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NASA NTRSDate not supplied

NASA's Certification and Qualification Challenges for Additively Manufactured Hardware: What Is Next?

In 2021, NASA released NASA-STD-6030 “Additive Manufacturing Requirements for Spaceflight Systems” to create qualification and certification strategies for mature metallic and non-metallic AM materials and technologies. While these standards have had an immediate impact on the additive manufacturing (AM) industry, there remain many challenges that have yet to be overcome. NASA and its partners in academia and industry are working together to proactively address these issues. One of the most critical needs is a Probabilistic Damage Tolerance Assessment (PDTA) approach, which includes the development of computational modeling, understanding the “effect of defects”, and the implementation of in-situ process monitoring and inspection techniques.

Will Tilson↗
NASA NTRS2008

An Uncertainty Structure Matrix for Models and Simulations

Software that is used for aerospace flight control and to display information to pilots and crew is expected to be correct and credible at all times. This type of software is typically developed under strict management processes, which are intended to reduce defects in the software product. However, modeling and simulation (M&S) software may exhibit varying degrees of correctness and credibility, depending on a large and complex set of factors. These factors include its intended use, the known physics and numerical approximations within the M&S, and the referent data set against which the M&S correctness is compared. The correctness and credibility of an M&S effort is closely correlated to the uncertainty management (UM) practices that are applied to the M&S effort. This paper describes an uncertainty structure matrix for M&S, which provides a set of objective descriptions for the possible states of UM practices within a given M&S effort. The columns in the uncertainty structure matrix contain UM elements or practices that are common across most M&S efforts, and the rows describe the potential levels of achievement in each of the elements. A practitioner can quickly look at the matrix to determine where an M&S effort falls based on a common set of UM practices that are described in absolute terms that can be applied to virtually any M&S effort. The matrix can also be used to plan those steps and resources that would be needed to improve the UM practices for a given M&S effort.

Green, Lawrence L.↗
NASA NTRS1990

Topological defects in extended inflation

The production of topological defects, especially cosmic strings, in extended inflation models was considered. In extended inflation, the Universe passes through a first-order phase transition via bubble percolation, which naturally allows defects to form at the end of inflation. The correlation length, which determines the number density of the defects, is related to the mean size of bubbles when they collide. This mechanism allows a natural combination of inflation and large scale structure via cosmic strings.

Copeland, Edmund J.↗
NASA NTRS2002

Towards Comprehensive Variation Models for Designing Vehicle Monitoring Systems

When designing vehicle vibration monitoring systems for aerospace devices, it is common to use well-established models of vibration features to determine whether failures or defects exist. Most of the algorithms used for failure detection rely on these models to detect significant changes in a flight environment. In actual practice, however, most vehicle vibration monitoring systems are corrupted by high rates of false alarms and missed detections. This crucial roadblock makes their implementation in real vehicles (e.g., helicopter transmissions and aircraft engines) difficult, making their operation costly and unreliable. Research conducted at the NASA Ames Research Center has determined that a major reason for the high rates of false alarms and missed detections is the numerous sources of statistical variations that are not taken into account in the modeling assumptions. In this paper, we address one such source of variations, namely, those caused during the design and manufacturing of rotating machinery components that make up aerospace systems. We present a novel way of modeling the vibration response by including design variations via probabilistic methods. Using such models, we develop a methodology to account for design and manufacturing variations, and explore the changes in the vibration response to determine its stochastic nature. We explore the potential of the methodology using a nonlinear cam-follower model, where the spring stiffness values are assumed to follow a normal distribution. The results demonstrate initial feasibility of the method, showing great promise in developing a general methodology for designing more accurate aerospace vehicle monitoring systems.

