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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
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

Application and Certification of Comparative Vacuum Monitoring Sensors for Structural Health Monitoring of 737 Wing Box Fittings

Multi-site fatigue damage, hidden cracks in hard-to-reach locations, disbonded joints, erosion, impact, and corrosion are among the major flaws encountered in today's extensive fleet of aging aircraft and space vehicles. The use of in-situ sensors for real-time health monitoring of aircraft structures are a viable option to overcome inspection impediments stemming from accessibility limitations, complex geometries, and the location and depth of hidden damage. Reliable, structural health monitoring systems can automatically process data, assess structural condition, and signal the need for human intervention. Prevention of unexpected flaw growth and structural failure can be improved if on-board health monitoring systems are used to continuously assess structural integrity. Such systems are able to detect incipient damage before catastrophic failures occurs. Condition-based maintenance practices could be substituted for the current time-based maintenance approach. Other advantages of on-board distributed sensor systems are that they can eliminate costly, and potentially damaging, disassembly, improve sensitivity by producing optimum placement of sensors and decrease maintenance costs by eliminating more time- consuming manual inspections. This report presents a Sandia Labs-aviation industry effort to move SHM into routine use for aircraft maintenance. This program addressed formal SHM technology validation and certification issues so that the full spectrum of concerns, including design, deployment, performance and certification were appropriately considered. The Airworthiness Assurance NDI Validation Center (AANC) at Sandia Labs, in conjunction with Boeing, Delta Air Lines, Structural Monitoring Systems Ltd., Anodyne Electronics Manufacturing Corp. and the Federal Aviation Administration (FAA) carried out a certification program to formally introduce Comparative Vacuum Monitoring (CVM) as a structural health monitoring solution to a specific aircraft wing box application. Validation tasks were designed to address the SHM equipment, the health monitoring task, the resolution required, the sensor interrogation procedures, the conditions under which the monitoring will occur, the potential inspector population, adoption of CVM into an airline maintenance program and the document revisions necessary to allow for routine use of CVM as an alternate means of performing periodic structural inspects. To carry out the validation process, knowledge of aircraft maintenance practices was coupled with an unbiased, independent evaluation. Sandia Labs designed, implemented, and analyzed the results from a focused and statistically-relevant experimental effort to quantify the reliability of the CVM system applied to the Boeing 737 Wing Box fitting application. All factors that affect SHM sensitivity were included in this program: flaw size, shape, orientation and location relative to the sensors, as well as operational and environmental variables. Statistical methods were applied to performance data to derive Probability of Detection (POD) values for CVM sensors in a manner that agrees with current nondestructive inspection (NDI) validation requirements and also is acceptable to both the aviation industry and regulatory bodies. This report presents the use of several different statistical methods, some of them adapted from NDI performance assessments and some proposed to address the unique nature of damage detection via SHM systems, and discusses how they can converge to produce a confident quantification of SHM performance An important element in developing SHM validation processes is a clear understanding of the regulatory measures needed to adopt SHM solutions along with the knowledge of the structural and maintenance characteristics that may impact the operational performance of an SHM system. This report describes the major elements of an SHM validation approach and differentiates the SHM elements from those found in NDI validation. The activities conducted in this program demonstrated the feasibility of routine SHM usage in general and CVM in particular for the application selected. They also helped establish an optimum OEM-airline-regulator process and determined how to safely adopt SHM solutions. This formal SHM validation will allow aircraft manufacturers and airlines to confidently make informed decisions about the proper utilization of CVM technology. It will also streamline the regulatory actions and formal certification measures needed to assure the safe application of SHM solutions.

42 ENGINEERING↗
NASA NTRS1990

An expert system to perform on-line controller restructuring for abrupt model changes

Work in progress on an expert system used to reconfigure and tune airframe/engine control systems on-line in real time in response to battle damage or structural failures is presented. The closed loop system is monitored constantly for changes in structure and performance, the detection of which prompts the expert system to choose and apply a particular control restructuring algorithm based on the type and severity of the damage. Each algorithm is designed to handle specific types of failures and each is applicable only in certain situations. The expert system uses information about the system model to identify the failure and to select the technique best suited to compensate for it. A depth-first search is used to find a solution. Once a new controller is designed and implemented it must be tuned to recover the original closed-loop handling qualities and responsiveness from the degraded system. Ideally, the pilot should not be able to tell the difference between the original and redesigned systems. The key is that the system must have inherent redundancy so that degraded or missing capabilities can be restored by creative use of alternate functionalities. With enough redundancy in the control system, minor battle damage affecting individual control surfaces or actuators, compressor efficiency, etc., can be compensated for such that the closed-loop performance in not noticeably altered. The work is applied to a Black Hawk/T700 system.

