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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 NTRS1985

Effect of bond coat creep and oxidation on TBC integrity

The potential of thermal barrier coatings (TBCs) on high-pressure turbine (HPT) nozzles and blades is limited at present by the inability to quantitatively predict TBC life for these components. The goal is to isolate the major TBC failure mechanisms, which is part of the larger program aimed at developing TBC life prediction models. Based on the results of experiments to isolate TBC failure mechanisms, the effects of bond coat oxidation and bond coat creep on TBC integrity is discussed. In bond coat oxidation experiments, Rene prime 80 specimens coated with a NiCrAlY/ZrO2-8 percent Y2O3 TBC received isothermal pre-exposures at 2000 F in static argon, static air, or received no pre-exposure. The effects of oxidation due to the pre-exposures were determined by thermal cycle tests in both static air and static argon at 2000 F. To study the effect of bond coat creep on TBS behavior, four bond coats with different creep properties were evaluated by thermal cycle tests in air at 2000 F. The test results, the relative importance of these two failure mechanisms, and how their effects may be quantified will also be discussed.

Duderstadt, E. C.↗
NASA NTRS2017

Failure Analysis of Heavy-Ion-Irradiated Schottky Diodes

In this paper, we use high- and low-magnification optical microscope images, thermal infrared camera images, and scanning electron microscope images to identify failure locations in heavy-ion-irradiated Schottky diodes. After failures have been identified, the parts were cross-sectioned to describe the structure of the failures and energy dispersive x-ray spectroscopy was used to characterize the materials in the failure structures.

Radiation effects↗
NASA NTRS2005

Fractographic Examination of the Vertical Stabilizer and Rudder from American Airlines Flight 587

The first major structural component failure of a composite part on a commercial airplane occurred during the crash of American Airlines Flight 587. The fractured composite lugs that attached the vertical stabilizer to the aircraft tail and the fractured composite honeycomb rudder were examined as part of the National Transportation Safety Board investigation of the accident. In this paper the composite fractures are described and the resulting clues to the failure events are discussed.

Fox, Matthew R.↗
NASA NTRS1996

Program For Evaluation Of Reliability Of Ceramic Parts

CARES/LIFE predicts probability of failure of monolithic ceramic component as function of service time. Assesses risk that component fractures prematurely as result of subcritical crack growth (SCG). Effect of proof testing of components prior to service also considered. Coupled to such commercially available finite-element programs as ANSYS, ABAQUS, MARC, MSC/NASTRAN, and COSMOS/M. Also retains all capabilities of previous CARES code, which includes estimation of fast-fracture component reliability and Weibull parameters from inert strength (without SCG contributing to failure) specimen data. Estimates parameters that characterize SCG from specimen data as well. Written in ANSI FORTRAN 77 to be machine-independent. Program runs on any computer in which sufficient addressable memory (at least 8MB) and FORTRAN 77 compiler available. For IBM-compatible personal computer with minimum 640K memory, limited program available (CARES/PC, COSMIC number LEW-15248).

Nemeth, N.↗
NASA NTRS2009

Orbiter Payload Bay Bucket Hoist Mishap...An Accident We Should Never Forget

This slide presentation reviews the accident that occurred in 1985 when a bay bucket hoist fell from its stowed position. This accident damaged the orbiter, injured a technician, and delayed the launch. The accident was investigated, and the cause of the accident was determined to be the practice of two-blocking. Two-blocking is the result of hoisting beyond the intended safe upper limit of hook travel to the point of solid contact between the load block and the upper block or hoist/trolley structure. The usual result is immediate failure of the wire rope, due to the ropes being cut by the grooves of the drum or sheaves. The design of the hoist, the inspection, and the operator training were all in part responsible for this failure.