McAdams, Daniel A.↗
NASA NTRS2001

Toward Failure Modeling In Complex Dynamic Systems: Impact of Design and Manufacturing Variations

When designing vehicle vibration monitoring systems for aerospace devices, it is common to use well-established models of vibration features to determine whether failures or defects exist. Most of the algorithms used for failure detection rely on these models to detect significant changes during a flight environment. In actual practice, however, most vehicle vibration monitoring systems are corrupted by high rates of false alarms and missed detections. Research conducted at the NASA Ames Research Center has determined that a major reason for the high rates of false alarms and missed detections is the numerous sources of statistical variations that are not taken into account in the. modeling assumptions. In this paper, we address one such source of variations, namely, those caused during the design and manufacturing of rotating machinery components that make up aerospace systems. We present a novel way of modeling the vibration response by including design variations via probabilistic methods. The results demonstrate initial feasibility of the method, showing great promise in developing a general methodology for designing more accurate aerospace vehicle vibration monitoring systems.

Tumer, Irem Y.↗
NASA NTRS1976

A complete model of turbulence

A set of constitutive equations suitable for a priori computation of turbulent shear flows has been developed. Since no properties of a given turbulent flow need be known in advance in order to obtain a solution, the equations comprise a complete model of turbulence. Perturbation analysis shows that the model predicts a composite five-layer structure for an incompressible turbulent boundary layer, viz, a defect layer, a law-of-the-wall layer, a viscous sublayer, a near-surface roughness layer, and a viscous superlayer at the boundary-layer edge. Analysis of the defect layer demonstrates the key improvement of the model over its predecessor, the Saffman-Wilcox two-equation model of turbulence. Examination of model-predicted sublayer structure yields model-parameter boundary conditions appropriate for surfaces with roughness and mass injection. Results of numerical computations of compressible and incompressible equilibrium boundary layers show that, for such flows, the model is as accurate as mixing-length theory. Applications to transitional boundary layers and to nonequilibrium relaxation of a boundary layer passing from a rough to a smooth surface indicate that the model's applicability extends far beyond that of mixing-length theory's.

Wilcox, D. C.↗
NASA NTRSDate not supplied

Modeling Pore Closure in the Hot Isostatic Pressing of Additively Manufactured Inconel 718 Samples

Additive manufacturing provides opportunity for a new world of possibilities for metallic component design and fabrication; however, as-built part quality is notoriously variable, anisotropic, and degraded by porous defects. To improve quality, parts are commonly post processed using a variety of techniques including hot isostatic pressing (HIP). During HIP, high temperature and pressure is employed to improve microstructure and reduce pore volume by inducing visco-plastic deformation in the metallic substrate. Validated computational capabilities can provide predictions to guide the selection of processing condition, expected pore reduction, and the effects of varying entrapped gas in the pores. This discussion describes a micro-scale finite element structural model developed to predict pore closure due to HIP in as-built additively manufactured Inconel 718 samples produced by the laser powder bed fusion process. The model accounts for plastic deformation, creep, and internal pressure for a single pore. Pores are characterized in physical samples before and after HIP, and model predictions are compared to this measured data.

defect model prediction↗
NASA NTRS1992

SiO(X) coatings for atomic oxygen protection of polyimide Kapton in low earth orbit

Sputter-deposited SiO(X) (where X between 1.9 and 2.0) thin film coatings have been found to be durable to atomic oxygen. Such coatings will be used to protect polyimide Kapton photovoltaic array blankets from atomic oxygen attack in low earth orbit (LEO) on the Space Station Freedom (SSF). Monte Carlo modeling of atomic oxygen attack at defect sites in protected Kapton exposed in laboratory RF plasma ashers and on solar tracking photovoltaic arrays in space has been conducted to enable understanding of degradation processes relevant to the durability of the SSF solar array blanket. SiO(X) protective coating performance data from RF plasma asher tests will be presented, along with Monte Carlo modeling considerations, to enable the projection of in-space durability of the SSF solar array blankets based on ground laboratory test results.

