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At least 793 records · Page 44

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NASA NTRS2006

Mars Exploration Rover potentiometer problems, failures and lessons learned

During qualification testing of three types of nonwire-wound precision potentiometers for the Mars Exploration Rover, a variety of problems and failures were encountered. This paper will describe some of the more interesting problems, detail their investigations and present their final solutions. The failures were found to be caused by design errors, manufacturing errors, improper handling, test errors, and carelessness. A trend of decreasing total resistance was noted, and a resistance histogram was used to identify an outlier. A gang fixture is described for simultaneously testing multiple pots, and real time X-ray imaging was used extensively to assist in the failure analyses. Lessons learned are provided.

potentiometer↗

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 NTRS2007

The Effect of Delamination on Damage Path and Failure Load Prediction for Notched Composite Laminates

The influence of delamination on the progressing damage path and initial failure load in composite laminates is investigated. Results are presented from a numerical and an experimental study of center-notched tensile-loaded coupons. The numerical study includes two approaches. The first approach considers only intralaminar (fiber breakage and matrix cracking) damage modes in calculating the progression of the damage path. In the second approach, the model is extended to consider the effect of interlaminar (delamination) damage modes in addition to the intralaminar damage modes. The intralaminar damage is modeled using progressive damage analysis (PDA) methodology implemented with the VUMAT subroutine in the ABAQUS finite element code. The interlaminar damage mode has been simulated using cohesive elements in ABAQUS. In the experimental study, 2-3 specimens each of two different stacking sequences of center-notched laminates are tensile loaded. The numerical results from the two different modeling approaches are compared with each other and the experimentally observed results for both laminate types. The comparisons reveal that the second modeling approach, where the delamination damage mode is included together with the intralaminar damage modes, better simulates the experimentally observed damage modes and damage paths, which were characterized by splitting failures perpendicular to the notch tips in one or more layers. Additionally, the inclusion of the delamination mode resulted in a better prediction of the loads at which the failure took place, which were higher than those predicted by the first modeling approach which did not include delaminations.

Satyanarayana, Arunkumar↗

NASA NTRS2007

Failure Maps for Rectangular 17-4PH Stainless Steel Sandwiched Foam Panels

A new and innovative concept is proposed for designing lightweight fan blades for aircraft engines using commercially available 17-4PH precipitation hardened stainless steel. Rotating fan blades in aircraft engines experience a complex loading state consisting of combinations of centrifugal, distributed pressure and torsional loads. Theoretical failure plastic collapse maps, showing plots of the foam relative density versus face sheet thickness, t, normalized by the fan blade span length, L, have been generated for rectangular 17-4PH sandwiched foam panels under these three loading modes assuming three failure plastic collapse modes. These maps show that the 17-4PH sandwiched foam panels can fail by either the yielding of the face sheets, yielding of the foam core or wrinkling of the face sheets depending on foam relative density, the magnitude of t/L and the loading mode. The design envelop of a generic fan blade is superimposed on the maps to provide valuable insights on the probable failure modes in a sandwiched foam fan blade.

Raj, S. V.↗

NASA NTRS2007

Independent Review Support for Phoenix Mars Mission Robotic Arm Brush Motor Failure

The Phoenix Project requested the NASA Engineering and Safety Center (NESC) perform an independent peer review of the Robotic Arm (RA) Direct Current (DC) motor brush anomalies that originated during the Mars Exploration Rover (MER) Project and recurred during the Phoenix Project. The request was to evaluate the Phoenix Project investigation efforts and provide an independent risk assessment. This includes a recommendation for additional work and assessment of the flight worthiness of the RA DC motors. Based on the investigation and findings contained within this report, the IRT concurs with the risk assessment Failure Cause / Corrective Action (FC/CA) by the project, "Failure Effect Rating "3"; Major Degradation or Total Loss of Function, Failure Cause/Corrective Action Rating Currently "4"; Unknown Cause, Uncertainty in Corrective Action."

