SEARCH · Search NASA

Results for “interface failure”

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.

SourceResearch connectionFrom yearThrough year

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 793 records · Page 44

All sources NASA NTRS DOE OSTI

DOE OSTI2015

High-dose neutron irradiation performance of dielectric mirrors

The study presents the high-dose behavior of dielectric mirrors specifically engineered for radiation-tolerance: alternating layers of Al 2 O 3 /SiO 2 and HfO 2 /SiO 2 were grown on sapphire substrates and exposed to neutron doses of 1 and 4 dpa at 458 10K in the High Flux Isotope Reactor (HFIR). In comparison to previously reported results, these higher doses of 1 and 4 dpa results in a drastic drop in optical reflectance, caused by a failure of the multilayer coating. HfO 2 /SiO 2 mirrors failed completely when exposed to 1 dpa, whereas the reflectance of Al 2 O 3 /SiO 2 mirrors reduced to 44%, eventually failing at 4 dpa. Transmission electron microscopy (TEM) observation of the Al 2 O 3 /SiO 2 specimens showed SiO 2 layer defects which increases size with irradiation dose. The typical size of each defect was 8 nm in 1 dpa and 42 nm in 4 dpa specimens. Buckling type delamination of the interface between the substrate and first layer was typically observed in both 1 and 4 dpa HfO 2 /SiO 2 specimens. Composition changes across the layers were measured in high resolution scanning-TEM mode using energy dispersive spectroscopy. A significant interdiffusion between the film layers was observed in Al 2 O 3 /SiO 2 mirror, though less evident in HfO 2 /SiO 2 system. Lastly, the ultimate goal of this work is the provide insight into the radiation-induced failure mechanisms of these mirrors.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

NASA NTRS1972

Auxiliary engine digital interface unit (DIU)

This auxiliary propulsion engine digital unit controls both the valving of the fuel and oxidizer to the engine combustion chamber and the ignition spark required for timely and efficient engine burns. In addition to this basic function, the unit is designed to manage it's own redundancy such that it is still operational after two hard circuit failures. It communicates to the data bus system several selected information points relating to the operational status of the electronics as well as the engine fuel and burning processes.

Source record↗

NASA NTRS1983

Investigation of accelerated stress factors and failure/degradation mechanisms in terrestrial solar cells

Results of an ongoing research program into the reliability of terrestrial solar cells are presented. Laboratory accelerated testing procedures are used to identify failure/degradation modes which are then related to basic physical, chemical, and metallurgical phenomena. In the most recent tests, ten different types of production cells, both with and without encapsulation, from eight different manufacturers were subjected to a variety of accelerated tests. Results indicated the presence of a number of hitherto undetected failure mechanisms, including Schottky barrier formation at back contacts and loss of adhesion of grid metallization. The mechanism of Schottky barrier formation is explained by hydrogen, formed by the dissociation of water molecules at the contact surface, diffusing to the metal semiconductor interface. This same mechanism accounts for the surprising increase in sensitivity to accelerated stress conditions that was observed in some cells when encapsulated.

Lathrop, J. W.↗

NASA NTRS1986

Crystalline-silicon photovoltaics summary module design and reliability

The evolution of the design and reliability of solar modules was described. Design requirements involved 14 different considerations, including residential building and material electrical codes, wind-loading, hail impact, operating temperature levels, module flammability, and interfaces for both the array structure and the operation of the system. Reliability research involved in diverse investigations including glass-fracture strength, soiling levels, electrochemical corrosion, and bypass-diode qualification tests. Based on these internationally recognized studies, performance assessments, and failure analyses, the Flat-plate Solar Array Project in its 11-year duration served to nuture the development of 45 different solar module designs from 15 PV manufacturers.

Ross, R. G., Jr.↗

NASA NTRS1985

Integrated Application of Active Controls (IAAC) technology to an advanced subsonic transport project: Test act system validation

The primary objective of the Test Active Control Technology (ACT) System laboratory tests was to verify and validate the system concept, hardware, and software. The initial lab tests were open loop hardware tests of the Test ACT System as designed and built. During the course of the testing, minor problems were uncovered and corrected. Major software tests were run. The initial software testing was also open loop. These tests examined pitch control laws, wing load alleviation, signal selection/fault detection (SSFD), and output management. The Test ACT System was modified to interface with the direct drive valve (DDV) modules. The initial testing identified problem areas with DDV nonlinearities, valve friction induced limit cycling, DDV control loop instability, and channel command mismatch. The other DDV issue investigated was the ability to detect and isolate failures. Some simple schemes for failure detection were tested but were not completely satisfactory. The Test ACT System architecture continues to appear promising for ACT/FBW applications in systems that must be immune to worst case generic digital faults, and be able to tolerate two sequential nongeneric faults with no reduction in performance. The challenge in such an implementation would be to keep the analog element sufficiently simple to achieve the necessary reliability.