Lytle, Bradford P.↗
DOE OSTI2025

Failure Strain and Related Triaxiality of Aluminum 6061-T6, A36 Carbon Steel, 304 Stainless Steel, and Nitronic 60 Metals, Part I: Experimental Investigation

The objective of this study is to develop failure-limit material models for Aluminum 6061-T6, A36 Carbon Steel, 304 Stainless Steel, and Nitronic 60 metals, based on parameters of plastic equivalent strain (failure strain) and stress triaxiality. The research is conducted in two parts. This paper presents Part One of the study. In Part One, custom-designed test specimens undergo controlled uniaxial tension and compression testing at ambient temperature. These tests are performed at quasi-static speeds using Universal Testing Machines (UTMs) in accordance with ASTM E8 and ASTM E9 standards. Experimental data, specifically engineering stress–strain and force–displacement curves, are recorded from the onset of loading until specimen fracture, or in the case of compression tests, until the capacity of the testing machine is reached. In Part Two, the emphasis shifts to the calibration of Finite Element Analysis (FEA) models of the custom-designed test specimens. Plastic equivalent strain and the corresponding stress triaxiality values at failure are extracted from each test specimen for the given metal. These values are then systematically plotted onto a single graph to construct the failure-limit curve, which delineates the boundary conditions for material failure. This approach will facilitate the development of a comprehensive material property definition that correlates plastic equivalent strain with stress triaxiality at failure for Aluminum 6061-T6, A36 Carbon Steel, 304 Stainless Steel, and Nitronic 60 metals.

Harwell, Ron↗
NASA NTRS2016

Reliability and Maintainability Analysis for the Amine Swingbed Carbon Dioxide Removal System

I have performed a reliability & maintainability analysis for the Amine Swingbed payload system. The Amine Swingbed is a carbon dioxide removal technology that has gone through 2,400 hours of International Space Station on-orbit use between 2013 and 2016. While the Amine Swingbed is currently an experimental payload system, the Amine Swingbed may be converted to system hardware. If the Amine Swingbed becomes system hardware, it will supplement the Carbon Dioxide Removal Assembly (CDRA) as the primary CO2 removal technology on the International Space Station. NASA is also considering using the Amine Swingbed as the primary carbon dioxide removal technology for future extravehicular mobility units and for the Orion, which will be used for the Asteroid Redirect and Journey to Mars missions. The qualitative component of the reliability and maintainability analysis is a Failure Modes and Effects Analysis (FMEA). In the FMEA, I have investigated how individual components in the Amine Swingbed may fail, and what the worst case scenario is should a failure occur. The significant failure effects are the loss of ability to remove carbon dioxide, the formation of ammonia due to chemical degradation of the amine, and loss of atmosphere because the Amine Swingbed uses the vacuum of space to regenerate the Amine Swingbed. In the quantitative component of the reliability and maintainability analysis, I have assumed a constant failure rate for both electronic and nonelectronic parts. Using this data, I have created a Poisson distribution to predict the failure rate of the Amine Swingbed as a whole. I have determined a mean time to failure for the Amine Swingbed to be approximately 1,400 hours. The observed mean time to failure for the system is between 600 and 1,200 hours. This range includes initial testing of the Amine Swingbed, as well as software faults that are understood to be non-critical. If many of the commercial parts were switched to military-grade parts, the expected mean time to failure would be 2,300 hours. Both calculated mean times to failure for the Amine Swingbed use conservative failure rate models. The observed mean time to failure for CDRA is 2,500 hours. Working on this project and for NASA in general has helped me gain insight into current aeronautics missions, reliability engineering, circuit analysis, and different cultures. Prior my internship, I did not have a lot knowledge about the work being performed at NASA. As a chemical engineer, I had not really considered working for NASA as a career path. By engaging in interactions with civil servants, contractors, and other interns, I have learned a great deal about modern challenges that NASA is addressing. My work has helped me develop a knowledge base in safety and reliability that would be difficult to find elsewhere. Prior to this internship, I had not thought about reliability engineering. Now, I have gained a skillset in performing reliability analyses, and understanding the inner workings of a large mechanical system. I have also gained experience in understanding how electrical systems work while I was analyzing the electrical components of the Amine Swingbed. I did not expect to be exposed to as many different cultures as I have while working at NASA. I am referring to both within NASA and the Houston area. NASA employs individuals with a broad range of backgrounds. It has been great to learn from individuals who have highly diverse experiences and outlooks on the world. In the Houston area, I have come across individuals from different parts of the world. Interacting with such a high number of individuals with significantly different backgrounds has helped me to grow as a person in ways that I did not expect. My time at NASA has opened a window into the field of aeronautics. After earning a bachelor's degree in chemical engineering, I plan to go to graduate school for a PhD in engineering. Prior to coming to NASA, I was not aware of the graduate Pathways program. I intend to apply for the graduate Pathways program as positions are opened up. I would like to pursue future opportunities with NASA, especially as my engineering career progresses.

