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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 127 records · Page 7
All sourcesNASA NTRSDOE OSTI
NASA NTRS1978

On reliable control system designs

A mathematical model for use in the design of reliable multivariable control systems is discussed with special emphasis on actuator failures and necessary actuator redundancy levels. The model consists of a linear time invariant discrete time dynamical system. Configuration changes in the system dynamics are governed by a Markov chain that includes transition probabilities from one configuration state to another. The performance index is a standard quadratic cost functional, over an infinite time interval. The actual system configuration can be deduced with a one step delay. The calculation of the optimal control law requires the solution of a set of highly coupled Riccati-like matrix difference equations. Results can be used for off-line studies relating the open loop dynamics, required performance, actuator mean time to failure, and functional or identical actuator redundancy, with and without feedback gain reconfiguration strategies.

Birdwell, J. D.↗
NASA NTRS2007

A Procedure for Modeling Structural Component/Attachment Failure Using Transient Finite Element Analysis

Structures often comprise smaller substructures that are connected to each other or attached to the ground by a set of finite connections. Under static loading one or more of these connections may exceed allowable limits and be deemed to fail. Of particular interest is the structural response when a connection is severed (failed) while the structure is under static load. A transient failure analysis procedure was developed by which it is possible to examine the dynamic effects that result from introducing a discrete failure while a structure is under static load. The failure is introduced by replacing a connection load history by a time-dependent load set that removes the connection load at the time of failure. The subsequent transient response is examined to determine the importance of the dynamic effects by comparing the structural response with the appropriate allowables. Additionally, this procedure utilizes a standard finite element transient analysis that is readily available in most commercial software, permitting the study of dynamic failures without the need to purchase software specifically for this purpose. The procedure is developed and explained, demonstrated on a simple cantilever box example, and finally demonstrated on a real-world example, the American Airlines Flight 587 (AA587) vertical tail plane (VTP).

Lovejoy, Andrew E.↗
NASA NTRS2015

Insulation Resistance Degradation in Ni-BaTiO3 Multilayer Ceramic Capacitors

Insulation resistance (IR) degradation in NiBaTiO3 multilayer ceramic capacitors has been characterized by the measurement of both time to failure (TTF) and direct current leakage current as a function of stress time under highly accelerated life test conditions. The measured leakage current time dependence data fit well to an exponential form, and a characteristic growth time tau (sub SD) can be determined. A greater value of tau (sub SD) represents a slower IR degradation process. Oxygen vacancy migration and localization at the grain boundary region results in the reduction of the Schottky barrier height and has been found to be the main reason for IR degradation in NiBaTiO3 capacitors. The reduction of barrier height as a function oftime follows an exponential relation of phi (t ) = phi (0) e (exp -2Kt), where 13 the degradation rate constant K Koe (Ek/kT) is inversely proportional to the mean TTF (MTTF) and can be determined using an Arrhenius plot. For oxygen vacancy electromigration, a lower barrier height phi (0) will favor a slow IR degradation process, but a lower phi (0) will also promote electronic carrier conduction across the barrier and decrease the IR. As a result, a moderate barrier height phi (0) (and therefore a moderate IR value) with a longer MTTF (smaller degradation rate constant K) will result in a minimized IR degradation process and the most improved reliability in NiBaTiO3 multilayer ceramic capacitors.

reliability↗
NASA NTRS1993

Enhanced methods for determining operational capabilities and support costs of proposed space systems

This report documents the work accomplished during the first two years of research to provide support to NASA in predicting operational and support parameters and costs of proposed space systems. The first year's research developed a methodology for deriving reliability and maintainability (R & M) parameters based upon the use of regression analysis to establish empirical relationships between performance and design specifications and corresponding mean times of failure and repair. The second year focused on enhancements to the methodology, increased scope of the model, and software improvements. This follow-on effort expands the prediction of R & M parameters and their effect on the operations and support of space transportation vehicles to include other system components such as booster rockets and external fuel tanks. It also increases the scope of the methodology and the capabilities of the model as implemented by the software. The focus is on the failure and repair of major subsystems and their impact on vehicle reliability, turn times, maintenance manpower, and repairable spares requirements. The report documents the data utilized in this study, outlines the general methodology for estimating and relating R&M parameters, presents the analyses and results of application to the initial data base, and describes the implementation of the methodology through the use of a computer model. The report concludes with a discussion on validation and a summary of the research findings and results.