Banks, Bruce A.↗
NASA NTRS2010

Fracture Mechanics Analyses of Reinforced Carbon-Carbon Wing-Leading-Edge Panels

Fracture mechanics analyses of subsurface defects within the joggle regions of the Space Shuttle wing-leading-edge RCC panels are performed. A 2D plane strain idealized joggle finite element model is developed to study the fracture behavior of the panels for three distinct loading conditions - lift-off and ascent, on-orbit, and entry. For lift-off and ascent, an estimated bounding aerodynamic pressure load is used for the analyses, while for on-orbit and entry, thermo-mechanical analyses are performed using the extreme cold and hot temperatures experienced by the panels. In addition, a best estimate for the material stress-free temperature is used in the thermo-mechanical analyses. In the finite element models, the substrate and coating are modeled separately as two distinct materials. Subsurface defects are introduced at the coating-substrate interface and within the substrate. The objective of the fracture mechanics analyses is to evaluate the defect driving forces, which are characterized by the strain energy release rates, and determine if defects can become unstable for each of the loading conditions.

Raju, Ivatury S.↗
NASA NTRS1989

Metastable defects in Be-doped Al(x)Ga(1-x)As

Deep-level transient spectroscopy has been used to study metastable defects in Be-doped Al(x)Ga(1-x)As grown by molecular-beam epitaxy. The metastability manifests itself by the appearance of different spectra depending upon whether the sample is cooled from a high temperature with zero bias or a reverse bias applied to it. The defects are found in concentrations of 10 to the 15th/cu cm in a sample doped with 10 to the 18th Be/cu cm and in much lower concentrations in a 10 to the 17th Be/cu cm sample. Isochronal annealing experiments indicate that the defect is multistable and that it is best modeled as a mobile interstitial which can reside at several sites near acceptor. The activation energies for these defects are between 0.2 and 0.5 eV above the valence band.

Magno, R.↗
NASA NTRS1994

Comprehensive stellar population models and the disentanglement of age and metallicity effects

The construction of detailed models for intermediate and old stellar populations is described. Input parameters include metallicity (-2 less than (Fe/H) less than 0.5), single-burst age (between 1.5 and 17 Gyr), and initial mass function (IMF) exponent. Quantities output include broadband magnitudes, spectral energy distributions, surface brightness fluctuation magnitudes, and a suite of 21 absorption feature indices. The models are checked against a wide variety of available observations. Examinations of model output yield the following conclusions. (1) If the percentage change delta age/delta Z approximately equals 3/2 for two populations, they will appear almost identical in most indices. A few indices break this degeneracy by being either more abundance sensitive (Fe4668, Fe5015, Fe5709, and Fe5782) or more age sensitive (G4300, H beta, and presumably higher order Balmer lines) than usual. (2) Present uncertainties in stellar evolution are of the same magnitude as the effects of IMF and Y in the indices studied. (3) Changes in abundance ratios (like (Mg/Fe)) are predicted to be readily apparent in the spectra of old stellar populations. (4) The I-band flux of a stellar population is predicted to be nearly independent of metallicity and only modestly sensitive to age. The I band is therefore recommended for standard candle work or studies of M/L in galaxies. Other conclusions stem from this work. (1) Intercomparison of models and observations of two TiO indices seem to indicate variation of the (V/Ti) ratio among galaxies, but it is not clear how this observation ties into the standard picture of chemical enrichment. (2) Current estimates of (Fe/H) for the most metal-rich globulars that are based on integrated indices are probably slightly too high. (3) Colors of population models from different authors exhibit a substantial range. At solar metallicity and 13 Gyr, this range corresponds to an age error of roughly +/- 7 Gyr. Model colors from different authors applied in a differential sense have smaller uncertainties. (4) In the present models the dominant error for colors is probably the transformation from stellar atmospheric parameters to stellar colors. (5) Stellar B - V is difficult to model, and current spreads among different authors can reach 0.2 mag. (6) If known defects in the stellar flux library are corrected, the population model colors of this work in passbands redder than U would be accurate to roughly 0.03 mag in an absolute sense. These corrections are not made in the tables of model output.

