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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 NTRS1991

Design for Validation

The use of computer hardware and software in life-critical applications, such as for civil air transports, demands the use of rigorous formal mathematical validation procedures. However, formal specification and verification will only be tractable if the system is designed in a manner that lends itself to formal methods. Likewise, accurate reliability analysis will only be tractable if the number of interacting components that must be individually included in a single reliability model is kept to a low number and if their failure behavior interactions can be modeled simply. Also, the system must be designed such that the system reliability does not directly depend on system parameters that cannot be accurately determined. This paper presents a design methodology based on the concept of designing a system in such a manner that it can be rigorously validated, or "design for validation."

Johnson, Sally C.↗

NASA NTRS2012

Damage Tolerance Assessment of Friction Pull Plug Welds in Two Aluminum Alloy Systems

A plug weld is a non-homogenous anisotropic material system. Local deformation and failure behavior not initially understood Pre-crack placement is non-straightforward

McGill, Preston↗

NASA NTRS2018

Cryogenic Fuel Valve Testbed Development

The goal for this project is to update the cryogenic valve testbed program in LabVIEW to schedule and automate tests and experiments. By using an automated system, tens or hundreds of tests may be performed. This will ensure that accurate data is being collected for testing of the remaining useful life and end of life predictions. From the data obtained, new diagnostic and prognostic methods will be developed to manage or predict potential leaks which may occur in the future. The Cryogenic valve testbed injects controlled faults into the cryogenic fuel valve system in order to accurately determine failure behavior.

Prognostics↗

NASA NTRSDate not supplied

Application of the NASA Multiscale Analysis Tool: Multiscale Integration and Interoperability

In order to demonstrate NASMAT’s multiscale operability, a series of illustrative examples will be presented that focus on the application of NASMAT to practical problems. First, the multiscale integration and data recursion is demonstrated by performing a multiscale analysis using only built-in micromechanics methods. NASMAT’s integration is then highlighted by running a multiscale analysis where an external finite element software calls NASMAT. In this case, at each integration point within the finite element model, a local NASMAT analysis is performed to account for failure behavior at the constituent scale. In a similar example, an external program is called from within NASMAT. This case would be relevant for a user wanting to implement an outside micromechanics technique. A combination of these examples is then presented to further illustrate the code’s flexibility when interfacing with outside codes in a multiscale framework. For all examples, data is presented using a custom-developed visualization tool. Additional potential use cases are also addressed. Finally, the plan for upcoming features and added capabilities is discussed.

NASMAT↗

NASA NTRS1975

An investigation of the failure and fracture behavior of graphite/epoxy laminates

A fundamental investigation of the fracture behavior of fiber reinforced composites is discussed. It is suggested that experimental and analytical investigations should compliment each other. Further, it is suggested that in order to understand and mathematically model composite fracture it is necessary to explore, understand and characterize the stress-strain behavior of each type of laminate tested from initial loading to incipient fracture. That is, it is not only necessary to perform fracture studies but it is necessary to perform stress-strain characterization and failure studies as well. For this reason a literature survey is presented in which these three elements are discussed. An experimental program to determine tensile properties of unnotched and notched unidirectional and multi-directional laminates composed of Hercules AS Fiber and 3501 Resin is described. Experimental unnotched moduli and strengths are presented, discussed and compared to lamination theory predictions. It is shown that rate effects are small and that lamination theory gives good results for moduli but not for strengths.

Brinson, H. F.↗

NASA NTRS1988

Fatigue damage mapping

Observations of fatigue crack nucleation and early growth are presented. The state of stress/strain was shown to play a significant role in this process. Early growth occurs on planes experiencing the largest range of shear strain (Mode 2) or normal strain (Mode 1) depending on the stress state, strain amplitude, and microstructure. These observations were summarized in a fatigue map for each material. These maps provide regions where one fatigue failure mode dominates the behavior. Each failure mechanism results in a different failure mode. Once the expected failure mode is identified, bulk deformation models based on the cyclic stresses and strains can be used to obtain reliable estimates of fatigue lives for complex loading situations.