Litt, Jonathan S.↗
DOE OSTI2022

Understanding Lithium Local Environments in LiMn 0.5 Ni 0.5 O 2 Cathodes: A DFT-Supported 6 Li Solid-State NMR Study

LiMn 0.5 Ni 0.5 O 2 has been plagued by the structural failure driven by the irreversible phase change upon subsequent cycling and the structural degradation caused by the seemingly unavoidable Li/Ni exchange. This begs for a better understanding of the correlation between lithium local structures, synthesis conditions, and overall electrochemical properties of materials. In this study, we use density functional theory (DFT) to assist experimental 6 Li solid-state magic angle spinning (MAS) nuclear magnetic resonance (NMR) spectroscopy to understand the nature and change in lithium local structures with extended annealing times (168 vs 15 h) synthesized at 900 °C. To correlate the NMR peak changes after different synthesis conditions, we calculated the NMR spectra of representative low-energy model configurations of LiMn 0.5 Ni 0.5 O 2 composition–zigzag, row, and flower structures–as well as the influence of Ni/Mn ordering and Li/Ni exchange on each spectrum using a supercell that is large enough to allow us to consider the effect of different relative configurations of adjacent transition metal (TM) layers. The analysis based on a combination of the calculated NMR and the experimental spectra suggests that most configurations contributing to the experimental spectra are in fact composed of a blend of configurations higher in energy than the classical well-ordered ground-state structures. Further, the extended annealing of LiMn 0.5 Ni 0.5 O 2 slightly enhances Ni/Mn and Li/Mn orderings while reducing the Li/Ni mixing ratio. This study shows how DFT calculations are crucial in providing a better understanding of the experimental characterization data and therefore local environments and domain structures in oxide materials, such as Li-ion battery cathodes.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
NASA NTRS2016

Roller Testing to Mimic Damage of the ISS SARJ Ring and Durability Test to Simulate Fifteen Years of SARJ Operation Using the Damaged Surface

The International Space Station's starboard Solar Alpha Rotary Joint (SARJ) experienced a breakdown of the joint's race ring surface. The starboard SARJ mechanism was cleaned and lubricated with grease. To provide some guidance on the expected behavior of the damaged SARJ ring with continued operations, experiments were conducted using rollers and a vacuum roller test rig. The approach of the experimental work involved three main steps: (1) initiate damage using conditions representative of the SARJ with inadequate lubrication; (2) propagate the damage by operating the test rollers without lubrication; and (3) assess the durability of the roller by testing to simulate the equivalent of 15 years of SARJ operation on the damaged surface assuming adequate grease lubrication. During the rig testing, additional and/or replacement grease was introduced at regular intervals to maintain good lubrication in the rig. The damage to the nitride layer continued even after application of grease. The grease lubrication proved to be effective for limiting the value of the axial force that can be developed. Limiting the axial force on the SARJ mechanism is important since the larger the axial force the more concentrated the load pressure becomes on the blend-radius location on the SARJ roller. After the testing simulating 15 years of SARJ operations, the wear depths were the order of 0.2 mm for the nitrided 15-5 roller and the order of 0.06 mm for the mating 440C roller. Metallographic inspections were done to search for indications of impending fatigue or other fracture indications that might eventually propagate and cause structural failure. There were no indications or features found that could eventually compromise structural integrity.

mechanical devices↗
NASA NTRS1991

Nondestructive Structural Damage Detection in Flexible Space Structures Using Vibration Characterization