Ebeling, Charles↗
NASA NTRS2018

A Fast Monte Carlo Method for Model-Based Prognostics Based on Stochastic Calculus

This work proposes a fast Monte Carlo method to solve differential equations utilized in model-based prognostics. The methodology is derived from the theory of stochastic calculus, and the goal of such a method is to speed up the estimation of the probability density functions describing the independent variable evolution over time. In the prognostic scenarios presented in this paper, the stochastic differential equations describe variables directly or indirectly related to the degradation of a monitored system. The method allows the estimation of the probability density functions by solving the deterministic equation and approximating the stochastic integrals using samples of the model noise. By so doing, the prognostic problem is solved without the Monte Carlo simulation based on Euler's forward method, which is typically the most time consuming task of the prediction stage. Three different prognostic scenarios are presented as proof of concept: (i) life prediction of electrolytic capacitors, (ii) remaining time to discharge of Lithium-ion batteries, and (iii) prognostic of cracked structures under fatigue loading. The paper shows how the method produces probability density functions that are statistically indistinguishable from the distributions estimated with Euler's forward Monte Carlo simulation. However, the proposed solution is orders of magnitude faster when computing the time-to-failure distribution of the monitored system. The approach may enable complex real-time prognostics and health management solutions with limited computing power.

Corbetta, M.↗
NASA NTRS2019

A Fast Monte Carlo Method for Model-Based Prognostics Based on Stochastic Calculus

This work proposes a fast Monte Carlo method to solve differential equations utilized in model-based prognostics. The methodology is derived from the theory of stochastic calculus, and the goal of such a method is to speed up the estimation of the probability density functions describing the independent variable evolution over time. In the prognostic scenarios presented in this paper, the stochastic differential equations describe variables directly or indirectly related to the degradation of a monitored system. The method allows the estimation of the probability density functions by solving the deterministic equation and approximating the stochastic integrals using samples of the model noise. By so doing, the prognostic problem is solved without the Monte Carlo simulation based on Euler's forward method, which is typically the most time consuming task of the prediction stage. Three different prognostic scenarios are presented as proof of concept: (i) life prediction of electrolytic capacitors, (ii) remaining time to discharge of Lithium-ion batteries, and (iii) prognostic of cracked structures under fatigue loading. The paper shows how the method produces probability density functions that are statistically indistinguishable from the distributions estimated with Euler's forward Monte Carlo simulation. However, the proposed solution is orders of magnitude faster when computing the time-to-failure distribution of the monitored system. The approach may enable complex real-time prognostics and health management solutions with limited computing power.

stochastic calculus↗
NASA NTRS1977

Rotor burst protection program: Statistics on aircraft gas turbine engine rotor failures that occurred in US commercial aviation during 1975

Statistics on gas turbine rotor failures that have occurred in U.S. commercial aviation during 1975 are presented. The compiled data were analyzed to establish: (1) The incidence of rotor failures and the number of contained and uncontained rotor bursts; (2) The distribution of rotor bursts with respect to engine rotor component; i.e., fan, compressor or turbine; (3) The type of rotor fragment (disk, rim or blade) typically generated at burst; (4) The cause of failure; (5) The type of engines involved; and (6) The flight condition at the time of failure.

Delucia, R. A.↗
NASA NTRS2011

Reliability Evaluation of Base-Metal-Electrode Multilayer Ceramic Capacitors for Potential Space Applications

Base-metal-electrode (BME) ceramic capacitors are being investigated for possible use in high-reliability spacelevel applications. This paper focuses on how BME capacitors construction and microstructure affects their lifetime and reliability. Examination of the construction and microstructure of commercial off-the-shelf (COTS) BME capacitors reveals great variance in dielectric layer thickness, even among BME capacitors with the same rated voltage. Compared to PME (precious-metal-electrode) capacitors, BME capacitors exhibit a denser and more uniform microstructure, with an average grain size between 0.3 and 0.5 m, which is much less than that of most PME capacitors. BME capacitors can be fabricated with more internal electrode layers and thinner dielectric layers than PME capacitors because they have a fine-grained microstructure and do not shrink much during ceramic sintering. This makes it possible for BME capacitors to achieve a very high capacitance volumetric efficiency. The reliability of BME and PME capacitors was investigated using highly accelerated life testing (HALT). Most BME capacitors were found to fail with an early avalanche breakdown, followed by a regular dielectric wearout failure during the HALT test. When most of the early failures, characterized with avalanche breakdown, were removed, BME capacitors exhibited a minimum mean time-to-failure (MTTF) of more than 105 years at room temperature and rated voltage. Dielectric thickness was found to be a critical parameter for the reliability of BME capacitors. The number of stacked grains in a dielectric layer appears to play a significant role in determining BME capacitor reliability. Although dielectric layer thickness varies for a given rated voltage in BME capacitors, the number of stacked grains is relatively consistent, typically around 12 for a number of BME capacitors with a rated voltage of 25V. This may suggest that the number of grains per dielectric layer is more critical than the thickness itself for determining the rated voltage and the life expectancy of the BME capacitor. The leakage current characterization and the failure analysis results suggest that most of these early avalanche failures are due to the extrinsic minor construction defects introduced during fabrication of BME capacitors. The concentration of the extrinsic defects must be reduced if the BME capacitors are considered for high reliability applications. There are two approaches that can reduce or prevent the occurrence of early failure in BME capacitors: (1) to reduce the defect concentration with improved processing control; (2) to prevent the use of BME capacitors under harsh external stress levels so that the extrinsic defects will never be triggered for a failure. In order to do so appropriate dielectric layer thickness must be determined for a given rated voltage.