Source record↗

NASA NTRS1987

Tensile behavior of glass/ceramic composite materials at elevated temperatures

This paper describes the tensile behavior of high-temperature composite materials containing continuous Nicalon ceramic fiber reinforcement and glass and glass/ceramic matrices. The longitudinal properties of these materials can approach theoretical expectations for brittle matrix composites, failing at a strength and ultimate strain level consistent with those of the fibers. The brittle, high-modulus matrices result in a nonlinear stress-strain curve due to the onset of stable matrix cracking at 10 to 30 percent of the fiber strain to failure, and at strains below this range in off-axis plies. Current fibers and matrices can provide attractive properties well above 1000 C, but composites experience embrittlement in oxidizing atmospheres at 800 to 1000 C due to oxidation of a carbon interface reaction layer.The oxidation effect greatly increases the interface bond strength, causing composite embrittlement.

Mandell, J. F.↗

NASA NTRS1989

REDEX: The ranging equipment diagnostic expert system

REDEX, an advanced prototype expert system that diagnoses hardware failures in the Ranging Equipment (RE) at NASA's Ground Network tracking stations is described. REDEX will help the RE technician identify faulty circuit cards or modules that must be replaced, and thereby reduce troubleshooting time. It features a highly graphical user interface that uses color block diagrams and layout diagrams to illustrate the location of a fault. A semantic network knowledge representation technique was used to model the design structure of the RE. A catalog of generic troubleshooting rules was compiled to represent heuristics that are applied in diagnosing electronic equipment. Specific troubleshooting rules were identified to represent additional diagnostic knowledge that is unique to the RE. Over 50 generic and 250 specific troubleshooting rules have been derived. REDEX is implemented in Prolog on an IBM PC AT-compatible workstation. Block diagram graphics displays are color-coded to identify signals that have been monitored or inferred to have nominal values, signals that are out of tolerance, and circuit cards and functions that are diagnosed as faulty. A hypertext-like scheme is used to allow the user to easily navigate through the space of diagrams and tables. Over 50 graphic and tabular displays have been implemented. REDEX is currently being evaluated in a stand-alone mode using simulated RE fault scenarios. It will soon be interfaced to the RE and tested in an online environment. When completed and fielded, REDEX will be a concrete example of the application of expert systems technology to the problem of improving performance and reducing the lifecycle costs of operating NASA's communications networks in the 1990's.

Luczak, Edward C.↗

NASA NTRS1989

REDEX - The ranging equipment diagnostic expert system

Luczak, Edward C.↗

NASA NTRS1991

Programs For Modeling Fault-Tolerant Computing Systems

Pade Approximation with Scaling, (PAWS) and Scaling Taylor Exponential Matrix (STEM) computer programs are software tools for design and validation. Provide flexible, user-friendly, language-based interface for input of Markov mathematical methods describing behaviors of fault-tolerant computer systems. Markov models include both recovery from faults via reconfiguration and behaviors of such systems when faults occur. PAWS and STEM produce exact solutions of probability of system failure and provide conservative estimate of number of significant digits in solution. Written in PASCAL and FORTRAN.

Butler, Ricky W.↗

NASA NTRS1992

Free-edge stress analysis of glass-epoxy laminates with matrix cracks

The effect of matrix cracks on the composite delamination and interlaminar stresses is investigated in (+15/90n/-15)s glass-epoxy laminates (with values of n equal to 0, 1, 2, or 3) subjected to monotonically increasing tension loads. Three-dimensional (3D) and quasi-3D (Q3D) finite-element analyses are used to model the free-edge stress states in the laminates with and without a matrix crack, respectively. The Q3D results show that in-plane transverse tensile stresses exist in the +15 deg plies near the free edges of all of the laminates used and that only the interlaminar shear stress is high at the +15/theta interface. The results of 3D analysis indicate that large tensile interlaminar normal as well as shear stresses develop at the intersection of the matrix crack and the free edge. This suggests that the interlaminar normal stress plays a significant role in the failure of these laminates.

Fish, John C.↗

NASA NTRS2004

Transient Region Coverage in the Propulsion IVHM Technology Experiment

Over the last several years researchers at NASA Glenn and Ames Research Centers have developed a real-time fault detection and isolation system for propulsion subsystems of future space vehicles. The Propulsion IVHM Technology Experiment (PITEX), as it is called follows the model-based diagnostic methodology and employs Livingstone, developed at NASA Ames, as its reasoning engine. The system has been tested on,flight-like hardware through a series of nominal and fault scenarios. These scenarios have been developed using a highly detailed simulation of the X-34 flight demonstrator main propulsion system and include realistic failures involving valves, regulators, microswitches, and sensors. This paper focuses on one of the recent research and development efforts under PITEX - to provide more complete transient region coverage. It describes the development of the transient monitors, the corresponding modeling methodology, and the interface software responsible for coordinating the flow of information between the quantitative monitors and the qualitative, discrete representation Livingstone.