Socie, Darrell↗

NASA NTRS2021

Architectural Modeling and Analysis for Safety Engineering

Model-based development tools are increasingly being used for system-level development of safety-critical systems. Architectural and behavioral models provide important information that can be leveraged to improve the system safety analysis process. Model-based design artifacts produced in early stage development activities can be used to perform system safety analysis, reducing costs and providing accurate results throughout the system life-cycle. In this report we describe an extension to the Architecture Analysis and Design Language (AADL) that supports modeling of system behavior under failure conditions. This Safety Annex enables the independent modeling of component failures and allows safety engineers to weave various types of fault behavior into the nominal system model. The accompanying tool support uses model checking to propagate errors from their source to their effect on safety properties without the need to add separate propagation specifications. The tool also captures all minimal set of fault combinations that can cause violation of the safety properties, that can be compared to qualitative and quantitative objectives as part of the safety assessment process. We describe the Safety Annex, illustrate its use with a representative example, and discuss and demonstrate the tool support enabling an analyst to investigate the system behavior under failure conditions.

FTA↗

NASA NTRS2000

A New Local Failure Model with Application to the Longitudinal Tensile Behavior of Continuously Reinforced Titanium Composites

A new model for local fiber failures in composite materials loaded longitudinally is presented. In developing the model, the goal was to account for the effects of fiber breakage on the global response of a composite in a relatively simple and efficient manner. Towards this end, the model includes the important feature of local stress unloading, even as global loading of the composite continues. The model has been incorporated into NASA Glenn's Micromechanics Analysis Code with Generalized Method of Cells (MAC/GMC) and was employed to simulate the longitudinal tensile deformation and failure behavior of several silicon carbide fiber/titanium matrix (SiC/Ti) composites. The model is shown to be quite realistic and capable of accurate predictions for various temperatures, fiber volume fractions, and fiber diameters. Further- more, the new model compares favorably to Curtin's (1993) effective fiber breakage model, which has also been incorporated into MAC/GMC.

Bednarcyk, Brett A.↗

NASA NTRS2017

Insights into the Behavior of Potential Structural Failures Originating from Localized High Stress Regions in Configurations Relevant to Solid Rocket Motor Nozzles

During the structural certification effort for the Space Launch System solid rocket booster nozzle, it was identified that no consistent method for addressing local negative margins of safety in non-metallic materials had been developed. Relevant areas included bond-line terminations and geometric features in the composite nozzle liners. In order to gain understanding, analog test specimens were designed that very closely mimic the conditions in the actual full scale hardware. Different locations in the nozzle were represented by different analog specimen designs. This paper describes those tests and corresponding results. Finite element analysis results for the tests are presented. Strain gage correlation of the analysis to the test results is addressed. Furthermore, finite fracture mechanics (a coupled stress and energy failure criterion) is utilized to predict the observed crack pop-in loads for the different configurations. The finite fracture mechanics predictions are found to be within a 10% error relative to the average measured pop-in load for each of four configurations. Initiation locations, arrest behaviors, and resistances to further post-arrest crack propagation are also discussed.

McCutcheon, David Matthew↗

NASA NTRS2017

High Speed Thermal Imaging on Ballistic Impact of Triaxially Braided Composites

Ballistic impact experiments were performed on triaxially braided polymer matrix composites to study the heat generated in the material due to projectile velocity and penetration damage. Quantifying the heat generation phenomenon is crucial for attaining a better understanding of composite behavior and failure under impact loading. The knowledge gained can also be used to improve physics-based models which can numerically simulate impact of composites. Triaxially braided (0/+60/-60) composite panels were manufactured with T700S standard modulus carbon fiber and two epoxy resins. The PR520 (toughened) and 3502 (untoughened) resin systems were used to make different panels to study the effects of resin properties on temperature rise. Ballistic impact tests were conducted on these composite panels using a gas gun, and different projectile velocities were applied to study the effect on the temperature results. Temperature contours were obtained from the rear surface of the panel during the test through a high speed, infrared (IR) thermal imaging system. The contours show that high temperatures were locally generated and more pronounced along the axial tows for the T700S/PR520 composite specimens; whereas, tests performed on T700S/3502 composite panels using similar impact velocities demonstrated a widespread area of lower temperature rises. Nondestructive, ultrasonic C-scan analyses were performed to observe and verify the failure patterns in the impacted panels. Overall, the impact experimentation showed temperatures exceeding 525 K (485degF) in both composites which is well above the respective glass transition temperatures for the polymer constituents. This expresses the need for further high strain rate testing and measurement of the temperature and deformation fields to fully understand the complex behavior and failure of the material in order to improve the confidence in designing aerospace components with these materials.