Liu, David (Donhang)↗
NASA NTRS1962

DESIGN AND TEST EXPERIENCES WITH INSTABILITY OF MAJOR AIRFRAME COMPONENTS

Two test incidents involving instability of large scale commercially built structures are described. Two classes of structure are discussed; the first, a fuselage with skin designed to buckle at low stress, and the second, a wing whose surface remains unbuckled to failure. The structure in the region of failure is defined and the failures described and illustrated. Insofar as possible, the stresses in the critical area at the time of failure are reported and compared to strength determined by analysis. Both fuselage and wing surfaces were observed to fail in the mode of a medium range column when adequate support was provided by ribs and frames. Initial failure in the wing example was premature due to a design deficiency in rib strength. A clear illustration is given of the effect of rib stiffness on wing surface stability. Adding stiffness to wing ribs increases the limit of surface stability to the theoretical flat panel value.

SHELL STABILITY↗
NASA NTRS1988

An Investigation of the Ability to Recover from Transients Following Failures for Single-Pilot Rotorcraft

A moving-base simulation was conducted to investigate a pilot's ability to recover from transients following single-axis hard-over failures of the flight-control system. The investigation was performed in conjunction with a host simulation that examined the influence of control modes on a single pilot's ability to perform various mission elements under high-workload conditions. The NASA Ames large-amplitude-motion Vertical Motion Simulator (VMS) was utilized, and the experimental variables were the failure axis, the severity of the failure, and the airspeed at which the failure occurred. Other factors, such as pilot workload and terrain and obstacle proximity at the time of failure, were kept as constant as possible within the framework of the host simulation task scenarios. No explicit failure warnings were presented to the pilot. Data from the experiment are shown, and pilot ratings are compared with the proposed handling-qualities requirements for military rotorcraft. Results indicate that the current proposed failure transient requirements may need revision.

Mansur, M. Hossein↗
NASA NTRSDate not supplied

The System Complexity Metric (SCM) Predicts System Costs and Failure Rates

A complex system has many parts and interactions and so is difficult to understand. Systems with higher complexity generally have higher costs and failure rates. A System Complexity Metric (SCM) is defined to be the sum of the number of nodes, N, in the system block diagram plus the number of one-way interactions, I, between the nodes. SCM = N + I. SCMs are easily determined by direct inspection of high level block diagrams of life support systems. System cost was found to be directly proportional to SCM. The system MTBF (Mean Time Before Failure) is the inverse of the system failure rate. MTBF = 1/f. The system MTBF was found to be proportional to SCM^(-2.2) for estimated preflight MTBFs. As is typical for systems that are not extensively tested and redesigned to eliminate unexpected failure modes, the life support flight failure rates were about ten times higher than the preflight estimates and the MTBFs one-tenth the preflight estimates. The system MTBF was found to be proportional to SCM^(-2.6) for observed flight MTBFs.

System compleity↗
NASA NTRS2003

A Survey of Logic Formalisms to Support Mishap Analysis

Mishap investigations provide important information about adverse events and near miss incidents. They are intended to help avoid any recurrence of previous failures. Over time, they can also yield statistical information about incident frequencies that helps to detect patterns of failure and can validate risk assessments. However, the increasing complexity of many safety critical systems is posing new challenges for mishap analysis. Similarly, the recognition that many failures have complex, systemic causes has helped to widen the scope of many mishap investigations. These two factors have combined to pose new challenges for the analysis of adverse events. A new generation of formal and semi-formal techniques have been proposed to help investigators address these problems. We introduce the term mishap logics to collectively describe these notations that might be applied to support the analysis of mishaps. The proponents of these notations have argued that they can be used to formally prove that certain events created the necessary and sufficient causes for a mishap to occur. These proofs can be used to reduce the bias that is often perceived to effect the interpretation of adverse events. Others have argued that one cannot use logic formalisms to prove causes in the same way that one might prove propositions or theorems. Such mechanisms cannot accurately capture the wealth of inductive, deductive and statistical forms of inference that investigators must use in their analysis of adverse events. This paper provides an overview of these mishap logics. It also identifies several additional classes of logic that might also be used to support mishap analysis.

