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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.

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At least 73 records · Page 4
All sourcesNASA NTRSDOE OSTI
NASA NTRS1995

Analysis of the progressive failure of brittle matrix composites

This report investigates two of the most common modes of localized failures, namely, periodic fiber-bridged matrix cracks and transverse matrix cracks. A modification of Daniels' bundle theory is combined with Weibull's weakest link theory to model the statistical distribution of the periodic matrix cracking strength for an individual layer. Results of the model predictions are compared with experimental data from the open literature. Extensions to the model are made to account for possible imperfections within the layer (i.e., nonuniform fiber lengths, irregular crack spacing, and degraded in-situ fiber properties), and the results of these studies are presented. A generalized shear-lag analysis is derived which is capable of modeling the development of transverse matrix cracks in material systems having a general multilayer configuration and under states of full in-plane load. A method for computing the effective elastic properties for the damaged layer at the global level is detailed based upon the solution for the effects of the damage at the local level. This methodology is general in nature and is therefore also applicable to (0(sub m)/90(sub n))(sub s) systems. The characteristic stress-strain response for more general cases is shown to be qualitatively correct (experimental data is not available for a quantitative evaluation), and the damage evolution is recorded in terms of the matrix crack density as a function of the applied strain. Probabilistic effects are introduced to account for the statistical nature of the material strengths, thus allowing cumulative distribution curves for the probability of failure to be generated for each of the example laminates. Additionally, Oh and Finney's classic work on fracture location in brittle materials is extended and combined with the shear-lag analysis. The result is an analytical form for predicting the probability density function for the location of the next transverse crack occurrence within a crack bounded region. The results of this study verified qualitatively the validity of assuming a uniform crack spacing (as was done in the shear-lag model).

Thomas, David J.↗
NASA NTRS2010

The Range Safety Debris Catalog Analysis in Preparation for the Pad Abort One Flight Test

The Pad Abort One flight test of the Orion Abort Flight Test Program is currently under development with the goal of demonstrating the capability of the Launch Abort System. In the event of a launch failure, this system will propel the Crew Exploration Vehicle to safety. An essential component of this flight test is range safety, which ensures the security of range assets and personnel. A debris catalog analysis was done as part of a range safety data package delivered to the White Sands Missile Range in New Mexico where the test will be conducted. The analysis discusses the consequences of an overpressurization of the Abort Motor. The resulting structural failure was assumed to create a debris field of vehicle fragments that could potentially pose a hazard to the range. A statistical model was used to assemble the debris catalog of potential propellant fragments. Then, a thermodynamic, energy balance model was applied to the system in order to determine the imparted velocity to these propellant fragments. This analysis was conducted at four points along the flight trajectory to better understand the failure consequences over the entire flight. The methods used to perform this analysis are outlined in detail and the corresponding results are presented and discussed.

Kutty, Prasad M.↗
NASA NTRS2011

Advanced Gear Alloys for Ultra High Strength Applications

Single tooth bending fatigue (STBF) test data of UHS Ferrium C61 and C64 alloys are presented in comparison with historical test data of conventional gear steels (9310 and Pyrowear 53) with comparable statistical analysis methods. Pitting and scoring tests of C61 and C64 are works in progress. Boeing statistical analysis of STBF test data for the four gear steels (C61, C64, 9310 and Pyrowear 53) indicates that the UHS grades exhibit increases in fatigue strength in the low cycle fatigue (LCF) regime. In the high cycle fatigue (HCF) regime, the UHS steels exhibit better mean fatigue strength endurance limit behavior (particularly as compared to Pyrowear 53). However, due to considerable scatter in the UHS test data, the anticipated overall benefits of the UHS grades in bending fatigue have not been fully demonstrated. Based on all the test data and on Boeing s analysis, C61 has been selected by Boeing as the gear steel for the final ERDS demonstrator test gearboxes. In terms of potential follow-up work, detailed physics-based, micromechanical analysis and modeling of the fatigue data would allow for a better understanding of the causes of the experimental scatter, and of the transition from high-stress LCF (surface-dominated) to low-stress HCF (subsurface-dominated) fatigue failure. Additional STBF test data and failure analysis work, particularly in the HCF regime and around the endurance limit stress, could allow for better statistical confidence and could reduce the observed effects of experimental test scatter. Finally, the need for further optimization of the residual compressive stress profiles of the UHS steels (resulting from carburization and peening) is noted, particularly for the case of the higher hardness C64 material.