Spacecraft are susceptible to structural damage over their operating life from impact, environmental loads, and fatigue. Structural damage that is not detected and not corrected may potentially cause more damage and eventually catastrophic structural failure. NASA's current fleet of reusable spacecraft, namely the Space Shuttle, has been flown on several missions. In addition, configurations of future NASA space structures, e.g. Space Station Freedom, are larger and more complex than current structures, making them more susceptible to damage as well as being more difficult to inspect. Consequently, a reliable structural damage detection capability is essential to maintain the flight safety of these structures. Visual inspections alone can not locate impending material failure (fatigue cracks, yielding); it can only observe post-failure situations. An alternative approach is to develop an inspection and monitoring system based on vibration characterization that assesses the integrity of structural and mechanical components. A methodology for detecting structural damage is presented. This methodology is based on utilizing modal test data in conjunction with a correlated analytical model of the structure to: (1) identify the structural dynamic characteristics (resonant frequencies and mode shapes) from measurements of ambient motions and/or force excitation; (2) calculate modal residual force vectors to identify the location of structural damage; and (3) conduct a weighted sensitivity analysis in order to assess the extent of mass and stiffness variations, where structural damage is characterized by stiffness reductions. The approach is unique from other existing approaches in that varying system mass and stiffness, mass center locations, the perturbation of both the natural frequencies and mode shapes, and statistical confidence factors for structural parameters and experimental instrumentation are all accounted for directly.

Ricles, James M.↗
NASA NTRS2011

Measuring Moisture Levels in Graphite Epoxy Composite Sandwich Structures

Graphite epoxy composite (GEC) materials are used in the construction of rocket fairings, nose cones, interstage adapters, and heat shields due to their high strength and light weight. However, they absorb moisture depending on the environmental conditions they are exposed to prior to launch. Too much moisture absorption can become a problem when temperature and pressure changes experienced during launch cause the water to vaporize. The rapid state change of the water can result in structural failure of the material. In addition, heat and moisture combine to weaken GEC structures. Diffusion models that predict the total accumulated moisture content based on the environmental conditions are one accepted method of determining if the material strength has been reduced to an unacceptable level. However, there currently doesn t exist any field measurement technique to estimate the actual moisture content of a composite structure. A multi-layer diffusion model was constructed with Mathematica to predict moisture absorption and desorption from the GEC sandwich structure. This model is used in conjunction with relative humidity/temperature sensors both on the inside and outside of the material to determine the moisture levels in the structure. Because the core materials have much higher diffusivity than the face sheets, a single relative humidity measurement will accurately reflect the moisture levels in the core. When combined with an external relative humidity measurement, the model can be used to determine the moisture levels in the face sheets. Since diffusion is temperaturedependent, the temperature measurements are used to determine the diffusivity of the face sheets for the model computations.

Nurge, Mark↗
NASA NTRS2002

Thermostructural Analysis of Carbon Cloth Phenolic Material Tested at the Laser Hardened Material Evaluation Laboratory

RSRM nozzle liner components have been analyzed and tested to explore the occurrence of anomalous material performance known as pocketing erosion. Primary physical factors that contribute to pocketing seem to include the geometric permeability, which governs pore pressure magnitudes and hence load, and carbon fiber high temperature tensile strength, which defines a material limiting capability. The study reports on the results of a coupled thermostructural finite element analysis of Carbon Cloth Phenolic (CCP) material tested at the Laser Hardened Material Evaluation Laboratory (the LHMEL facility). Modeled test configurations will be limited to the special case of where temperature gradients are oriented perpendicular to the composite material ply angle. Analyses were conducted using a transient, one-dimensional flow/thermal finite element code that models pore pressure and temperature distributions and in an explicitly coupled formulation, passes this information to a 2-dimensional finite element structural model for determination of the stress/deformation behavior of the orthotropic fiber/matrix CCP. Pore pressures are generated by thermal decomposition of the phenolic resin which evolve as a multi-component gas phase which is partially trapped in the porous microstructure of the composite. The nature of resultant pressures are described by using the Darcy relationships which have been modified to permit a multi-specie mass and momentum balance including water vapor condensation. Solution to the conjugate flow/thermal equations were performed using the SINDA code. Of particular importance to this problem was the implementation of a char and deformation state dependent (geometric) permeability as describing a first order interaction between the flow/thermal and structural models. Material property models are used to characterize the solid phase mechanical stiffness and failure. Structural calculations were performed using the ABAQUS code. Iterations were made between the two codes involving the dependent variables temperature, pressure and across-ply strain level. Model results comparisons are made for three different surface heat rates and dependent variable sensitivities discussed for the various cases.

