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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 91 records · Page 5

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NASA NTRS1985

Thermal barrier coating life prediction model development

A methodology was established to predict thermal barrier coating life in an environment simulative of that experienced by gas turbine airfoils. Specifically, work is being conducted to determine failure modes of thermal barrier coatings in the aircraft engine environment. Analytical studies coupled with appropriate physical and mechanical property determinations are being employed to derive coating life prediction model(s) on the important failure mode(s). An initial review of experimental and flight service components indicates that the predominant mode of TBC failure involves thermomechanical spallation of the ceramic coating layer. This ceramic spallation involves the formation of a dominant crack in the ceramic coating parallel to and closely adjacent to the metal-ceramic interface. Initial results from a laboratory test program designed to study the influence of various driving forces such as temperature, thermal cycle frequency, environment, and coating thickness, on ceramic coating spalling life suggest that bond coat oxidation damage at the metal-ceramic interface contributes significantly to thermomechanical cracking in the ceramic layer. Low cycle rate furnace testing in air and in argon clearly shows a dramatic increase of spalling life in the non-oxidizing environments.

Sheffler, K. D.↗

NASA NTRS1959

Performance of Two Boron-Modified S-816 Alloys in a Turbojet Engine Operated at 1650 F

S-816+B and modified S-816+B cast cobalt-base alloys were evaluated as turbine-bucket materials at 16500 F. Stress-rupture and tensile data obtained from these alloys had indicated satisfactory strength for engine operation at 1650 F. Although both alloys exhibited a limited ductility in room-temperature laboratory impact tests, there was a significant increase in impact resistance in the 1650 F tests. Bucket failures began after 10 hours of engine testing and continued at various intervals during the 107.5-hour test. Bucket lives were short relative to the predicted lives based on stress-rupture considerations (280 hr for S-816+B and 1750 hr for modified S-816+B). No significant difference was apparent in the performance of the two alloy groups. The primary cause of bucket failures in both alloys was mechanical fatigue. Impact damage occurred as a direct result of bucket tip fatigue failures and was a secondary cause of bucket failures. The impact of small pieces of fractured bucket tips on surrounding buckets caused a relatively large amount of impact damage to buckets of both alloys. The amount of impact damage from induced fractures at the bucket midspan, which provided relatively large failed fragments, was no greater than that which occurred as a result of tip failures.

Waters, William J.↗

NASA NTRS2008

Algorithms for Spectral Decomposition with Applications to Optical Plume Anomaly Detection

The analysis of spectral signals for features that represent physical phenomenon is ubiquitous in the science and engineering communities. There are two main approaches that can be taken to extract relevant features from these high-dimensional data streams. The first set of approaches relies on extracting features using a physics-based paradigm where the underlying physical mechanism that generates the spectra is used to infer the most important features in the data stream. We focus on a complementary methodology that uses a data-driven technique that is informed by the underlying physics but also has the ability to adapt to unmodeled system attributes and dynamics. We discuss the following four algorithms: Spectral Decomposition Algorithm (SDA), Non-Negative Matrix Factorization (NMF), Independent Component Analysis (ICA) and Principal Components Analysis (PCA) and compare their performance on a spectral emulator which we use to generate artificial data with known statistical properties. This spectral emulator mimics the real-world phenomena arising from the plume of the space shuttle main engine and can be used to validate the results that arise from various spectral decomposition algorithms and is very useful for situations where real-world systems have very low probabilities of fault or failure. Our results indicate that methods like SDA and NMF provide a straightforward way of incorporating prior physical knowledge while NMF with a tuning mechanism can give superior performance on some tests. We demonstrate these algorithms to detect potential system-health issues on data from a spectral emulator with tunable health parameters.