Shen, Tony↗
NASA NTRS1992

Long-life assessment of graphite epoxy materials for Space Station Freedom pressure vessels

Graphite/epoxy composite overwrapped pressure vessels are being considered for use on Space Station Freedom because of their light weight and high efficiency. These composite pressure vessels weigh roughly one-third of comparable all-metal aluminum pressure vessels, and could result in a 15,000-lb weight saving for the propulsion and fluid management and distribution systems. These vessels must resist failures under sustained pressure loads for crew safety considerations and adequate protection of the space structure during their 30-yr life. Weibull statistical analysis techniques have been applied, and a model developed, for predicting long-term stress-rupture behavior based on published short-term test data on composite strands and pressure vessels. Graphite/epoxy materials are calculated to have a 99.99-percent probability of surviving stress rupture for 30 yr under a sustained load of 50 percent ultimate failure strength. Stress-rupture lifetimes are predicted to increase as the size of the pressure vessels increases in support of the viscoelastic load-transfer mechanism proposed for stress rupture of fiber/epoxy composite materials.

Thomas, Donald A.↗
NASA NTRS2010

Development of NASA's Accident Precursor Analysis Process Through Application on the Space Shuttle Orbiter

Accident Precursor Analysis (APA) serves as the bridge between existing risk modeling activities, which are often based on historical or generic failure statistics, and system anomalies, which provide crucial information about the failure mechanisms that are actually operative in the system. APA docs more than simply track experience: it systematically evaluates experience, looking for under-appreciated risks that may warrant changes to design or operational practice. This paper presents the pilot application of the NASA APA process to Space Shuttle Orbiter systems. In this effort, the working sessions conducted at Johnson Space Center (JSC) piloted the APA process developed by Information Systems Laboratories (ISL) over the last two years under the auspices of NASA's Office of Safety & Mission Assurance, with the assistance of the Safety & Mission Assurance (S&MA) Shuttle & Exploration Analysis Branch. This process is built around facilitated working sessions involving diverse system experts. One important aspect of this particular APA process is its focus on understanding the physical mechanism responsible for an operational anomaly, followed by evaluation of the risk significance of the observed anomaly as well as consideration of generalizations of the underlying mechanism to other contexts. Model completeness will probably always be an issue, but this process tries to leverage operating experience to the extent possible in order to address completeness issues before a catastrophe occurs.

Maggio, Gaspare↗
NASA NTRS2006

A Framework for Performing Multiscale Stochastic Progressive Failure Analysis of Composite Structures

A framework is presented that enables coupled multiscale analysis of composite structures. The recently developed, free, Finite Element Analysis - Micromechanics Analysis Code (FEAMAC) software couples the Micromechanics Analysis Code with Generalized Method of Cells (MAC/GMC) with ABAQUS to perform micromechanics based FEA such that the nonlinear composite material response at each integration point is modeled at each increment by MAC/GMC. As a result, the stochastic nature of fiber breakage in composites can be simulated through incorporation of an appropriate damage and failure model that operates within MAC/GMC on the level of the fiber. Results are presented for the progressive failure analysis of a titanium matrix composite tensile specimen that illustrate the power and utility of the framework and address the techniques needed to model the statistical nature of the problem properly. In particular, it is shown that incorporating fiber strength randomness on multiple scales improves the quality of the simulation by enabling failure at locations other than those associated with structural level stress risers.