Clayton, J. Louie↗
NASA NTRS2010

Lifetime Assessment of the NEXT Ion Thruster

Ion thrusters are low thrust, high specific impulse devices with required operational lifetimes on the order of 10,000 to 100,000 hr. The NEXT ion thruster is the latest generation of ion thrusters under development. The NEXT ion thruster currently has a qualification level propellant throughput requirement of 450 kg of xenon, which corresponds to roughly 22,000 hr of operation at the highest throttling point. Currently, a NEXT engineering model ion thruster with prototype model ion optics is undergoing a long duration test to determine wear characteristics and establish propellant throughput capability. The NEXT thruster includes many improvements over previous generations of ion thrusters, but two of its component improvements have a larger effect on thruster lifetime. These include the ion optics with tighter tolerances, a masked region and better gap control, and the discharge cathode keeper material change to graphite. Data from the NEXT 2000 hr wear test, the NEXT long duration test, and further analysis is used to determine the expected lifetime of the NEXT ion thruster. This paper will review the predictions for all of the anticipated failure mechanisms. The mechanisms will include wear of the ion optics and cathode s orifice plate and keeper from the plasma, depletion of low work function material in each cathode s insert, and spalling of material in the discharge chamber leading to arcing. Based on the analysis of the NEXT ion thruster, the first failure mode for operation above a specific impulse of 2000 sec is expected to be the structural failure of the ion optics at 750 kg of propellant throughput, 1.7 times the qualification requirement. An assessment based on mission analyses for operation below a specific impulse of 2000 sec indicates that the NEXT thruster is capable of double the propellant throughput required by these missions.

VanNoord, Jonathan L.↗
NASA NTRS1997

Evaluation of a Progressive Failure Analysis Methodology for Laminated Composite Structures

A progressive failure analysis methodology has been developed for predicting the nonlinear response and failure of laminated composite structures. The progressive failure analysis uses C plate and shell elements based on classical lamination theory to calculate the in-plane stresses. Several failure criteria, including the maximum strain criterion, Hashin's criterion, and Christensen's criterion, are used to predict the failure mechanisms. The progressive failure analysis model is implemented into a general purpose finite element code and can predict the damage and response of laminated composite structures from initial loading to final failure.

Sleight, David W.↗
NASA NTRS1964

Probability Functions for Random Responses: Prediction of Peaks, Fatigue Damage, and Catastrophic Failures

This report reviews a number of theoretical matters in random process theory which can be applied to physical problems such as predicting peaks, structural fatigue damage, and catastrophic structural failures. The presentation emphasizes the basic assumptions which are involved, and discusses how to properly interpret the theoretical results. Various engineering examples are given as illustrations.

FATIGUE↗
NASA NTRS2003

Proof-of-Concept Application of Impedance-Based Health Monitoring on Space Shuttle Ground Structures

Many of the structures responsible for the launch, ground systems and support operations of the space shuttle are still being used well past their nominal expected design life. This has led to an increased interest in monitoring these structures in order to decrease the risk of eventual breakdown or structural failure. One monitoring method, which has shown promising results for such applications, is the impedance-based structural health monitoring technique. This paper presents results from proof-of-concept tests on the launch pad's orbiter access arm bolted connection, solid rocket booster hold down post, mobile launch platform heat shield and crawler transporter bearing. Modification for future tests are suggested.

Peairs, Daniel M.↗
NASA NTRS2006

Structural Continuum Modeling of Space Shuttle External Tank Foam Insulation

This document is a viewgraph presentation reporting on work in modeling the foam insulation of the Space Shuttle External Tank. An analytical understanding of foam mechanics is required to design against structural failure. The Space Shuttle External Tank is covered primarily with closed cell foam to: Prevent ice, Protect structure from ascent aerodynamic and engine plume heating, and Delay break-up during re-entry. It is important that the foam does not shed unacceptable debris during ascent environment. Therefore a modeling of the foam insulation was undertaken.

Steeve, Brian↗
NASA NTRS1996

The Study of the Relationship between Probabilistic Design and Axiomatic Design Methodology

Structural failure is rarely a "sudden death" type of event, such sudden failures may occur only under abnormal loadings like bomb or gas explosions and very strong earthquakes. In most cases, structures fail due to damage accumulated under normal loadings such as wind loads, dead and live loads. The consequence of cumulative damage will affect the reliability of surviving components and finally causes collapse of the system. The cumulative damage effects on system reliability under time-invariant loadings are of practical interest in structural design and therefore will be investigated in this study. The scope of this study is, however, restricted to the consideration of damage accumulation as the increase in the number of failed components due to the violation of their strength limits.