thermal imaging↗

NASA NTRS2017

Relationship Between Unusual High-Temperature Fatigue Crack Growth Threshold Behavior in Superalloys and Sudden Failure Mode Transitions

An investigation of high temperature cyclic fatigue crack growth (FCG) threshold behavior of two advanced nickel disk alloys was conducted. The focus of the study was the unusual crossover effect in the near-threshold region of these type of alloys where conditions which produce higher crack growth rates in the Paris regime, produce higher resistance to crack growth in the near threshold regime. It was shown that this crossover effect is associated with a sudden change in the fatigue failure mode from a predominant transgranular mode in the Paris regime to fully intergranular mode in the threshold fatigue crack growth region. This type of a sudden change in the fracture mechanisms has not been previously reported and is surprising considering that intergranular failure is typically associated with faster crack growth rates and not the slow FCG rates of the near-threshold regime. By characterizing this behavior as a function of test temperature, environment and cyclic frequency, it was determined that both the crossover effect and the onset of intergranular failure are caused by environmentally driven mechanisms which have not as yet been fully identified. A plausible explanation for the observed behavior is proposed.

Fatigue Crack Growth Thresholds; Grain boundary ox↗

NASA NTRS2017

Relationship Between Unusual High-Temperature Fatigue Crack Growth Threshold Behavior in Superalloys and Sudden Failure Mode Transitions

Fatigue Crack Growth Thresholds; Grain boundary ox↗

NASA NTRS1981

Mechanical characterization of PMR-15 graphite/polyimide bolted joints

Data are presented for the static and viscoelastic performance of Celion 6000/PMR-15 graphite/polyimide composite belted joints over the 21 to 315 C temperature range. Two laminate configurations were obtained by sectioning a panel into subpanels oriented parallel and perpendicular to the laminate principal direction. Three replicates of each specimen geometry were tested at each of the test temperatures for the two laminate configurations, and failure load was defined as the maximum load attained as indicated by the load/deflection curve. Effects of strain-rate on strength and failure mode behavior were assessed at room temperature for strain rates of 0.002, 0.01, 0.10, and 1.00/s, and creep behavior was examined for the case of bearing deformations at temperatures of 21 and 177 C. Results are presented, including: (1) two distinct mechanisms were responsible for bearing failure and related to laminate configuration, (2) the + or - 45 deg plies carried the shearing load in composite bolted joints, and (3) the material exhibited strain-rate sensitivity which varied with laminate configuration.

Wilson, D. W.↗

NASA NTRS2002

Modeling Composite Laminate Crushing for Crash Analysis

Crash modeling of composite structures remains limited in application and has not been effectively demonstrated as a predictive tool. While the global response of composite structures may be well modeled, when composite structures act as energy-absorbing members through direct laminate crushing the modeling accuracy is greatly reduced. The most efficient composite energy absorbing structures, in terms of energy absorbed per unit mass, are those that absorb energy through a complex progressive crushing response in which fiber and matrix fractures on a small scale dominate the behavior. Such failure modes simultaneously include delamination of plies, failure of the matrix to produce fiber bundles, and subsequent failure of fiber bundles either in bending or in shear. In addition, the response may include the significant action of friction, both internally (between delaminated plies or fiber bundles) or externally (between the laminate and the crushing surface). A figure shows the crushing damage observed in a fiberglass composite tube specimen, illustrating the complexity of the response. To achieve a finite element model of such complex behavior is an extremely challenging problem. A practical crushing model based on detailed modeling of the physical mechanisms of crushing behavior is not expected in the foreseeable future. The present research describes attempts to model composite crushing behavior using a novel hybrid modeling procedure. Experimental testing is done is support of the modeling efforts, and a test specimen is developed to provide data for validating laminate crushing models.

Fleming, David C.↗

NASA NTRS1945

Calculation of Centrally Loaded Thin-Walled Columns Above the Buckling Limit

When thin-walled columns formed from flanged sheet, such as used in airplane construction, are subjected to axial load, their behavior at failure varies according to the slenderness ratio. On long columns the axis deflects laterally while the cross section form is maintained; buckling results. The respective breaking load in the elastic range is computed by Euler's formula and for the plastic range by the Engesser- Karman formula. Its magnitude is essentially dependent upon the length. On intermediate length columns, especially where open sections are concerned, the cross section is distorted while the cross section form is preserved; twisting failure results. The buckling load in twisting is calculated according to Wagner and Kappus. On short columns the straight walls of low-bending resistance that form the column are deflected at the same time that the cross section form changes - buckling occurs without immediate failure. Then the buckling load of the total section computable from the buckling loads of the section walls is not the ultimate load; quite often, especially on thin-walled sections, it lies considerably higher and is secured by tests. Both loads, the buckling and the ultimate load are only in a small measure dependent upon length. The present report is an attempt to theoretically investigate the behavior of such short, thin-walled columns above the buckling load with the conventional calculating methods.