Bednarcyk, Brett A.↗
NASA NTRS2007

A Framework for Performing Multiscale Stochastic Progressive Failure Analysis of Composite Structures

A framework is presented that enables coupled multiscale analysis of composite structures. The recently developed, free, Finite Element Analysis-Micromechanics Analysis Code (FEAMAC) software couples the Micromechanics Analysis Code with Generalized Method of Cells (MAC/GMC) with ABAQUS to perform micromechanics based FEA such that the nonlinear composite material response at each integration point is modeled at each increment by MAC/GMC. As a result, the stochastic nature of fiber breakage in composites can be simulated through incorporation of an appropriate damage and failure model that operates within MAC/GMC on the level of the fiber. Results are presented for the progressive failure analysis of a titanium matrix composite tensile specimen that illustrate the power and utility of the framework and address the techniques needed to model the statistical nature of the problem properly. In particular, it is shown that incorporating fiber strength randomness on multiple scales improves the quality of the simulation by enabling failure at locations other than those associated with structural level stress risers.

Bednarcyk, Brett A.↗
NASA NTRS1986

Management of SSME hardware life utilization

Statistical and probabilistic reliability methodologies were developed for the determination of hardware life limits for the Space Shuttle Main Engine (SSME). Both methodologies require that a mathematical reliability model of the engine (system) performance be developed as a function of the reliabilities of the components and parts. The system reliability model should be developed from the Failute Modes and Effects Analysis/Critical Items List. The statistical reliability methodology establishes hardware life limits directly from the failure distributions of the components and parts obtained from statistically-designed testing. The probabilistic reliability methodology establishes hardware life limits from a decision analysis methodology which incorporates the component/part reliabilities obtained from a probabilistic structural analysis, a calibrated maintenance program, inspection techniques, and fabrication procedures. Probilistic structural analysis is recommended as a tool to prioritize upgrading of the components and parts. The Weibull probability distribution is presently being investigated by NASA/MSFC to characterize the failure distribution of the SSME hardware from a limited data base of failures.

Pauschke, J. M.↗
NASA NTRS2010

Failure Bounding And Sensitivity Analysis Applied To Monte Carlo Entry, Descent, And Landing Simulations

In the study of entry, descent, and landing, Monte Carlo sampling methods are often employed to study the uncertainty in the designed trajectory. The large number of uncertain inputs and outputs, coupled with complicated non-linear models, can make interpretation of the results difficult. Three methods that provide statistical insights are applied to an entry, descent, and landing simulation. The advantages and disadvantages of each method are discussed in terms of the insights gained versus the computational cost. The first method investigated was failure domain bounding which aims to reduce the computational cost of assessing the failure probability. Next a variance-based sensitivity analysis was studied for the ability to identify which input variable uncertainty has the greatest impact on the uncertainty of an output. Finally, probabilistic sensitivity analysis is used to calculate certain sensitivities at a reduced computational cost. These methods produce valuable information that identifies critical mission parameters and needs for new technology, but generally at a significant computational cost.

Gaebler, John A.↗
NASA NTRS1985

Signal analysis techniques for incipient failure detection in turbomachinery

Signal analysis techniques for the detection and classification of incipient mechanical failures in turbomachinery were developed, implemented and evaluated. Signal analysis techniques available to describe dynamic measurement characteristics are reviewed. Time domain and spectral methods are described, and statistical classification in terms of moments is discussed. Several of these waveform analysis techniques were implemented on a computer and applied to dynamic signals. A laboratory evaluation of the methods with respect to signal detection capability is described. Plans for further technique evaluation and data base development to characterize turbopump incipient failure modes from Space Shuttle main engine (SSME) hot firing measurements are outlined.

Coffin, T.↗
NASA NTRS1978

Data analysis of the LPSP experiment on OSO-8

The first and statistically most reliable step in the data analysis - the computation of the vertical phase lag between photospheric and chromospheric oscillations - was completed. Unfortunately, the error associated with this calculated phase lag is so great that the result has no physical significance. Since the subsequent data analysis that was originally planned would have much larger associated errors, it was concluded that the data available is insufficient to allow any meaningful results to be derived. Accordingly, the project was terminated. The reasons for the failure of the data are discussed. There are two basic reasons for this failure; (1) the very low signal to noise ratio of the raw data, and (1) the small statistical sample that resulted from the very small number of usable orbits. The final phase of data analysis is described. Finally, some comments and recommendations of a general nature are made concerning this entire contract effort. It is hoped that at least some lessons can be learned from this particular Guest Investigator project, so that future Guest Investigator programs can be pursued more effectively, and with less risk.