Srivastava, Askok N.↗

NASA NTRS2006

Analysis of Aircraft Control Performance using a Fuzzy Rule Base Representation of the Cooper-Harper Aircraft Handling Quality Rating

The Cooper-Harper rating of Aircraft Handling Qualities has been adopted as a standard for measuring the performance of aircraft since it was introduced in 1966. Aircraft performance, ability to control the aircraft, and the degree of pilot compensation needed are three major key factors used in deciding the aircraft handling qualities in the Cooper- Harper rating. We formulate the Cooper-Harper rating scheme as a fuzzy rule-based system and use it to analyze the effectiveness of the aircraft controller. The automatic estimate of the system-level handling quality provides valuable up-to-date information for diagnostics and vehicle health management. Analyzing the performance of a controller requires a set of concise design requirements and performance criteria. Ir, the case of control systems fm a piloted aircraft, generally applicable quantitative design criteria are difficult to obtain. The reason for this is that the ultimate evaluation of a human-operated control system is necessarily subjective and, with aircraft, the pilot evaluates the aircraft in different ways depending on the type of the aircraft and the phase of flight. In most aerospace applications (e.g., for flight control systems), performance assessment is carried out in terms of handling qualities. Handling qualities may be defined as those dynamic and static properties of a vehicle that permit the pilot to fully exploit its performance in a variety of missions and roles. Traditionally, handling quality is measured using the Cooper-Harper rating and done subjectively by the human pilot. In this work, we have formulated the rules of the Cooper-Harper rating scheme as fuzzy rules with performance, control, and compensation as the antecedents, and pilot rating as the consequent. Appropriate direct measurements on the controller are related to the fuzzy Cooper-Harper rating system: a stability measurement like the rate of change of the cost function can be used as an indicator if the aircraft is under control; the tracking error is a good measurement for performance needed in the rating scheme. Finally, the change of the control amount or the output of a confidence tool, which has been developed by the authors, can be used as an indication of pilot compensation. We use a number of known aircraft flight scenarios with known pilot ratings to calibrate our fuzzy membership functions. These include normal flight conditions and situations in which partial or complete failure of tail, aileron, engine, or throttle occurs.

Tseng, Chris↗

NASA NTRS1977

Failure detection and correction for turbofan engines

In this paper, a failure detection and correction strategy for turbofan engines is discussed. This strategy allows continuing control of the engines in the event of a sensor failure. An extended Kalman filter is used to provide the best estimate of the state of the engine based on currently available sensor outputs. Should a sensor failure occur the control is based on the best estimate rather than the sensor output. The extended Kalman filter consists of essentially two parts, a nonlinear model of the engine and up-date logic which causes the model to track the actual engine. Details on the model and up-date logic are presented. To allow implementation, approximations are made to the feedback gain matrix which result in a single feedback matrix which is suitable for use over the entire flight envelope. The effect of these approximations on stability and response is discussed. Results from a detailed nonlinear simulation indicate that good control can be maintained even under multiple failures.

Corley, R. C.↗

NASA NTRS2000

U.S. Civil Rotorcraft Accidents, 1963 Through 1997

Narrative summary data produced by the U.S. National Transportation Safety Board (NTSB) has been obtained and analyzed for all 8,436 U.S. civil registered rotorcraft accidents which occurred from mid-1963 through 1997. This analysis was based on the NTSB's assignment of each mishap into one of 21 "first event" categories. The number of U.S. civil registered rotorcraft as recorded by the Federal Aviation Administration (FAA) for the same period has also been obtained. Taken together, these data indicate the civil rotorcraft accident rate (on a per 1,000 registered rotorcraft basis) has decreased by almost a factor of 10 (i.e., from 130 accidents per 1,000 rotorcraft in 1964 to 13.4 per 1,000 in 1997). Analysis of the mishap data indicates over 70% of the rotorcraft accidents were associated with one of the following four NTSB "first event" categories: 2408 Loss of engine power (28.5%); 1,322 In-flight collisions with objects (15.7%); 1,114 Loss of control (13.2%); 1,083 Airframe/component/system failure or malfunction (12.8%).