Dunbar, Tyler↗
NASA NTRS1995

Optimal Category-A Helicopter Flight Trajectories for Operation From a Clear Heliport

Engine failure represents a major safety hazard to helicopter operation. As a result, FA certifies helicopters according to their abilities to survive engine failures. Federal Aviation Regulation Part 29 specifies that transport helicopters must be certified as either category A or B. Category-B certification applies to either single or multi-engine helicopters with gross weight less than 20,000 lbs. A Category-B helicopter must be able to land safely in the case of one or all engine failures. There is no requirement for continued flight capability. In contrast, Category-A certification applies to multi-engine helicopters with independent engine systems. It requires that helicopter can continue flight with one engine inoperative (OEI). Therefore, Category-A helicopters are capable of operating from rooftops and oil rigs and flying to areas where no emergency landing sites are available. While there is no maximum weight limit, a Category-A helicopter must be able to satisfy OEI operation requirements within the available runway field. Additional information is contained in the original extended abstract.

Sharma, Vivek↗
DOE OSTI2024

Mitigation of distortion of Al/steel part under simulated paint baking condition: Experiment and numerical model studies

Multi-material joining of lightweight structures is essential to reduce vehicle weight for more energy savings and less greenhouse gas emission. However, mismatch of thermal expansion coefficient for dissimilar materials during the paint baking process can induce part distortion and joint failure for adhesive bonding. Here, in the present work, a thermomechanical model based on contact mechanics and large deformation theory was developed for dissimilar high-strength Al alloy and steel components to study the distortion mechanism and influential factors of the residual gap. The established model was used to optimize joint conditions, such as pitch distance and part geometry. When a weld pitch is shorter than 100 mm, the maximum gap between Al and steel part can be greatly reduced to 0.1 mm, and the local stress and plastic strain around the joint during the oven heating and cooling cycle are also substantially reduced compared with the long pitch case (900 mm). The numerical modeling results revealed that a comparable bending stiffness ratio between the steel and Al cross sections is critical to the minimization of gap and distortion under paint baking condition. Digital image correlation technique was used to measure the overall part distortion and local strain distribution that were used to validate the model prediction. Weld bonding (adhesive bonding with friction bit joining) process was successfully employed to join Al to steel component without gap opening in adhesive after the paint baking and cooling.

36 MATERIALS SCIENCE↗
NASA NTRS1992

Reliability evaluation methodology for NASA applications

Liquid rocket engine technology has been characterized by the development of complex systems containing large number of subsystems, components, and parts. The trend to even larger and more complex system is continuing. The liquid rocket engineers have been focusing mainly on performance driven designs to increase payload delivery of a launch vehicle for a given mission. In otherwords, although the failure of a single inexpensive part or component may cause the failure of the system, reliability in general has not been considered as one of the system parameters like cost or performance. Up till now, quantification of reliability has not been a consideration during system design and development in the liquid rocket industry. Engineers and managers have long been aware of the fact that the reliability of the system increases during development, but no serious attempts have been made to quantify reliability. As a result, a method to quantify reliability during design and development is needed. This includes application of probabilistic models which utilize both engineering analysis and test data. Classical methods require the use of operating data for reliability demonstration. In contrast, the method described in this paper is based on similarity, analysis, and testing combined with Bayesian statistical analysis.

