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Nondestructive screening tests for identifying electronic and electromechanical parts susceptible to failure, reviewing techniques of Apollo spacecraft program
The reliability program consists of: parts stress analysis, failure mode, effect and criticality analysis, standardization of design practices, and a design review program. Malfunction reporting, and failure analysis is delineated, as well as identification of inputs and outputs.
Software which is used in life critical functions must be known to be highly reliable before installation. This requires a strong testing program to estimate the reliability, since neither formal methods, software engineering nor fault tolerant methods can guarantee perfection. Prior to the final testing software goes through a debugging period and many models have been developed to try to estimate reliability from the debugging data. However, the existing models are poorly validated and often give poor performance. This paper emphasizes the fact that part of their failures can be attributed to the random nature of the debugging data given to these models as input, and it poses the problem of correcting this defect as an area of future research.
Many high temperature aircraft and rocket engine components experience large mechanical loads as well as severe thermal gradients and transients. These nonisothermal conditions are often large enough to cause inelastic deformations, which are the ultimate cause for failure in those parts. A way to alleviate this problem is through improved engine designs based on better predictions of thermomechanical material behavior. To address this concern, an experimental effort was recently initiated within the Hot Section Technology (HOST) program at Lewis. As part of this effort, two new test systems were added to the Fatigue and Structures Lab., which allowed thermomechanical tests to be conducted under closely controlled conditions. These systems are now being used for thermomechanical testing for the Space Station Receiver program, and will be used to support development of metal matrix composites.
A sense of vision is a prerequisite for a robot to function in an unstructured environment. However, real-world scenes contain many interacting phenomena that lead to complex images which are difficult to interpret automatically. Typical computer vision research proceeds by analyzing various effects in isolation (e.g., shading, texture, stereo, defocus), usually on images devoid of realistic complicating factors. This leads to specialized algorithms which fail on real-world images. Part of this failure is due to the dichotomy of useful representations for these phenomena. Some effects are best described in the spatial domain, while others are more naturally expressed in frequency. In order to resolve this dichotomy, we present the combined space/frequency representation which, for each point in an image, shows the spatial frequencies at that point. Within this common representation, we develop a set of simple, natural theories describing phenomena such as texture, shape, aliasing and lens parameters. We show these theories lead to algorithms for shape from texture and for dealiasing image data. The space/frequency representation should be a key aid in untangling the complex interaction of phenomena in images, allowing automatic understanding of real-world scenes.
In this presentation we discuss a new theoretical model and supporting experimental results for the strength and lifetime in creep rupture of unidirectional, carbon fiber/epoxy matrix composites at ambient conditions. First we review the 'standard' Weibull/power-law methodology that has been standard practice. Then we discuss features of a recent model which build on the statistical aspects of fiber strength, micromechanical aspects of stress transfer around fiber breaks, and time-dependent creep of the matrix. The model is applied to 'microcomposites' consisting of seven fibers in a matrix for which strength and creep-rupture data are available. The model yields Weibull distributions in an envelope format for both strength and lifetime. The respective shape, scale and power-law parameters depend on such parameters as the Weibull shape parameter for fiber strength, the exponent for matrix creep, the effective load transfer length (which grows in time due to matrix creep) and the critical cluster size for failed fibers. The experimental results are consistent with the theory, though time-dependent debonding appears to be part of the failure process.
PURPOSE OF REVIEW: In response to decreased usage, skeletal muscle undergoes adaptive reductive remodeling due to the decrease in tension on the weight bearing components of the musculo-skeletal system. This response occurs with uncomplicated disuse (e.g. bed rest, space flight), as a secondary consequence of several widely prevalent chronic diseases for which activity is reduced (e.g. chronic obstructive pulmonary disease and chronic heart failure) and is part of the aging process. The problem is therefore one of considerable clinical importance. RECENT FINDINGS: The impaired function and exercise intolerance is related more to the associated muscle wasting rather than to the specific organ system primarily impacted by the disease. Progress has continued in describing the use of anabolic drugs and dietary manipulation. The major advance in the field has been: (i) the discovery of the atrogin-1 gene and (ii) the application of microarray expression analysis and proteomics with the objectives of obtaining comprehensive understanding of the pathways changed with disuse atrophy. SUMMARY: Disuse atrophy is a common clinical problem. There is a need for therapeutic interventions that do not involve exercise. A better understanding of the changes, particularly at the molecular level, could indicate hitherto unsuspected sites for nutritional and pharmacological intervention.