McManamen, John P.↗

NASA NTRS2008

Tensile Creep and Fatigue of Sylramic-iBN Melt-Infiltrated SiC Matrix Composites: Retained Properties, Damage Development, and Failure Mechanisms

An understanding of the elevated temperature tensile creep, fatigue, rupture, and retained properties of ceramic matrix composites (CMC) envisioned for use in gas turbine engine applications are essential for component design and life-prediction. In order to quantify the effect of stress, time, temperature, and oxidation for a state-of-the-art composite system, a wide variety of tensile creep, dwell fatigue, and cyclic fatigue experiments were performed in air at 1204 C for the SiC/SiC CMC system consisting of Sylramic-iBN SiC fibers, BN fiber interphase coating, and slurry-cast melt-infiltrated (MI) SiC-based matrix. Tests were either taken to failure or interrupted. Interrupted tests were then mechanically tested at room temperature to determine the residual properties. The retained properties of most of the composites subjected to tensile creep or fatigue were usually within 20% of the as-produced strength and 10% of the as-produced elastic modulus. It was observed that during creep, residual stresses in the composite are altered to some extent which results in an increased compressive stress in the matrix upon cooling and a subsequent increased stress required to form matrix cracks. Microscopy of polished sections and the fracture surfaces of specimens which failed during stressed-oxidation or after the room-temperature retained property test was performed on some of the specimens in order to quantify the nature and extent of damage accumulation that occurred during the test. It was discovered that the distribution of stress-dependent matrix cracking at 1204 C was similar to the as-produced composites at room temperature; however, matrix crack growth occurred over time and typically did not appear to propagate through thickness except at final failure crack. Failure of the composites was due to either oxidation-induced unbridged crack growth, which dominated the higher stress regime (> 179 MPa) or controlled by degradation of the fibers, probably caused by intrinsic creep-induced flaw growth of the fibers or internal attack of the fibers via Si diffusion through the CVI SiC and/or microcracks at the lower stress regime (< 165 MPa).

Morscher, Greg↗

NASA NTRS2008

Improved Relief Valve Would Be Less Susceptible to Failure

The balanced-piston relief valve with side vented reaction cavity has been proposed as an improved alternative to a conventional high-pressure, high-flow relief valve. The proposed valve would be less susceptible to failure. A typical conventional high-pressure, high-flow relief valve contains a piston that is exposed to the upstream pressure across the full valve-seat diameter and is held against the valve seat and the upstream pressure by a large spring. In the event of an increase in upstream pressure to a level above the valve set point (the pressure above which the valve opens), the opening force on the piston can be so large that the piston becomes accelerated to a speed high enough that the ensuing hard impact of the piston within the valve housing results in failure of the valve. For a given flow cross section, the proposal would significantly reduce the force, thereby reducing susceptibility to failure. A basic version of the proposed balanced-piston relief valve with side vented reaction cavity is described.

Farner, Bruce R.↗

NASA NTRS2009

Apollo CSM Power Generation System Design Considerations, Failure Modes and Lessons Learned

The objectives of this slide presentation are to: review the basic design criteria for fuel cells (FC's), review design considerations during developmental phase that affected Block I and Block II vehicles, summarize the conditions that led to the failure of components in the FC's, and state the solution implemented for each failure. It reviews the location of the fuel cells, the fuel cell theory the design criteria going into development phase and coming from the development phase, failures and solutions of Block I and II, and the lessons learned.

Interbartolo, Michael↗

NASA NTRS2009

Shuttle Gaseous Hydrogen Venting Risk from Flow Control Valve Failure

This paper describes a series of studies to assess the potential risk associated with the failure of one of three gaseous hydrogen flow control valves in the orbiter's main propulsion system during the launch of Shuttle Endeavour (STS-126) in November 2008. The studies focused on critical issues associated with the possibility of combustion resulting from release of gaseous hydrogen from the external tank into the atmosphere during assent. The Shuttle Program currently assumes hydrogen venting from the external tank will result in a critical failure. The current effort was conducted to increase understanding of the risk associated with venting hydrogen given the flow control valve failure scenarios being considered in the Integrated In-Flight Anomaly Investigation being conducted by NASA.