Balaban, Edward↗

NASA NTRS2005

Prediction of Fretting Crack Location and Orientation in a Single Crystal Nickel Alloy

Fretting is a structural damage mechanism arising between two nominally clamped surfaces subjected to an oscillatory loading. A critical location for fretting induced damage has been identified at the blade/disk and blade/damper interfaces of gas turbine engine turbomachinery and space propulsion components. The high- temperature, high-frequency loading environment seen by these components lead to severe stress gradients at the edge-of-contact that could potentially foster crack growth leading to component failure. These contact stresses drive crack nucleation in fretting and are very sensitive to the geometry of the contacting bodies, the contact loads, materials, temperature, and contact surface tribology (friction). Recently, a high-frequency, high-temperature load frame has been designed for experimentally investigating fretting damage of single crystal nickel materials employed in aircraft and spacecraft turbomachinery. A modeling method for characterizing the fretting stresses of the spherical fretting contact stress behavior in this experiment is developed and described. The calculated fretting stresses for a series of experiments are then correlated to the observed fretting damage. Results show that knowledge of the normal stresses and resolved shear stresses on each crystal plane can aid in predicting crack locations and orientations.

Matlik, J. F.↗

NASA NTRS2007

EVA Hazards due to TPS Inspection and Repair

Tile inspection and repair activities have implicit hazards associated with them. When an Extra Vehicular Activities (EVA) crewmember and associated hardware are added into the equation, additional hazards are introduced. Potential hazards to the Extravehicular Mobility Unit (EMU), the Orbiter or the crew member themselves are created. In order to accurately assess the risk of performing a TPS inspection or repair, an accurate evaluation of potential hazards and how adequately these hazards are controlled is essential. The EMU could become damaged due to sharp edges, protrusions, thermal extremes, molten metal or impact with the Orbiter. Tools, tethers and the presence of a crew member in the vicinity of the Orbiter Thermal Protection System (TPS) pose hazards to the Orbiter. Hazards such as additional tile or Reinforced Carbon-Carbon (RCC) damage from a loose tool, safety tethers, crewmember or arm impact are introduced. Additionally, there are hazards to the crew which should be addressed. Crew hazards include laser injury, electrical shock, inability to return to the airlock for EMU failures or Orbiter rapid safing scenarios, as well as the potential inadvertent release of a crew member from the arm/boom. The aforementioned hazards are controlled in various ways. Generally, these controls are addressed operationally versus by design, as the majority of the interfaces are to the Orbiter and the Orbiter design did not originally account for tile repair. The Shuttle Remote Manipulator System (SRMS), for instance, was originally designed to deploy experiments, and therefore has insufficient design controls for retention of the Orbiter Boom Sensor System (OBSS). Although multiple methods to repair the Orbiter TPS exist, the majority of the hazards are applicable no matter which specific repair method is being performed. TPS Inspection performed via EVA also presents some of the same hazards. Therefore, the hazards common to all TPS inspection or repair methods will be addressed.

Stewart, Christine E.↗

DOE OSTI2021

Dissimilar joining of ZEK100 and AA6022 for automotive application

Mg and Al joining is problematic due to different high temperature flow characteristics that often results in weld defects and brittle intermetallic compounds (IMC). We present process development on lap joining of 1.27 mm 6022 (top sheet) and 1.5mm ZEK100 (bottom sheet) for an automotive door application. We conducted process development in linear welding using power control mode (modulating torque and spindle speed) with multiple tool designs, and welding parameters. Process variables were correlated to joint micro-structure and mechanical properties. A 2D computational model was created to understand the failure mechanism and contribution of mechanical interlocking towards joint strength. For a thin (< 2 mm) automotive sheet with softer material as a bottom sheet, adequate control of process variables is critical to maintain weld stability and avoid excessive IMC layer at the interface. A combination of mechanical anchoring and metallurgical reaction is likely responsible for bonding.