Reinitzhuber, F.↗

NASA NTRSDate not supplied

Thermomechanical Modeling of Woven Materials With Particle-Based, Explicit-Fiber Simulations

Fiber-based materials are extensively used to protect spacecraft during entry. Insulative fibers, often in a fiber network or woven, provide rigidity, strength, and control of material anisotropy and density. Woven thermal protection materials, such as ADEPT (Adaptable, Deployable Entry and Placement Technology), 3D-MAT (3-Dimensional Multifunctional Ablative Thermal Protection), and 3MDCP (3D Woven Mid-Density Carbon Phenolic), enable missions with stronger and denser materials for entry profiles with high shear and heat flux. Vulnerabilities to woven thermal protection materials include manufacturing-induced material property variation, and impact from micrometeoroids. Simulating woven materials under these conditions require models that can resolve hierarchal structures, thermomechanical behavior, and failure. To address this, we simulate weave thermal conduction and mechanical deformation. We simulate the full weave with a coarse-grained yarn model is presented. The model combines a validated, high-resolution single 3MDCP yarn model and phenolic resin model. Instead of modeling every fiber, each yarn ply with order 10, instead of order 1000, fibers. The discrete element bonded particle model (DEM-BPM) of fibers captures the thermal and mechanical behavior within and between fibers. We study the proportion of heat transfer and stress via the contact network, fiber bonds, and overall weave geometry.

bonded particle↗

NASA NTRSDate not supplied

Utilizing 3D-DIC on Mars 2020 Rover Wheel Assembly: Test-Analysis Correlation

Following the successful implementation of full-field photogrammetry, more specifically three-dimensional Digital Image Correlation (3D-DIC), on the Mars 2020 Heat Shield Structural Failure Review assessment, 3D-DIC was selected as one of the primary measurement techniques for the Mars 2020 Rover wheel assembly qualification test at the NASA Jet Propulsion Laboratory (JPL). To validate the Rover wheel landing loads simulations, it was extremely important to have high confidence in the wheel models. Due to the large deformations and strains that the wheel would be subject to during landing, traditional instrumentation such as linear variable displacement transducers (LVDTs), electrical-resistance strain gages and string potentiometers, would not be sufficient on their own to provide all the necessary validation data. Therefore, the NASA Engineering and Safety Center (NESC) provided the 3D-DIC expertise and support to measure the high deformation and strain in the wheel flexures and qualify the overall structural response of the Mars 2020 rover wheel assembly. There were two key objectives for the photogrammetry technique: (1) monitor the wheel response in real-time, guarding against anomalous behavior and failure, and (2) provide test data for test-analysis correlation to validate and/or improve the high-fidelity computational model. The contents of this paper will focus on the challenges of applying 3D-DIC to the Mars 2020 Rover wheel assembly and how these challenges were overcome. Examples of test-analysis correlation during the stiffness characterization and structural qualification will be presented and discussed in detail. Experimental results were compared with the analysis and showed excellent agreement between the predicted behavior and helped validate the high-fidelity models.

Mars 2020 Rover Wheel↗

NASA NTRS2014

Humidity Testing of PME and BME Ceramic Capacitors with Cracks

Cracks in ceramic capacitors are one of the major causes of failures during operation of electronic systems. Humidity testing has been successfully used for many years to verify the absence of cracks and assure quality of military grade capacitors. Traditionally, only precious metal electrode (PME) capacitors were used in high reliability applications and the existing requirements for humidity testing were developed for this type of parts. With the advance of base metal electrode (BME) capacitors, there is a need for assessment of the applicability of the existing techniques for the new technology capacitors. In this work, variety of different PME and BME capacitors with introduced cracks were tested in humid environments at different voltages and temperatures. Analysis of the test results indicates differences in the behavior and failure mechanisms for BME and PME capacitors and the need for different testing conditions.

reliability↗