Onwubiko, Chin-Yere↗
NASA NTRS1995

Alternative Computational Approaches for Probalistic Fatigue Analysis

The feasibility is discussed for alternative methods of direct Monte Carlo simulation for failure probability computations. First and second order reliability methods are used for fatigue crack growth and low cycle fatigue structural failure modes to illustrate typical problems.

fatigue analysis failure models simulation↗
NASA NTRS1989

A mechanics framework for a progressive failure methodology for laminated composites

A laminate strength and life prediction methodology has been postulated for laminated composites which accounts for the progressive development of microstructural damage to structural failure. A damage dependent constitutive model predicts the stress redistribution in an average sense that accompanies damage development in laminates. Each mode of microstructural damage is represented by a second-order tensor valued internal state variable which is a strain like quantity. The mechanics framework together with the global-local strategy for predicting laminate strength and life is presented in the paper. The kinematic effects of damage are represented by effective engineering moduli in the global analysis and the results of the global analysis provide the boundary conditions for the local ply level stress analysis. Damage evolution laws are based on experimental results.

Harris, Charles E.↗
DOE OSTI2023

Probabilistic Multi-Hazard Performance Assessment of Concrete Structures in Nuclear Installations

Concrete structures in nuclear installations are subject to time-dependent degradation mechanisms that can deteriorate their physical and mechanical properties, potentially exacerbating the risk of structural failure under external forces such as a seismic event. Previous research has extensively investigated the seismic response of nuclear concrete structures and the associated risk, as well as their effect on structural components safety margins. However, substantial work is still necessary to incorporate concrete aging effects into such evaluations. In fact, most models in the literature assume pristine concrete conditions and do not account for the impact of aging on the structural components’ fragility curves. This work identifies relevant time-dependent degradation mechanisms and provides simplified models to predict the the evolution of key material properties based on data from the literature. Namely, this work focuses on the aging effects of corrosion, alkali–silica reaction (ASR), and irradiation on reinforced concrete within US Department of Energy (DOE) nuclear facilities and nuclear power plants (NPP) structures. Furthermore, degradation models based on literature data are presented that define the relationship between probabilistic material properties and the concrete’s age. In this work, sampled material properties served as input for a simplified finite element model (FEM) of a critical nuclear structural system, with the output of the FEM being the seismic response for a given ground motion. The results of the FEM were then used within a probabilistic performance assessment with a statistically significant number of samples. The research presented herein addresses the detrimental effects of hazards caused by natural phenomena on deteriorated concrete elements of nuclear installations. This work directly benefits the safety analysis performed on US DOE/ National Nuclear Security Administration (NNSA) nuclear facilities located in areas prone to seismic activity. The results presented herein could aid in the improvement of DOE-STD-1020, the DOE Standard that addresses seismic risk analysis and capacity evaluation in DOE facilities. DOE-STD-1020 refers to the requirements in American Society of Civil Engineers (ASCE) 4-98, now superseded by ASCE 4-16, that shall be met in performing dynamic response analyses and generating in-structure response spectra, provided that such requirements are consistent with the requirements of ASCE/Structural Engineering Institute (SEI) 43-05. Moreover, the results presented herein could also aid in the updating of section C3.1.1. of ASCE 4-16 to account for the effects of aging on the stiffness of reinforced elements and American Concrete Institute (ACI) 349.3R-18, “Report on Evaluation and Repair of Existing Nuclear Safety-Related Concrete Structures.” Ultimately, this work can assist the risk assessment of potential lifetime extension of the existing US commercial nuclear fleet (light water reactors) and the safety analysis of the emerging advanced nuclear reactors. The proposed proof-of-concept methodology employs open-source DOE computational tools and is transferable to commercial software commonly used by engineering firms.

42 ENGINEERING↗
NASA NTRS1976

Optimal periodic proof test based on cost-effective and reliability criteria

An exploratory study for the optimization of periodic proof tests for fatigue-critical structures is presented. The optimal proof load level and the optimal number of periodic proof tests are determined by minimizing the total expected (statistical average) cost, while the constraint on the allowable level of structural reliability is satisfied. The total expected cost consists of the expected cost of proof tests, the expected cost of structures destroyed by proof tests, and the expected cost of structural failure in service. It is demonstrated by numerical examples that significant cost saving and reliability improvement for fatigue-critical structures can be achieved by the application of the optimal periodic proof test. The present study is relevant to the establishment of optimal maintenance procedures for fatigue-critical structures.

Yang, J.-N.↗