Harris, Franklin D.↗

NASA NTRS2012

Mars Science Laboratory Rover Integrated Pump Assembly Bellows Jamming Failure

The Mars Science Laboratory rover and spacecraft utilize two mechanically pumped fluid loops for heat transfer to and from the internal electronics assemblies and the Radioisotope Thermo-Electric Generator (RTG). The heat transfer fluid is Freon R-11 (CFC-11) which has a large coefficient of thermal expansion. The Freon within the heat transfer system must have a volume for safe expansion of the fluid as the system temperature rises. The device used for this function is a gas-over-liquid accumulator. The accumulator uses a metal bellows to separate the fluid and gas sections. During expansion and contraction of the fluid in the system, the bellows extends and retracts to provide the needed volume change. During final testing of a spare unit, the bellows would not extend the full distance required to provide the needed expansion volume. Increasing the fluid pressure did not loosen the jammed bellows either. No amount of stroking the bellows back and forth would get it to pass the jamming point. This type of failure, if it occurred during flight, would result in significant overpressure of the heat transfer system leading to a burst failure at some point in the system piping. A loss of the Freon fluid would soon result in a loss of the mission. The determination of the source of the jamming of the bellows was quite elusive, leading to an extensive series of tests and analyses. The testing and analyses did indicate the root cause of the failure, qualitatively. The results did not provide a set of dimensional limits for the existing hardware design that would guarantee proper operation of the accumulator. In the end, a new design was developed that relied on good engineering judgment combined with the test results to select a reliable enough solution that still met other physical constraints of the hardware, the schedule, and the rover system.

bellows↗

NASA NTRS1990

Simulated fault injection - A methodology to evaluate fault tolerant microprocessor architectures

A simulation-based fault-injection method for validating fault-tolerant microprocessor architectures is described. The approach uses mixed-mode simulation (electrical/logic analysis), and injects transient errors in run-time to assess the resulting fault impact. As an example, a fault-tolerant architecture which models the digital aspects of a dual-channel real-time jet-engine controller is used. The level of effectiveness of the dual configuration with respect to single and multiple transients is measured. The results indicate 100 percent coverage of single transients. Approximately 12 percent of the multiple transients affect both channels; none result in controller failure since two additional levels of redundancy exist.

Choi, Gwan S.↗

NASA NTRS2010

JANNAF Lessons Learned Panel Discussion

The difference between the AS-510 observed and predicted separation distance is attributed to a greater F-1 engine "tail off" impulse than that used in the separation distance prediction. . The F-1 thrust decay was normal and not appreciably different from previous (AS-505 through 509) flights. . Analysis indicates that with an S-IC stage having only four retro motors, failure of one retro motor to ignite would result in marginal separation distances and, in the 3-sigma case, re-contact of the two stages. . S-IC-11 and subsequent flight stages were equipped with eight retro motors rather than the planned four.

Richards, Steve↗

NASA NTRS1996

Pilot-in-the-Loop Analysis of Propulsive-Only Flight Control Systems

Longitudinal control system architectures are presented which directly couple flight stick motions to throttle commands for a multi-engine aircraft. This coupling enables positive attitude control with complete failure of the flight control system. The architectures chosen vary from simple feedback gains to classical lead-lag compensators with and without prefilters. Each architecture is reviewed for its appropriateness for piloted flight. The control systems are then analyzed with pilot-in-the-loop metrics related to bandwidth required for landing. Results indicate that current and proposed bandwidth requirements should be modified for throttles only flight control. Pilot ratings consistently showed better ratings than predicted by analysis. Recommendations are made for more robust design and implementation. The use of Quantitative Feedback Theory for compensator design is discussed. Although simple and effective augmented control can be achieved in a wide variety of failed configurations, a few configuration characteristics are dominant for pilot-in-the-loop control. These characteristics will be tested in a simulator study involving failed flight controls for a multi-engine aircraft.