Johnson, Chris↗
NASA NTRS1989

A real time microcomputer implementation of sensor failure detection for turbofan engines

An algorithm was developed which detects, isolates, and accommodates sensor failures using analytical redundancy. The performance of this algorithm was demonstrated on a full-scale F100 turbofan engine. The algorithm was implemented in real-time on a microprocessor-based controls computer which includes parallel processing and high order language programming. Parallel processing was used to achieve the required computational power for the real-time implementation. High order language programming was used in order to reduce the programming and maintenance costs of the algorithm implementation software. The sensor failure algorithm was combined with an existing multivariable control algorithm to give a complete control implementation with sensor analytical redundancy. The real-time microprocessor implementation of the algorithm which resulted in the successful completion of the algorithm engine demonstration, is described.

Delaat, John C.↗
NASA NTRS1990

A real time microcomputer implementation of sensor failure detection for turbofan engines

An algorithm was developed that detects, isolates, and accommodates sensor failures using analytical redundancy. The performance of this algorithm has been demonstrated on a full-scale F100 turbofan engine. The algorithm was implemented in real-time on a microprocessor-based controls computer which includes parallel processing and high order language programming. Parallel processing was used to achieve the required computational power for the real-time implementation. High order language programming was used in order to reduce the programming and maintenance costs of the algorithm implementation software. The sensor failure algorithm was combined with an existing multivariable control algorithm to give a complete control implementation with sensor analytical redundancy. The real-time microprocessor implementation of the algorithm, which resulted in the successful completion of the algorithm engine demonstration, is described.

Delaat, John C.↗
NASA NTRS2006

Effect of High Temperature Storage in Vacuum, Air, and Humid Conditions on Degradation of Gold/Aluminum Wire Bonds in PEMs

Microcircuits encapsulated in three plastic package styles were stored in different environments at temperatures varying from 130 C to 225 C for up to 4,000 hours in some cases. To assess the effect of oxygen, the parts were aged at high temperatures in air and in vacuum chambers. The effect of humidity was evaluated during long-term highly accelerated temperature and humidity stress testing (HAST) at temperatures of 130 C and 150 C. High temperature storage testing of decapsulated microcircuits in air, vacuum, and HAST chambers was carried out to evaluate the role of molding compounds in the environmentally-induced degradation and failure of wire bonds (WB). This paper reports on accelerating factors of environment and molding compound on WB failures. It has been shown that all environments, including oxygen, moisture, and the presence of molding compounds reduce time-to-failures compared to unencapsulated devices in vacuum conditions. The mechanism of the environmental effect on KB degradation is discussed.

Teverovsky, Alexander↗
NASA NTRSDate not supplied

Inflatable Softgoods Testing Capability Development for Habitation

The Habitation Systems Development Office (HP40) at NASA Marshall Space Flight Center supports systems engineering, integration, and project management for next generation space habitats. The office is responsible for formulation activities for Lunar Surface Habitat and Mars Transit Habitat. HP40 also manages commercial partnerships for exploration habitat development. The Lunar Surface Habitat is intended to initially support a minimum of two crew on the lunar surface for an approximately 30-day mission, with the ability to accommodate four crew for short durations. The Mars Transit Habitat will transport four crew to and from Mars orbit on a potentially 1,200 day mission. Both concepts are envisioned to leverage inflatable softgoods as the primary structural material for the habitation portion of the architecture. Inflatable softgoods are a complex, multi-material system consisting of multiple layers which perform specific functions. A bladder layer (polymer) contains the habitat’s atmosphere. The bladder is indexed to a woven restraint layer, usually Kevlar or Vectran, which serves as the structural layer. The remaining outer layers are for micro-meteoroid orbital debris (MMOD) shielding, protection from atomic Oxygen (if the material system is to be deployed in low earth orbit), and thermal insulation. The primary advantage of inflatable softgoods is that they can offer a larger volume per unit mass relative to a rigid metal structure. Inflatable softgoods have a strong development heritage within NASA, beginning with work in the 1960s in partnership with Goodyear Aerospace and continuing with Johnson Space Center’s TransHab project in the 1990s . Some development efforts subsequently transitioned into the private sector to mature the material technology for flight applications, including human habitation. In August 2022, NASA published its guidelines for certification of crewed inflatable softgoods structures (JSC-67721). This document outlines a series of tests which will be needed to certify inflatable softgoods material systems for use in crewed mission applications. It includes burst testing at the subscale and full-scale to determine the ultimate burst pressure of the softgoods architecture. Creep (long term deformation of the material under stress) is a key failure mode which must be characterized. Creep testing at the component and module levels is also recommended to generate time to failure curves and verify that the inflatable system has a predicted operational life which exceeds mission parameters. ET (Test Engineering) at MSFC and HP40 have worked together to establish softgoods testing capabilities for the center. This includes the ability to conduct module level burst tests and creep tests. The poster will highlight these capabilities and provide examples of testing which has been performed to date by ET. NASA MSFC anticipates that these test capabilities will continue to offer critical support for companies pursuing inflatable softgoods for exploration applications (lunar surface habitation, Mars transit) as well as commercial low earth orbit platforms.