Das, Hrishikesh↗

DOE OSTI2021

Understanding the phase transformation mechanisms that affect the dynamic response of Fe-based microstructures at the atomic scales

Large-scale molecular dynamics (MD) simulations were carried out to investigate the shock-induced evolution of microstructure in Fe-based systems comprising single-crystal and layered Cu/Fe alloys with a distribution of interfaces. The shock compression of pure single-crystal Fe oriented along [110] above a threshold pressure results in a BCC (α)→HCP (ε) phase transformation behavior that generates a distribution of ε phase variants in the phase transformed region of the microstructure behind the shock front. The propagation of the release wave through a phase transformed ε phase causes a reverse ε→α phase transformation and renders a distribution of twins for the [110] oriented Fe that serve as void nucleation sites during spall failure. The simulations reveal that the α→ε→α transformation-induced twinning for shock loading along the [110] direction is due to a dominant ε phase variant formed during compression that rotates on the arrival of the release wave followed by a reverse phase transformation to twins in the α phase. The modifications in the evolution of the ε phase variants and twins in Fe behavior are also studied for Cu–Fe layered microstructures due to the shock wave interactions with the Cu/Fe interfaces using a newly constructed Cu–Fe alloy potential. Here, the MD simulations suggest that interfaces affect the observed variants during shock compression and, hence, distributions of twins during shock release that affects the void nucleation stresses in the Fe phase of Cu/Fe microstructures.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Additive manufacturing of sandwich panels with continuous fiber reinforced high modulus composite facings

Abstract An improved approach consisting of a combination of fiber placement and fused filament fabrication is introduced for the additive manufacture (AM) of structural grade sandwich beams. Here, sandwich beams are additively manufactured using in‐situ deposition and consolidation of continuous fiber unidirectional facings made from a commingled yarn system of e‐glass fiber (~50% vol.) and amorphous PET, and a hexagonal honeycomb core structure made from PETG. Both facings and the sandwich core are manufactured on a single machine, in one sequence (skin‐core‐skin), employing the benefit of matrix compatibility to create autohesion at the interfaces. Flexural and transverse shear rigidity are determined experimentally and compared with analytical predictions and show correlation to within 3%. Flexural strength and core shear strength are also measured. Post‐mortem examinations show that core fracture and core facing debond were the dominant failure mode in flexure. Single cantilever beam tests were performed to evaluate core facing debond toughness. Subsequently, surface preheat using infrared heaters was utilized to increase autohesion between core and facing. The results show debond toughness was increased 4 times using infrared heating. This research effort presents a manufacturing approach that has the potential for the AM of stiff, well bonded, structural grade sandwich beams, in an integrated sequence, employing in‐situ consolidation to the facings, without the need for the use of intermediate adhesives for skin‐to‐core bonding. Highlights An improved additive manufacturing technique for making sandwich panels is developed. Sandwich panel facings have fiber volume fractions of approximately 50%. Surface preheat improves core‐to‐facing debond toughness by a factor of 4. Top and bottom facings are consolidated during manufacture leading to better properties. Experimental results are compared to analytical predictions and show good correlation.

17 WIND ENERGY↗

DOE OSTI2019

A Reactive Element Approach to Improve Fracture Healing in Metallic Systems

Self-healing materials demonstrate the ability to close fractures and regain mechanical integrity after a catastrophic failure. However, self-healing in metals can be inhibited by the natural tendency for technologically-relevant metallic systems to oxidize on the crack surface. This study seeks to provide a thermodynamically-based mechanism to enhance healing capability at a solid/liquid interface through alloys designed with a reactive element alloying addition possessing a lower free energy of oxide formation than the parent element. In this study, model Sb-Cu and Sb-Zn systems enable comparisons between mechanistic behaviors based only on thermodynamic reactivity. Mechanical and microstructural investigation demonstrated that the more reactive alloying addition resulted in more effective bonding through increasing bond area and load-bearing capacity of the system. The improved bonding was attributed to improved wetting and reduction of the passivating surface oxide across an interface. The work has potential to advance self-healing capabilities in metallic systems through more appropriate alloy selection to enable improved healing.

36 MATERIALS SCIENCE↗

NASA NTRS1975

A study to define an in-flight dynamics measurement and data applications program for space shuttle payloads

Data measurement and interpretation techniques were defined for application to the first few space shuttle flights, so that the dynamic environment could be sufficiently well established to be used to reduce the cost of future payloads through more efficient design and environmental test techniques. It was concluded that: (1) initial payloads must be given comprehensive instrumentation coverage to obtain detailed definition of acoustics, vibration, and interface loads, (2) analytical models of selected initial payloads must be developed and verified by modal surveys and flight measurements, (3) acoustic tests should be performed on initial payloads to establish realistic test criteria for components and experiments in order to minimize unrealistic failures and retest requirements, (4) permanent data banks should be set up to establish statistical confidence in the data to be used, (5) a more unified design/test specification philosophy is needed, (6) additional work is needed to establish a practical testing technique for simulation of vehicle transients.

Rader, W. P.↗