Chou, Hwei-Lan↗

NASA NTRS2020

A Method and Model to Predict Initial Failure Rates

It has long been well known that actual system reliability typically falls well short of early estimates. Failure rates are often ten or more times higher than anticipated. Many reasons have been given for this, but over-optimism is the fundamental cause of too-favorable reliability predictions. Most forecasts of reliability are essentially best-case scenarios, as are predictions of budget and schedule. Confident engineers assemble estimates bottom-up, including the known factors and ignoring problems that they hope won’t happen. Traditional reliability estimation is based on simply summing up the component failure rates. This ignores most actual failure causes. The way to reduce over-optimism is to use the historical system level failure rate from similar projects. Adjustments should not be made based purely on engineering judgment, but only if there is so logical quantitative justification. The traditional component-based reliability estimate is useful as a lower bound on the system failure rate. The difference between this lower bound component-based reliability and the historical system level reliability indicates how much of the total failure rate is due to system level problems rather than component failures.

Jones, Harry W.↗

NASA NTRS2020

A Method and Model to Predict Initial Failure Rates

It has long been well known that actual system reliability typically falls well short of early estimates. Failure rates are often ten or more times higher than anticipated. Many reasons have been given for this, but over-optimism is the fundamental cause of too-favorable reliability predictions. Most forecasts of reliability are essentially best-case scenarios, as are predictions of budget and schedule. Confident engineers assemble estimates bottom-up, including the known factors and ignoring problems that they hope won't happen. Traditional reliability estimation is based on simply summing up the component failure rates. This ignores most actual failure causes. The way to reduce over-optimism is to use the historical system level failure rate from similar projects. Adjustments should not be made based purely on engineering judgment, but only if there is so logical quantitative justification. The traditional component-based reliability estimate is useful as a lower bound on the system failure rate. The difference between this lower bound component-based reliability and the historical system level reliability indicates how much of the total failure rate is due to system level problems rather than component failures

Jones, Harry W.↗

NASA NTRS1992

Viscoplastic analysis of an experimental cylindrical thrust chamber liner

A viscoplastic stress-strain analysis of an experimental cylindrical thrust chamber is presented. A viscoelastic constitutive model incorporating a single internal state variable that represents kinematic hardening was employed to investigate whether such a viscoplastic model could predict the experimentally observed behavior of the thrust chamber. Two types of loading cycles were considered: a short cycle of 3.5-s duration that corresponded to the experiments, and an extended loading cycle of 485.1 s duration that is typical of the Space Shuttle Main Engine (SSME) operating cycle. The analysis qualitatively replicated the deformation behavior of the component as observed in experiments designed to simulate SSME operating conditions. The analysis also showed that the mode and location of failure in the component may depend on the loading cycle. The results indicate that using viscoplastic models for structural analysis can lead to a more realistic life assessment of thrust chambers.

Arya, Vinod K.↗

NASA NTRSDate not supplied

Applying the System Complexity Metric (SCM)

A fundamental cause of difficulty in larger engineering projects is their inherent complexity. An impression of complexity occurs if a system is simply difficult to understand, so that there is no obvious mental model that correctly predicts its behavior. Higher complexity is usually associated with higher cost and higher failure rate. Complexity is indicated by a system having more and diverse components, multiple interactions and feedback loops, transients and dynamic behavior, and often the emergence of unanticipated failure modes. Identifying and removing these signs of complexity should reduce complexity and improve performance. Here we limit complexity measurement to the number of components and their interactions. A System Complexity Metric (SCM) is defined as equal to the sum of the number of parts in a system, N, plus the sum of the one-way interconnections between them, I. SCM = N + I. The SCM is easily determined by direct inspection of system block diagrams. Previous work found that life support system cost was directly proportional to SCM and that failure rate increased faster than SCM squared. SCM can be used to compare systems or to guide their redesign to reduce cost and failure rate. Carbon dioxide removal systems will be analyzed using SCM, cost, and failure rate.

Harry W Jones↗

NASA NTRS1976

Improved impact-resistant boron/aluminum composites for use as turbine engine fan blades

Thin-sheet Charpy and Izod impact tests and standard full-size Charpy impact tests were conducted on unidirectional and angleply composites containing 4, 5.6 and 8 mil boron in 1100, 2024, 5052 and 6061 Al matrices. Impact failure modes of B/Al are proposed to describe the mechanisms involved and to provide insight for maximizing impact resistance. The impact strength of B/Al was significantly increased by proper selection of materials and processing. The use of more ductile matrices and larger diameter boron fibers gave the highest impact strengths by allowing matrix shear deformation and multiple fiber breakage. Pendulum impact test results of improved B/Al were higher than notched titanium and indicate sufficient foreign object damage protection to warrant consideration of B/Al for application to fan blades in aircraft gas turbine engines.