Worthey, Guy↗
NASA NTRS1977

Wake characteristics of an eight-leg tower for a MOD-0 type wind turbine

Low speed wind tunnel tests were conducted to determine the flow characteristics of the wake downwind of a 1/25th scale, all tubular eight leg tower concept suitable for application to the DOE-NASA MOD-0 wind power turbine. Measurements were made of wind speed profiles, and from these were determined the wake local minimum velocity, average velocity, and width for several wind approach angles. These data are presented herein along with tower shadow photographs and comparisons with data from an earlier lattice type, four leg tower model constructed of tubular members. Values of average wake velocity defect ratio and average ratio of wake width to blade radius for the eight leg model were estimated to be around 0.17 and 0.30, respectively, at the plane of the rotor blade. These characteristics suggest that the tower wake of the eight leg concept is slightly less than that of the four leg design.

Savino, J. M.↗
NASA NTRS1987

Calculations of the displacement damage and short-circuit current degradation in proton irradiated (AlGa)As-GaAs solar cells

A theoretical model for computing the displacement damage defect density and the short-circuit current (I sub sc) degradation in proton-irradiated (AlGa)As-GaAs p-n junction solar cells is presented. Assumptions were made with justification that the radiation induced displacement defects form an effective recombination center which controls the electron and hole lifetimes in the junction space charge region and in the n-GaAs active layer of the irradiated GaAs p-n junction cells. The degradation of I sub sc in the (AlGa)As layer was found to be negligible compared to the total degradation. In order to determine the I sub sc degradation, the displacement defect density, path length, range, reduced energy after penetrating a distance x, and the average number of displacements formed by one proton scattering event were first calculated. The I sub sc degradation was calculated by using the electron capture cross section in the p-diffused layer and the hole capture cross section in the n-base layer as well as the wavelength dependent absorption coefficients. Excellent agreement was found between the researchers calculated values and the measured I sub sc in the proton irradiated GaAs solar cells for proton energies of 100 KeV to 10 MeV and fluences from 10 to the 10th power p/square cm to 10 to the 12th power p/square cm.

Yeh, C. S.↗
NASA NTRS1987

Investigation of the acoustic properties of composite materials

An effort to provide inspection of the bondlines in the Space Shuttle Solid Rocket Motor (SRM) is discussed. Investigation of the bondlines in the membrane region of the SRM has centered on representative samples provided by Morton Thiokol. These samples have pull-tabs, or in one case grafoil inserts, to simulate delaminations at various points in the multilayer structure of steel case, liner, insulation, liner, and propellant. Discussed here is the continuing approach to examining these defects which is predicated on a model of an ultrasonic wave propagating in a lossy multilayer resonant structure, the experimental arrangements used, and the results of these experiments.

Smith, B. T.↗
NASA NTRS1989

Anomalous effects in silicon solar cell irradiated by 1-MeV protons

Several silicon solar cells having thicknesses of approximately 63 microns, with and without back-surface fields (BSF), were irradiated with 1-MeV protons having fluences between 10 to the 10th and 10 to the 12th sq cm. The irradiations were performed using both normal and isotropic incidence on the rear surfaces of the cells. It was observed that after irradiation with fluences greater than 10 to the 11th protons/sq cm, all BSF cells degraded at a faster rate than cells without BSF. The irradiation results are analyzed using a model in which irradiation-induced defects in the BSF region are taken into account. Tentatively, it is concluded that an increase in defect density due to the formation of aluminum and proton complexes in BSF cells is responsible for the higher-power loss in the BSF cells compared to the non-BSF cells.

Kachare, R.↗
NASA NTRS1990

Bias and design in software specifications

Implementation bias in a specification is an arbitrary constraint in the solution space. Presented here is a model of bias in software specifications. Bias is defined in terms of the specification process and a classification of the attributes of the software product. Our definition of bias provides insight into both the origin and the consequences of bias. It also shows that bias is relative and essentially unavoidable. Finally, we describe current work on defining a measure of bias, formalizing our model, and relating bias to software defects.

Straub, Pablo A.↗