Taneja, Vidya S.↗
NASA NTRS1988

Delamination durability of composite materials for rotorcraft

Delamination is the most commonly observed failure mode in composite rotorcraft dynamic components. Although delamination may not cause immediate failure of the composite part, it often precipitates component repair or replacement, which inhibits fleet readiness, and results in increased life cycle costs. A fracture mechanics approach for analyzing, characterizing, and designing against delamination will be outlined. Examples of delamination problems will be illustrated where the strain energy release rate associated with delamination growth was found to be a useful generic parameter, independent of thickness, layup, and delamination source, for characterizing delamination failure. Several analysis techniques for calculating strain energy release rates for delamination from a variety of sources will be outlined. Current efforts to develop ASTM standard test methods for measuring interlaminar fracture toughness and developing delamination failure criteria will be reviewed. A technique for quantifying delamination durability due to cyclic loading will be presented. The use of this technique for predicting fatigue life of composite laminates and developing a fatigue design philosophy for composite structural components will be reviewed.

Obrien, T. Kevin↗
NASA NTRS1979

Computation of spare parts requirements

Statistical analysis determines probability of failure for N-1 spares. Analysis can help reduce downtime in industrial processes by determining number of spare parts that must be stockpiled. Analysis can also be inverted to decide if number of spares on hand is sufficient for lifetime needs of system.

Mezzacappa, M. A.↗
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 NTRS2008

Effect of Surge Current Testing on Reliability of Solid Tantalum Capacitors

Tantalum capacitors manufactured per military specifications are established reliability components and have less than 0.001% of failures per 1000 hours for grades D or S, thus positioning these parts among electronic components with the highest reliability characteristics. Still, failures of tantalum capacitors do happen and when it occurs it might have catastrophic consequences for the system. To reduce this risk, further development of a screening and qualification system with special attention to the possible deficiencies in the existing procedures is necessary. The purpose of this work is evaluation of the effect of surge current stress testing on reliability of the parts at both steady-state and multiple surge current stress conditions. In order to reveal possible degradation and precipitate more failures, various part types were tested and stressed in the range of voltage and temperature conditions exceeding the specified limits. A model to estimate the probability of post-surge current testing-screening failures and measures to improve the effectiveness of the screening process has been suggested.

Teverovsky, Alexander↗
NASA NTRS2005

Verification of the Multi-Axial, Temperature and Time Dependent (MATT) Failure Criterion

An extensive test and analytical effort has been completed by the Space Shuttle's Reusable Solid Rocket Motor (KSKM) nozzle program to characterize the failure behavior of two epoxy adhesives (TIGA 321 and EA946). As part of this effort, a general failure model, the "Multi-Axial, Temperature, and Time Dependent" or MATT failure criterion was developed. In the initial development of this failure criterion, tests were conducted to provide validation of the theory under a wide range of test conditions. The purpose of this paper is to present additional verification of the MATT failure criterion, under new loading conditions for the adhesives TIGA 321 and EA946. In many cases, the loading conditions involve an extrapolation from the conditions under which the material models were originally developed. Testing was conducted using three loading conditions: multi-axial tension, torsional shear, and non-uniform tension in a bondline condition. Tests were conducted at constant and cyclic loading rates ranging over four orders of magnitude. Tests were conducted under environmental conditions of primary interest to the RSRM program. The temperature range was not extreme, but the loading ranges were extreme (varying by four orders of magnitude). It should be noted that the testing was conducted at temperatures below the glass transition temperature of the TIGA 321 adhesive. However for the EA946, the testing was conducted at temperatures that bracketed the glass transition temperature.