Cereal leaves subjected to the osmotica routinely used for protoplast isolation show a rapid increase in arginine decarboxylase activity, a massive accumulation of putrescine, and slow conversion of putrescine to the higher polyamines, spermidine and spermine (HE Flores, AW Galston 1984 Plant Physiol 75: 102). Mesophyll protoplasts from these leaves, which have a high putrescine:polyamine ratio, do not undergo sustained division. By contrast, in Nicotiana, Capsicum, Datura, Trigonella, and Vigna, dicot genera that readily regenerate plants from mesophyll protoplasts, the response of leaves to osmotic stress is opposite to that in cereals. Putrescine titer as well as arginine and ornithine decarboxylase activities decline in these osmotically stressed dicot leaves, while spermidine and spermine titers increase. Thus, the putrescine:polyamine ratio in Vigna protoplasts, which divide readily, is 4-fold lower than in oat protoplasts, which divide poorly. We suggest that this differing response of polyamine metabolism to osmotic stress may account in part for the failure of cereal mesophyll protoplasts to develop readily in vitro.
The original thrust of our Genesis funding was to extend and refine the noble gas analytical capabilities of this laboratory to improve the precision and accuracy of noble gas measurements in order to optimize the scientific return from the Genesis Mission. This process involved both instrumental improvement (supplemented by a SRLIDAP instrument grant) and refinement of technique. The Genesis landing mishap shifted our emphasis to the irregular aluminum heat shield material from the flat collector wafers. This has required redesign of our laser extraction cells to accommodate the longer focal lengths required for laser extraction from non-flat surfaces. Extraction of noble gases from solid aluminum surfaces, rather than thin coatings on transparent substrates has required refinement of controlled-depth laser ablation techniques. Both of these bring new problems, both with potentially higher blanks form larger laser cells and the larger quantities of evaporated aluminum which can coat the sapphire entrance ports. This is mainly a problem for the heavy noble gases where larger extraction areas are required, necessitating the new aluminum vapor containment techniques described below. With the Genesis Mission came three new multiple multiplier noble gas mass spectrometers to this laboratory, one built solely by us (Supergnome-M), one built in collaboration with Nu-Instruments (Noblesse), and one built in collaboration with GVI (Helix). All of these have multiple multiplier detection sections with the Nu-Instruments using a pair of electrostatic quad lenses for isotope spacing and the other two using mechanically adjustable positions for the electron multipliers. The Supergnome-M and Noblesse are installed and running. The GVI instrument was delivered a year late (in March 2005) and is yet to be installed by GVI. As with all new instruments there were some initial development issues, some of which are still outstanding. The most serious of these are performance issues with the miniature channel electron multipliers. The delayed installation of Helix by the GVI is partly due to failure of the initial batch of Burle channel multipliers to perform as expected. A number of the channel multipliers designed for Noblesse by Burle have also failed upon baking. Burle has now refined the design of these and we have installed two of the new multipliers and are assessing their performance. The remaining multipliers Will be upgraded to the new design from Burle once we confirm that the problem has been fixed.
How should life support for deep space be developed? The International Space Station (ISS) life support system is the operational result of many decades of research and development. Long duration deep space missions such as Mars have been expected to use matured and upgraded versions of ISS life support. Deep space life support must use the knowledge base incorporated in ISS but it must also meet much more difficult requirements. The primary new requirement is that life support in deep space must be considerably more reliable than on ISS or anywhere in the Earth-Moon system, where emergency resupply and a quick return are possible. Due to the great distance from Earth and the long duration of deep space missions, if life support systems fail, the traditional approaches for emergency supply of oxygen and water, emergency supply of parts, and crew return to Earth or escape to a safe haven are likely infeasible. The Orbital Replacement Unit (ORU) maintenance approach used by ISS is unsuitable for deep space with ORU's as large and complex as those originally provided in ISS designs because it minimizes opportunities for commonality of spares, requires replacement of many functional parts with each failure, and results in substantial launch mass and volume penalties. It has become impractical even for ISS after the shuttle era, resulting in the need for ad hoc repair activity at lower assembly levels with consequent crew time penalties and extended repair timelines. Less complex, more robust technical approaches may be needed to meet the difficult deep space requirements for reliability, maintainability, and reparability. Developing an entirely new life support system would neglect what has been achieved. The suggested approach is use the ISS life support technologies as a platform to build on and to continue to improve ISS subsystems while also developing new subsystems where needed to meet deep space requirements.