Drummond, J. Philip↗

NASA NTRS2010

Finite Element Model for Failure Study of Two-Dimensional Triaxially Braided Composite

A new three-dimensional finite element model of two-dimensional triaxially braided composites is presented in this paper. This meso-scale modeling technique is used to examine and predict the deformation and damage observed in tests of straight sided specimens. A unit cell based approach is used to take into account the braiding architecture as well as the mechanical properties of the fiber tows, the matrix and the fiber tow-matrix interface. A 0 deg / plus or minus 60 deg. braiding configuration has been investigated by conducting static finite element analyses. Failure initiation and progressive degradation has been simulated in the fiber tows by use of the Hashin failure criteria and a damage evolution law. The fiber tow-matrix interface was modeled by using a cohesive zone approach to capture any fiber-matrix debonding. By comparing the analytical results to those obtained experimentally, the applicability of the developed model was assessed and the failure process was investigated.

Li, Xuetao↗

NASA NTRS2011

Failure Investigation of an Intra-Manifold Explosion in a Horizontally-Mounted 870 lbf Reaction Control Thruster

In June 2010, an 870 lbf Space Shuttle Orbiter Reaction Control System Primary Thruster experienced an unintended shutdown during a test being performed at the NASA White Sands Test Facility. Subsequent removal and inspection of the thruster revealed permanent deformation and misalignment of the thruster valve mounting plate. Destructive evaluation determined that after three nominal firing sequences, the thruster had experienced an energetic event within the fuel (monomethylhydrazine) manifold at the start of the fourth firing sequence. The current understanding of the phenomenon of intra-manifold explosions in hypergolic bipropellant thrusters is documented in literature where it is colloquially referred to as a ZOT. The typical ZOT scenario involves operation of a thruster in a gravitational field with environmental pressures above the triple point pressure of the propellants. Post-firing, when the thruster valves are commanded closed, there remains a residual quantity of propellant in both the fuel and oxidizer (nitrogen tetroxide) injector manifolds known as the "dribble volume". In an ambient ground test configuration, these propellant volumes will drain from the injector manifolds but are impeded by the local atmospheric pressure. The evacuation of propellants from the thruster injector manifolds relies on the fluids vapor pressure to expel the liquid. The higher vapor pressure oxidizer will evacuate from the manifold before the lower vapor pressure fuel. The localized cooling resulting from the oxidizer boiling during manifold draining can result in fuel vapor migration and condensation in the oxidizer passage. The liquid fuel will then react with the oxidizer that enters the manifold during the next firing and may produce a localized high pressure reaction or explosion within the confines of the oxidizer injector manifold. The typical ZOT scenario was considered during this failure investigation, but was ultimately ruled out as a cause of the explosion. Converse to the typical ZOT failure mechanism, the failure of this particular thruster was determined to be the result of liquid oxidizer being present within the fuel manifold.

Durning, Joseph G., III↗

NASA NTRS2011

Failure Assessment Diagram for Brazed 304 Stainless Steel Joints

Interaction equations were proposed earlier to predict failure in Albemet 162 brazed joints. Present study demonstrates that the same interaction equations can be used for lower bound estimate of the failure criterion in 304 stainless steel joints brazed with silver-based filler metals as well as for construction of the Failure Assessment Diagrams (FAD).

Flom, Yory↗

NASA NTRS2011

ISS Solar Array Alpha Rotary Joint (SARJ) Bearing Failure and Recovery: Technical and Project Management Lessons Learned

The photovoltaic solar panels on the International Space Station (ISS) track the Sun through continuous rotating motion enabled by large bearings on the main truss called solar array alpha rotary joints (SARJs). In late 2007, shortly after installation, the starboard SARJ had become hard to turn and had to be shut down after exceeding drive current safety limits. The port SARJ, of the same design, had been working well for over 2 years. An exhaustive failure investigation ensued that included multiple extravehicular activities to collect information and samples for engineering forensics, detailed structural and thermal analyses, and a careful review of the build records. The ultimate root cause was determined to be kinematic design vulnerability coupled with inadequate lubrication, and manufacturing flaws; this was corroborated through ground tests, metallurgical studies, and modeling. A highly successful recovery plan was developed and implemented that included replacing worn and damaged components in orbit and applying space-compatible grease to improve lubrication. Beyond the technical aspects, however, lie several key programmatic lessons learned. These lessons, such as running ground tests to intentional failure to experimentally verify failure modes, are reviewed and discussed so they can be applied to future projects to avoid such problems.

