperature piezoelectric substrate. Three SAW devices were attached to a cantilever panel with removable side stiffeners. Damage in the form of fastener failure was simulated by removal of bolts from the side stiffeners. During testing, three different force conditions were used to simulate static aircraft structural response under loads. The design of the sensor, the panel arrangement and the panel testing results are reported. The results show that the sensors successfully detected single fastener failure at distances up to 54.6 cm from the failure site under loaded conditions.

Wilson, W. C.↗

NASA NTRS2010

Space Shuttle Main Propulsion System Gaseous Hydrogen Flow Control Valve Poppet Failure

The presentation provides background information pertinent to the MPS GH2 Flow Control Valve Poppet failure which occurred on the Space Shuttle Endeavour during STS-126 flight. The presentation provides general MPS system operating information which is pertinent to understanding the failure causes and affects. The presentation provides additional background information on the operating environment in which the FCV functions and basic design history of the flow control valve. The presentation provides an overview of the possible flight failure modes and a brief summary of the flight rationale which was developed for this failure event. This presentation is an introductory presentation to 3 other speakers at the conference who will be speaking on M&P aspects of the investigation, non destructive inspection techniques development, and particle impact testing.

Zeitler, Rick↗