Mcdanels, D. L.↗

NASA NTRS2023

X-57 Cockpit Interface Control Document (ICD-CEPT-006)

The Cockpit Interface Control Document defines the hardware interfaces between the X-57 cockpit and subsystems. It provides locational and operational information in support of ground and flight operations with details on controls and displays that include Modes of Operation, Start-Up and Shut- Down Sequence diagrams and captures the current state of the MOD II Avionics Power Architecture. There is also preliminary information of the MOD III and MOD IV configurations. Microsoft PowerPoint was chosen for the document as early development required frequent meetings with multiple customers including aircraft operators (pilots), ground operations, support contractors and power, instrumentation, and human systems integration engineers and PowerPoint enabled presentations that could be quickly modified based on customer and developer interaction. One of the driving requirements for the cockpit design was to keep the left side panel as close the stock Tecnam panel as possible to reduce the failure risk of flight critical indicators. The original annunciator panel in the left side panel was modified to alert the pilot to failures in critical X-57 subsystems and an operator audio alert capability was added for these subsystems. Power-Up switches for the aircraft low voltage 13.8 VDC systems are located at the bottom of the left side panel and center panel, the same location as the stock Tecnam 13.8 VDC switches. The switches for energizing the high voltage system were located in the overhead panel to reduce the risk of inadvertently energizing the high voltage system during the low voltage power-up sequence. The Cruise Motor ARM switches were also located in the overhead panel and correspond to the same location as the stock Tecnam ignition switches. The stock Tecnam throttle levers and prop pitch levers were retained for the X-57. The throttle levers were renamed torque levers since they controlled the commanded torque to the cruise motors. The prop pitch levers provide a commanded RPM signal to an electronic prop pitch controller. X-57 specific displays, located in the right-side panel, are driven by dedicated sensors that monitor right and left side cruise motor RPM, right and left high voltage “Traction Bus” A and B (voltage, current and power) and the Avionics Bus DC converters (A and B) voltage and current. An X-57 Multi-Function Display (MFD) located in the center panel displays CAN Bus parameters. CAN Bus architecture is not certified for flight so these displays could not be used for safety critical information but were designed to be used for test point information only.

Laura Kushner↗

NASA NTRS1974

Saving Skylab

Initial difficulties encountered with the launch and operational deployment of the Skylab vehicle are described in terms of early indications of hardware failures, ground-based efforts at diagnosing the nature and significance of damage, and organization of improvized means and procedures for repair operations. Attention is given to heating and power-supply problems stemming from the loss of a micrometeoroid shield and a solar cell array. Systems engineering problems arising from the necessity of achieving a compromise among thermal, electrical, and stabilization requirements are explained, and repair solutions and operations in space and on the ground are described in detail.-

Schneider, W. C.↗

NASA NTRS1990

A model for the Space Shuttle Main Engine High Pressure Oxidizer Turbopump shaft seal system

A model of the High Pressure Oxidizer Turbopump (HPOTP) shaft seal system on the Space Shuttle Main Engine (SSME) is described. The model predicts the fluid properties and flow rates throughout this system for a number of conditions simulating failed seals. The results agree well with qualitative expectations and redline values but cannot be verified with actual data due to the lack thereof. The results indicate that each failure mode results in a unique distribution of properties throughout the seal system and can therefore be individually identified given the proper instrumentation. Furthermore, the detection process can be built on the principle of qualitative reasoning without the use of exact fluid property values. A simplified implementation of the model which does not include the slinger/labyrinth seal combination has been developed and will be useful for inclusion in a real-time diagnostic system.

Paxson, Daniel E.↗