DellaCorte, Christopher↗

NASA NTRS2011

Handling Qualities of Model Reference Adaptive Controllers with Varying Complexity for Pitch-Roll Coupled Failures

Three model reference adaptive controllers (MRAC) with varying levels of complexity were evaluated on a high performance jet aircraft and compared along with a baseline nonlinear dynamic inversion controller. The handling qualities and performance of the controllers were examined during failure conditions that induce coupling between the pitch and roll axes. Results from flight tests showed with a roll to pitch input coupling failure, the handling qualities went from Level 2 with the baseline controller to Level 1 with the most complex MRAC tested. A failure scenario with the left stabilator frozen also showed improvement with the MRAC. Improvement in performance and handling qualities was generally seen as complexity was incrementally added; however, added complexity usually corresponds to increased verification and validation effort required for certification. The tradeoff between complexity and performance is thus important to a controls system designer when implementing an adaptive controller on an aircraft. This paper investigates this relation through flight testing of several controllers of vary complexity.

Schaefer, Jacob↗

NASA NTRS2011

Failure Assessment Diagram for Titanium Brazed Joints

The interaction equation was used to predict failure in Ti-4V-6Al joints brazed with Al 1100 filler metal. The joints used in this study were geometrically similar to the joints in the brazed beryllium metering structure considered for the ATLAS telescope. This study confirmed that the interaction equation R(sub sigma) + R(sub Tau) = 1, where R(sub sigma) and R(sub Tau)are normal and shear stress ratios, can be used as conservative lower bound estimate of the failure criterion in ATLAS brazed joints as well as for construction of the Failure Assessment Diagram (FAD).

Flom, Yury↗

NASA NTRS2012

Bounding the Failure Probability Range of Polynomial Systems Subject to P-box Uncertainties

This paper proposes a reliability analysis framework for systems subject to multiple design requirements that depend polynomially on the uncertainty. Uncertainty is prescribed by probability boxes, also known as p-boxes, whose distribution functions have free or fixed functional forms. An approach based on the Bernstein expansion of polynomials and optimization is proposed. In particular, we search for the elements of a multi-dimensional p-box that minimize (i.e., the best-case) and maximize (i.e., the worst-case) the probability of inner and outer bounding sets of the failure domain. This technique yields intervals that bound the range of failure probabilities. The offset between this bounding interval and the actual failure probability range can be made arbitrarily tight with additional computational effort.

Crespo, Luis G.↗

NASA NTRS2012

Failure Mode Analysis of V-Shaped Pyrotechnically Actuated Valves

Current V-shaped stainless steel pyrovalve initiators have rectified many of the deficiencies of the heritage Y-shaped aluminum design. However, a credible failure mode still exists for dual simultaneous initiator (NSI) firings in which low temperatures were detected at the booster cap and less consistent ignition was observed than when a single initiator was fired. In order to asses this issue, a numerical framework has been developed for predicting the flow through pyrotechnically actuated valves. This framework includes a fully coupled solution of the gas-phase equation with a non-equilibrium dispersed phase for solid particles as well as the capability to model conjugate gradient heat transfer to the booster cap. Through a hierarchy of increasingly complex simulations, a hypothesis for the failure mode of the nearly simultaneous dual NSI firings has been proven. The simulations indicate that the failure mode for simultaneous dual NSI firings may be caused by flow interactions between the flame channels. The shock waves from each initiator interact in the booster cavity resulting in a high pressure that prevents the gas and particulate velocity from rising in the booster cap region. This impedes the bulk of the particulate phase from impacting the booster cap and reduces the heat transfer to the booster cap since the particles do not impact it. Heat transfer calculations to the solid metal indicate that gas-phase convective heat transfer may not be adequate by itself and that energy transfer from the particulate phase may be crucial for the booster cap burn through.

Sachdev, Jai S.↗