Anomalous charging currents (ACC) in polymer tantalum capacitors may appear as a temporary short circuit that can last for dozens of milliseconds, cause failures to the parts, or cause malfunctions to fast operating electronic systems. Currently, there is no standard technique or set of metrics to evaluate the level of ACC which compares results obtained by different users and manufacturers. In this work, ACC in different types of capacitors were characterized by analysis of current transients during the constant voltage ramp or power surge testing (PST) techniques. It is shown that although the shape of transients may vary at different test conditions, the transfer charge and energy remain practically the same. The level of ACC is characterized by the energy dissipated in the part during PST. Variations of the dissipated energy with moisture content, test temperature, and voltage are evaluated. Effects of different reflow soldering conditions and long-term (up to 3000 hours) storage at 125 °C are discussed.
This thesis researches potential failure conditions within supersonic and potential hypersonic aircraft. The most critical off-nominal situations have been identified to be Engine Failures, Rapid Decompression and High Altitude Radiation. Having in mind, current regulatory requirements as well as past operations of Concorde, potential locations for different speeds have been modeled to identify safe operational volumes. With an emphasis on the engine failure case as part of the thesis requirement, a potential first order approach to future DAA systems is described in order to add these models on top of current conflict resolution models.
The objective of the CMC turbine blade durability program is to identify critical material and design parameters that affect durability of ceramic matrix composite (CMC) turbine blades. A baseline architecture for a cooled high-pressure turbine (HPT) CMC blade and accompanying sub-component test articles were developed with the intent to demonstrate through analysis and subcomponent testing how material and design parameters impact key failure modes. As part of this program, a notional architecture for a cooled CMC blade was matured through a design review rhythm to produce a blade test article containing the necessary features required for operation in an engine like environment. Further validation of the durability of these features were achieved through coupon and sub-component testing to demonstrate the durability of cooling hole configurations and blade attachment designs. Analytical methods were also used to evaluate the acceptability of the baseline blade test article architecture against relevant design requirements and identify abatement and recommended changes to key design drivers to improve component durability for future design iterations.
A three degree of freedom (DOF) spherical actuator is proposed that will replace functions requiring three single DOF actuators in robotic manipulators, thus reducing, cost, mass, volume, part count, and failure rate. The proposed will support lunar surface construction, advanced manufacturing for in-space resource utilization, and in-space manufacturing for in-space resource utilization. Steven Peeples (ES33) serves as the PI and leverages ES33’s existing additive manufacturing equipment to enhance the department’s current robotics and manufacturing capabilities, directly leading to future proposals, patents, and commercialization.
A three degree of freedom (DOF) spherical actuator is proposed that will replace functions requiring three single DOF actuators in robotic manipulators providing space and weight savings while reducing the overall failure rate. Exploration satellites, Space Station payload manipulators, and rovers requiring pan, tilt, and rotate movements need an actuator for each function. Not only does each actuator introduce additional failure modes and require bulky mechanical gimbals, each contains many moving parts, decreasing mean time to failure. A conventional robotic manipulator is shown in figure 1. Spherical motors perform all three actuation functions, i.e., three DOF, with only one moving part. Given a standard three actuator system whose actuators have a given failure rate compared to a spherical motor with an equal failure rate, the three actuator system is three times as likely to fail over the latter. The Jet Propulsion Laboratory reliability studies of NASA robotic spacecraft have shown that mechanical hardware/mechanism failures are more frequent and more likely to significantly affect mission success than are electronic failures. Unfortunately, previously designed spherical motors have been unable to provide the performance needed by space missions. This inadequacy is also why they are unavailable commercially. An improved patentable spherically actuated motor (SAM) is proposed to provide the performance and versatility required by NASA missions.