Frazier, E. N.↗
NASA NTRS1998

Automated System Checkout to Support Predictive Maintenance for the Reusable Launch Vehicle

The Propulsion Checkout and Control System (PCCS) is a predictive maintenance software system. The real-time checkout procedures and diagnostics are designed to detect components that need maintenance based on their condition, rather than using more conventional approaches such as scheduled or reliability centered maintenance. Predictive maintenance can reduce turn-around time and cost and increase safety as compared to conventional maintenance approaches. Real-time sensor validation, limit checking, statistical anomaly detection, and failure prediction based on simulation models are employed. Multi-signal models, useful for testability analysis during system design, are used during the operational phase to detect and isolate degraded or failed components. The TEAMS-RT real-time diagnostic engine was developed to utilize the multi-signal models by Qualtech Systems, Inc. Capability of predicting the maintenance condition was successfully demonstrated with a variety of data, from simulation to actual operation on the Integrated Propulsion Technology Demonstrator (IPTD) at Marshall Space Flight Center (MSFC). Playback of IPTD valve actuations for feature recognition updates identified an otherwise undetectable Main Propulsion System 12 inch prevalve degradation. The algorithms were loaded into the Propulsion Checkout and Control System for further development and are the first known application of predictive Integrated Vehicle Health Management to an operational cryogenic testbed. The software performed successfully in real-time, meeting the required performance goal of 1 second cycle time.

Patterson-Hine, Ann↗
NASA NTRS2008

Reliability and Confidence Interval Analysis of a CMC Turbine Stator Vane

High temperature ceramic matrix composites (CMC) are being explored as viable candidate materials for hot section gas turbine components. These advanced composites can potentially lead to reduced weight, enable higher operating temperatures requiring less cooling and thus leading to increased engine efficiencies. However, these materials are brittle and show degradation with time at high operating temperatures due to creep as well as cyclic mechanical and thermal loads. In addition, these materials are heterogeneous in their make-up and various factors affect their properties in a specific design environment. Most of these advanced composites involve two- and three-dimensional fiber architectures and require a complex multi-step high temperature processing. Since there are uncertainties associated with each of these in addition to the variability in the constituent material properties, the observed behavior of composite materials exhibits scatter. Traditional material failure analyses employing a deterministic approach, where failure is assumed to occur when some allowable stress level or equivalent stress is exceeded, are not adequate for brittle material component design. Such phenomenological failure theories are reasonably successful when applied to ductile materials such as metals. Analysis of failure in structural components is governed by the observed scatter in strength, stiffness and loading conditions. In such situations, statistical design approaches must be used. Accounting for these phenomena requires a change in philosophy on the design engineer s part that leads to a reduced focus on the use of safety factors in favor of reliability analyses. The reliability approach demands that the design engineer must tolerate a finite risk of unacceptable performance. This risk of unacceptable performance is identified as a component's probability of failure (or alternatively, component reliability). The primary concern of the engineer is minimizing this risk in an economical manner. The methods to accurately determine the service life of an engine component with associated variability have become increasingly difficult. This results, in part, from the complex missions which are now routinely considered during the design process. These missions include large variations of multi-axial stresses and temperatures experienced by critical engine parts. There is a need for a convenient design tool that can accommodate various loading conditions induced by engine operating environments, and material data with their associated uncertainties to estimate the minimum predicted life of a structural component. A probabilistic composite micromechanics technique in combination with woven composite micromechanics, structural analysis and Fast Probability Integration (FPI) techniques has been used to evaluate the maximum stress and its probabilistic distribution in a CMC turbine stator vane. Furthermore, input variables causing scatter are identified and ranked based upon their sensitivity magnitude. Since the measured data for the ceramic matrix composite properties is very limited, obtaining a probabilistic distribution with their corresponding parameters is difficult. In case of limited data, confidence bounds are essential to quantify the uncertainty associated with the distribution. Usually 90 and 95% confidence intervals are computed for material properties. Failure properties are then computed with the confidence bounds. Best estimates and the confidence bounds on the best estimate of the cumulative probability function for R-S (strength - stress) are plotted. The methodologies and the results from these analyses will be discussed in the presentation.

