Assessing Next-Gen Spacesuit Reliability: A Probabilistic Analysis Case Study
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The identification, analysis, and optimization of life support systems and subsystems have been investigated. For each system or subsystem that has been considered, the procedure involves the establishment of a set of system equations (or mathematical model) based on theory and experimental evidences; the analysis and simulation of the model; the optimization of the operation, control, and reliability; analysis of sensitivity of the system based on the model; and, if possible, experimental verification of the theoretical and computational results. Research activities include: (1) modeling of air flow in a confined space; (2) review of several different gas-liquid contactors utilizing centrifugal force: (3) review of carbon dioxide reduction contactors in space vehicles and other enclosed structures: (4) application of modern optimal control theory to environmental control of confined spaces; (5) optimal control of class of nonlinear diffusional distributed parameter systems: (6) optimization of system reliability of life support systems and sub-systems: (7) modeling, simulation and optimal control of the human thermal system: and (8) analysis and optimization of the water-vapor eletrolysis cell.
Probabilistic failure analysis is a tool to predict the reliability of a part or system. Probabalistic techniques were used to predict critical stresses which occur in the solid rocket booster aft-skirt during main engine buildup, immediately prior to lift-off. More than any other hold down post (HDP) load component, the Z loads are sensitive to variations in strains and calibration constants. Also, predicted aft-skirt stresses are strongly affected by HDP load variations. Therefore, the instrumented HDP are not effective load transducers for Z loads, and, when used with aft skirt stress indicator equations, yield estimates with large uncertainty. Monte Carlo simulation proved to be a straight forward way of studying the overlapping effects of multiple parameters on predicted equipment performance. An advantage of probabilistic analysis is the degree of uncertainty of each parameter as stated explicitly by its probability distribution. It was noted, however, that the choice of parameter distribution had a large effect on the simulation results. Many times these distributions must be assumed. The engineer who is designing the part should be responsible for the choice of parameter distribution.
The computer program CARES/LIFE calculates the time-dependent reliability of monolithic ceramic components subjected to thermomechanical and/or proof test loading. This program is an extension of the CARES (Ceramics Analysis and Reliability Evaluation of Structures) computer program. CARES/LIFE accounts for the phenomenon of subcritical crack growth (SCG) by utilizing the power law, Paris law, or Walker equation. The two-parameter Weibull cumulative distribution function is used to characterize the variation in component strength. The effects of multiaxial stresses are modeled using either the principle of independent action (PIA), Weibull's normal stress averaging method (NSA), or Batdorf's theory. Inert strength and fatigue parameters are estimated from rupture strength data of naturally flawed specimens loaded in static, dynamic, or cyclic fatigue. Two example problems demonstrating cyclic fatigue parameter estimation and component reliability analysis with proof testing are included.
This effort is to investigate probabilistic life prediction methodologies for ceramic matrix composites and MicroElectroMechanical Systems (MEMS) and to analyze designs that determine stochastic properties of MEMS. For CMC's this includes a brief literature survey regarding lifing methodologies. Also of interest for MEMS is the design of a proper test for the Weibull size effect in thin film (bulge test) specimens. The Weibull size effect is a consequence of a stochastic strength response predicted from the Weibull distribution. Confirming that MEMS strength is controlled by the Weibull distribution will enable the development of a probabilistic design methodology for MEMS - similar to the GRC developed CARES/Life program for bulk ceramics. A main objective of this effort is to further develop and verify the ability of the Ceramics Analysis and Reliability Evaluation of Structures/Life (CARES/Life) code to predict the time-dependent reliability of MEMS structures subjected to multiple transient loads. A second set of objectives is to determine the applicability/suitability of the CARES/Life methodology for CMC analysis, what changes would be needed to the methodology and software, and if feasible, run a demonstration problem. Also important is an evaluation of CARES/Life coupled to the ANSYS Probabilistic Design System (PDS) and the potential of coupling transient reliability analysis to the ANSYS PDS.
An analysis of reliability data on Nickel-Cadmium (NiCd) batteries (for use in spacecraft) is presented. The data were collected by Gates Aerospace and represent a substantial reliability database. The data were taken from the performance of 183 satellites which were in operation from between .1 and 22 years, for a total of 278 million cell-hours of operation.