habitation↗
NASA NTRS2017

A Thermal Runaway Failure Model for Low-Voltage BME Ceramic Capacitors with Defects

Reliability of base metal electrode (BME) multilayer ceramic capacitors (MLCCs) that until recently were used mostly in commercial applications, have been improved substantially by using new materials and processes. Currently, the inception of intrinsic wear-out failures in high quality capacitors became much greater than the mission duration in most high-reliability applications. However, in capacitors with defects degradation processes might accelerate substantially and cause infant mortality failures. In this work, a physical model that relates the presence of defects to reduction of breakdown voltages and decreasing times to failure has been suggested. The effect of the defect size has been analyzed using a thermal runaway model of failures. Adequacy of highly accelerated life testing (HALT) to predict reliability at normal operating conditions and limitations of voltage acceleration are considered. The applicability of the model to BME capacitors with cracks is discussed and validated experimentally.

reliability↗
NASA NTRS2009

Space Transportation System Availability Relationships to Life Cycle Cost

Future space transportation architectures and designs must be affordable. Consequently, their Life Cycle Cost (LCC) must be controlled. For the LCC to be controlled, it is necessary to identify all the requirements and elements of the architecture at the beginning of the concept phase. Controlling LCC requires the establishment of the major operational cost drivers. Two of these major cost drivers are reliability and maintainability, in other words, the system's availability (responsiveness). Potential reasons that may drive the inherent availability requirement are the need to control the number of unique parts and the spare parts required to support the transportation system's operation. For more typical space transportation systems used to place satellites in space, the productivity of the system will drive the launch cost. This system productivity is the resultant output of the system availability. Availability is equal to the mean uptime divided by the sum of the mean uptime plus the mean downtime. Since many operational factors cannot be projected early in the definition phase, the focus will be on inherent availability which is equal to the mean time between a failure (MTBF) divided by the MTBF plus the mean time to repair (MTTR) the system. The MTBF is a function of reliability or the expected frequency of failures. When the system experiences failures the result is added operational flow time, parts consumption, and increased labor with an impact to responsiveness resulting in increased LCC. The other function of availability is the MTTR, or maintainability. In other words, how accessible is the failed hardware that requires replacement and what operational functions are required before and after change-out to make the system operable. This paper will describe how the MTTR can be equated to additional labor, additional operational flow time, and additional structural access capability, all of which drive up the LCC. A methodology will be presented that provides the decision makers with the understanding necessary to place constraints on the design definition. This methodology for the major drivers will determine the inherent availability, safety, reliability, maintainability, and the life cycle cost of the fielded system. This methodology will focus on the achievement of an affordable, responsive space transportation system. It is the intent of this paper to not only provide the visibility of the relationships of these major attribute drivers (variables) to each other and the resultant system inherent availability, but also to provide the capability to bound the variables, thus providing the insight required to control the system's engineering solution. An example of this visibility is the need to provide integration of similar discipline functions to allow control of the total parts count of the space transportation system. Also, selecting a reliability requirement will place a constraint on parts count to achieve a given inherent availability requirement, or require accepting a larger parts count with the resulting higher individual part reliability requirements. This paper will provide an understanding of the relationship of mean repair time (mean downtime) to maintainability (accessibility for repair), and both mean time between failure (reliability of hardware) and the system inherent availability.

Rhodes, Russel E.↗