Richardson, David E.↗
NASA NTRS2006

Performance and Reliability of Solid Tantalum Capacitors at Cryogenic Conditions

Performance of different types of solid tantalum capacitors was evaluated at room and low temperatures, down to 15 K. The effect of temperature on frequency dependencies of capacitance, effective series resistances (ESR), leakage currents, and breakdown voltages has been investigated and analyzed. To assess thermo-mechanical robustness of the parts, several groups of loose capacitors and those soldered on FR4 boards were subjected to multiple (up to 500) temperature cycles between room temperature and 77 K. Experiments and mathematical modeling have shown that degradation in tantalum capacitors at low temperatures is mostly due to increasing resistance of the manganese cathode layer, resulting in substantial decrease of the roll-off frequency. Absorption currents follow a power law, I approximately t(sup -m), with the exponent m varying from 0.8 to 1.1. These currents do not change significantly at cryogenic conditions and the value of the exponent remains the same down to 15 K. Variations of leakage currents with voltage can be described by Pool-Frenkel and Schottky mechanisms of conductivity, with the Schottky mechanism prevailing at cryogenic conditions. Breakdown voltages of tantalum capacitors increase and the probability of scintillations decreases at cryogenic temperatures. However, breakdown voltages measured during surge current testing decrease at liquid nitrogen (LN) compared to room-temperature conditions. Results of temperature cycling suggest that tantalum capacitors are capable of withstanding multiple exposures to cryogenic conditions, but the probability of failures varies for different part types.

Teverovsky, Alexander↗
NASA NTRS2017

Parametric Failures in COTS Capacitors

Insertion of COTS components into hi-rel systems require extensive environmental testing of the parts that often results in parametric failures. Based on experience with commercial and hi-rel PME and BME ceramic capacitors and polymer and MnO2 cathode tantalum capacitors, this presentation discusses two major reasons for parametric failures. One is due to the marketing pressure that forces manufacturers to squeeze performance of COTS components thus leaving insufficient margin between the rated and actual characteristics. Another, and probably a more serious reason is degradation of characteristics caused by physico-chemical processes in materials under environmental stresses. Reliability assessment requires development of models to predict behavior of the parts during applications based on accelerated testing that might be outside the specified conditions and target applications. Examples of models developed to simulate and predict wear-out failures are presented. Risks associated with overstressing during HALT are discussed.

Teverovsky, Alexander↗
NASA NTRS2011

Digital Interface Board to Control Phase and Amplitude of Four Channels

An increasing number of parts are designed with digital control interfaces, including phase shifters and variable attenuators. When designing an antenna array in which each antenna has independent amplitude and phase control, the number of digital control lines that must be set simultaneously can grow very large. Use of a parallel interface would require separate line drivers, more parts, and thus additional failure points. A convenient form of control where single-phase shifters or attenuators could be set or the whole set could be programmed with an update rate of 100 Hz is needed to solve this problem. A digital interface board with a field-programmable gate array (FPGA) can simultaneously control an essentially arbitrary number of digital control lines with a serial command interface requiring only three wires. A small set of short, high-level commands provides a simple programming interface for an external controller. Parity bits are used to validate the control commands. Output timing is controlled within the FPGA to allow for rapid update rates of the phase shifters and attenuators. This technology has been used to set and monitor eight 5-bit control signals via a serial UART (universal asynchronous receiver/transmitter) interface. The digital interface board controls the phase and amplitude of the signals for each element in the array. A host computer running Agilent VEE sends commands via serial UART connection to a Xilinx VirtexII FPGA. The commands are decoded, and either outputs are set or telemetry data is sent back to the host computer describing the status and the current phase and amplitude settings. This technology is an integral part of a closed-loop system in which the angle of arrival of an X-band uplink signal is detected and the appropriate phase shifts are applied to the Ka-band downlink signal to electronically steer the array back in the direction of the uplink signal. It will also be used in the non-beam-steering case to compensate for phase shift variations through power amplifiers. The digital interface board can be used to set four 5-bit phase shifters and four 5-bit attenuators and monitor their current settings. Additionally, it is useful outside of the closed-loop system for beamsteering alone. When the VEE program is started, it prompts the user to initialize variables (to zero) or skip initialization. After that, the program enters into a continuous loop waiting for the telemetry period to elapse or a button to be pushed. A telemetry request is sent when the telemetry period is elapsed (every five seconds). Pushing one of the set or reset buttons will send the appropriate command. When a command is sent, the interface status is returned, and the user will be notified by a pop-up window if any error has occurred. The program runs until the End Program button is depressed.

Smith, Amy E.↗