An investigation was conducted to predict the failure strength response of IG-100 nuclear grade graphite exposed to multiaxial stresses. As part of this effort, a review of failure criteria accounting for the stochastic strength response is provided. The experimental work was performed in the early 1990s at the Oak Ridge National Laboratory (ORNL) on hollow graphite tubes under the action of axial tensile loading and internal pressurization. As part of the investigation, finite-element analysis (FEA) was performed and compared with results of FEA from the original ORNL report. The new analysis generally compared well with the original analysis, although some discrepancies in the location of peak stresses was noted. The Ceramics Analysis and Reliability Evaluation of Structures Life prediction code (CARES/Life) was used with the FEA results to predict the quadrants I (tensile-tensile) and quadrant IV (compression-tension) strength response of the graphite tubes for the principle of independent action (PIA), the Weibull normal stress averaging (NSA), and the Batdorf multiaxial failure theories. The CARES/Life reliability analysis showed that all three failure theories gave similar results in quadrant I but that in quadrant IV, the PIA and Weibull normal stress-averaging theories were not conservative, whereas the Batdorf theory was able to correlate well with experimental results. The conclusion of the study was that the Batdorf theory should generally be used to predict the reliability response of graphite and brittle materials in multiaxial loading situations.
Owing to its excellent mechanical properties and stability under high temperature and neutron irradiation conditions, SiC/SiC composites have emerged as a promising material for light water reactors (LWRs) in the development of accident-tolerant fuel (ATF) systems. Structural integrity and retention of hermeticity are two crucial requirements for SiC/SiC claddings during normal operations, and both of them are closely related to the proportional limit stress (PLS) of the material. Understanding the behavior of SiC/SiC composites under multiaxial stress states and developing a probabilistic approach for evaluating the structural vulnerability are of paramount importance for reliability-based analysis and design of SiC/SiC composite claddings. So far, there has been very limited effort towards experimental and analytical investigations of probabilistic failure of SiC/SiC claddings. This critical knowledge gap motivates this research. A probabilistic failure criterion for SiC/SiC composites under multi-axial loading is developed, and this criterion is incorporated into reliability analysis of the structural integrity of SiC/SiC fuel cladding. The research consists of two parts: 1) experimental investigation of multiaxial failure behavior of SiC/SiC composites, and 2) theoretical modeling of time-dependent probabilistic failure of SiC/SiC cladding. In the experimental investigation, the PLS is determined through the examination of stress-strain response, the acoustic emission measurement, as well as the X-ray computed tomography. The theoretical framework is derived by combin- ing the finite weakest-link statistical model and the subcritical damage growth model. This theoretical model captures the time-dependent failure mechanism of the material, which has a major consequence for predicting the lifetime distribution of the cladding. Meanwhile, the model also predicts that the failure statistics of the cladding depends strongly on the cladding length. The results of the multiaxial experiments reveal the level of statistical variation of the PLS of SiC/SiC materials under different stress states. The theoretical model provides a robust analytical tool for extrapolation of small-scale laboratory test results to the behavior of full-scale claddings. These findings establish a scientific foundation for the development of reliability-based design of SiC/SiC fuel claddings, which will play an essential role in improving the structural safety and integrity of LWRs.
A forward-looking research opportunity number (RON) is defined for photovoltaic reliability researchers. The RON enables researchers to prioritize their efforts toward the highest impact. For a given degradation mode, the RON is based on three factors: the effect on levelized cost of electricity, the susceptibility of future module products, and the maturity of accelerated tests that can detect and quantify the mode. Reporting bias is avoided because the RON does not rely on polls. The RON is derived for three example cases: light and elevated temperature degradation, backsheet cracking, and antireflective coating abrasion. Finally, these examples demonstrate that targeted research has reduced the risk for these modes over the last several years.
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.
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.
The application of a software reliability model having a well defined correspondence of computer program properties to requirements error analysis is described. Requirements error categories which can be related to program structural elements are identified and their effect on program execution considered. The model is applied to a hypothetical B-5 requirement specification for a program module.
Reliability procedure involving stress analysis and safety factor number determination applied to ion engine subsystem
This paper describes the technology, design features and reliability characterization methodology of a CMOS Active Pixel Sensor. Both overall chip reliability and pixel reliability are projected for the imagers.
Structural Reliability Consultants' computer program creates graphic plots showing the statistical parameters of glue laminated timbers, or 'glulam.' The company president, Dr. Joseph Murphy, read in NASA Tech Briefs about work related to analysis of Space Shuttle surface tile strength performed for Johnson Space Center by Rockwell International Corporation. Analysis led to a theory of 'consistent tolerance bounds' for statistical distributions, applicable in industrial testing where statistical analysis can influence product development and use. Dr. Murphy then obtained the Tech Support Package that covers the subject in greater detail. The TSP became the basis for Dr. Murphy's computer program PC-DATA, which he is marketing commercially.