Decisions made during the operational phase of a space mission often have significant and immediate consequences. Without the explicit consideration of the risks involved and their representation in a solid model, it is very likely that these risks are not considered systematically in trade studies. Wrong decisions during the operational phase of a space mission can lead to immediate system failure whereas correct decisions can help recover the system even from faulty conditions. A problem of special interest is the determination of the system fault protection strategies upon the occurrence of faults within the system. Decisions regarding the fault protection strategy also heavily rely on a correct understanding of the state of the system and an integrated risk model that represents the various possible scenarios and their respective likelihoods. Probabilistic Risk Assessment (PRA) modeling is applicable to the full lifecycle of a space mission project, from concept development to preliminary design, detailed design, development and operations. The benefits and utilities of the model, however, depend on the phase of the mission for which it is used. This is because of the difference in the key strategic decisions that support each mission phase. The focus of this paper is on describing the particular methods used for PRA modeling during the operational phase of a spacecraft by gleaning insight from recently conducted case studies on two operational Mars orbiters. During operations, the key decisions relate to the commands sent to the spacecraft for any kind of diagnostics, anomaly resolution, trajectory changes, or planning. Often, faults and failures occur in the parts of the spacecraft but are contained or mitigated before they can cause serious damage. The failure behavior of the system during operations provides valuable data for updating and adjusting the related PRA models that are built primarily based on historical failure data. The PRA models, in turn, provide insight into the effect of various faults or failures on the risk and failure drivers of the system and the likelihood of possible end case scenarios, thereby facilitating the decision making process during operations. This paper describes the process of adjusting PRA models based on observed spacecraft data, on one hand, and utilizing the models for insight into the future system behavior on the other hand. While PRA models are typically used as a decision aid during the design phase of a space mission, we advocate adjusting them based on the observed behavior of the spacecraft and utilizing them for decision support during the operations phase.
Ballistic limit equations define the failure of metallic Whipple shields in three parts: low velocity, shatter, and hypervelocity. Failure limits in the shatter regime are based on a linear interpolation between the onset of projectile fragmentation, and impulsive rupture of the shield rear wall. A series of hypervelocity impact tests have been performed on aluminum alloy Whipple shields to investigate failure mechanisms and performance limits in the shatter regime. Test results demonstrated a more rapid increase in performance than predicted by the latest iteration of the JSC Whipple shield BLE following the onset of projectile fragmentation. This increase in performance was found to level out between 4.0-5.0 km/s, with a subsequent decrease in performance for velocities up to 6.0 km/s. For a detached spall failure criterion, the failure limit was found to continually decrease up to a velocity of 7.0 km/s, substantially varying from the BLE, while for perforation-based failure an increase in performance was observed. An existing phenomenological ballistic limit curve was found to provide a more accurate reproduction of shield behavior that the BLE, however a number of underlying assumptions such as the occurrence of complete projectile fragmentation and the effect on performance of incipient projectile melt were found to be inaccurate. A cratering relationship based on the largest residual fragment size has been derived for application at velocities between 3.0-4.0 km/s, and was shown to accurately reproduce the trends of the experimental data. Further investigation is required to allow a full analytical description of shatter regime performance for metallic Whipple shields.
17-4 is used regularly to manufacture force transducers particularly for wind tunnel testing. Such applications place demanding structural requirements on the transducers with static safety factors of 1.5 common and the potential for additional dynamic loads. Additive manufacturing (AM) of transducers is very appealing because of significant potential cost and time savings as well as increased design flexibility. This study looks at the processing of 17-4 powder using selective laser melting by two different facilities using their own best practices. Hot isostatic pressing (HIP) is used by both facilities as part of the thermomechanical processing following printing to explore whether it can improve the consistency of mechanical properties. Results revealed that HIP reduced average porosity of 17-4 parts and that the yield strength of parts following solutionization and aging met wrought material property targets. Strain to failure of one of the facilities parts was less than 5% compared to greater than 9% for the other facility. Inspection of failure surfaces revealed this discrepancy could be attributed to pores (2-4% area fraction) on the failure surface of the low ductility parts. Phase content varied between the facilities with one facility producing fully martensitic parts and the other containing some retained austenite. The phase content of the starting powder and a slower than air cooling rate following the final heat treatment above the austenite eutectoid temperature are likely sources of the retained austenite. Taken together these results suggest that the current state of the art in AM 17-4 processing is sufficient for many NASA force measurement applications, but that attention is required at each stage of processing to assure desired mechanical properties.