Murthy, Pappu L. N.↗
NASA NTRS1983

Statistical Analysis of a Debugging Model

Suppose that a system is undergoing a sequence of trials and design changes in an effort to find and eliminate design flaws in the system. Specifically, suppose that each trial is classified as an assignable cause failure (if the failure is due to one or more design flaws), an inherent failure (if the failure is not due to a design flaw), or a success. After each assignable cause failure, the design flaws that caused the failure are removed. In the case of statistically independent and identical design flaws, a probabilistic model is developed to describe this debugging process. Explicit expressions are obtained for the distributions of the important random variables and for the important measures of reliability. Statistical methods are developed for estimating the parameters of the model from accumulated test data.

Siegrist, K.↗
NASA NTRS2010

An Accident Precursor Analysis Process Tailored for NASA Space Systems

Accident Precursor Analysis (APA) serves as the bridge between existing risk modeling activities, which are often based on historical or generic failure statistics, and system anomalies, which provide crucial information about the failure mechanisms that are actually operative in the system and which may differ in frequency or type from those in the various models. These discrepancies between the models (perceived risk) and the system (actual risk) provide the leading indication of an underappreciated risk. This paper presents an APA process developed specifically for NASA Earth-to-Orbit space systems. The purpose of the process is to identify and characterize potential sources of system risk as evidenced by anomalous events which, although not necessarily presenting an immediate safety impact, may indicate that an unknown or insufficiently understood risk-significant condition exists in the system. Such anomalous events are considered accident precursors because they signal the potential for severe consequences that may occur in the future, due to causes that are discernible from their occurrence today. Their early identification allows them to be integrated into the overall system risk model used to intbrm decisions relating to safety.

Groen, Frank↗
NASA NTRS1987

Analysis of Convair 990 rejected-takeoff accident with emphasis on decision making, training and procedures

This paper analyzes a NASA Convair 990 (CV-990) accident with emphasis on rejected-takeoff (RTO) decision making, training, procedures, and accident statistics. The NASA Aircraft Accident Investigation Board was somewhat perplexed that an aircraft could be destroyed as a result of blown tires during the takeoff roll. To provide a better understanding of tire failure RTO's, The Board obtained accident reports, Federal Aviation Administration (FAA) studies, and other pertinent information related to the elements of this accident. This material enhanced the analysis process and convinced the Accident Board that high-speed RTO's in transport aircraft should be given more emphasis during pilot training. Pilots should be made aware of various RTO situations and statistics with emphasis on failed-tire RTO's. This background information could enhance the split-second decision-making process that is required prior to initiating an RTO.

Batthauer, Byron E.↗
NASA NTRS1990

Ceramics Analysis and Reliability Evaluation of Structures (CARES). Users and programmers manual

This manual describes how to use the Ceramics Analysis and Reliability Evaluation of Structures (CARES) computer program. The primary function of the code is to calculate the fast fracture reliability or failure probability of macroscopically isotropic ceramic components. These components may be subjected to complex thermomechanical loadings, such as those found in heat engine applications. The program uses results from MSC/NASTRAN or ANSYS finite element analysis programs to evaluate component reliability due to inherent surface and/or volume type flaws. CARES utilizes the Batdorf model and the two-parameter Weibull cumulative distribution function to describe the effect of multiaxial stress states on material strength. The principle of independent action (PIA) and the Weibull normal stress averaging models are also included. Weibull material strength parameters, the Batdorf crack density coefficient, and other related statistical quantities are estimated from four-point bend bar or unifrom uniaxial tensile specimen fracture strength data. Parameter estimation can be performed for single or multiple failure modes by using the least-square analysis or the maximum likelihood method. Kolmogorov-Smirnov and Anderson-Darling goodness-of-fit tests, ninety percent confidence intervals on the Weibull parameters, and Kanofsky-Srinivasan ninety percent confidence band values are also provided. The probabilistic fast-fracture theories used in CARES, along with the input and output for CARES, are described. Example problems to demonstrate various feature of the program are also included. This manual describes the MSC/NASTRAN version of the CARES program.

Nemeth, Noel N.↗