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The impact analysis of composite aircraft structures is discussed. Topics discussed include: background remarks on aircraft crashworthiness; comments on modeling strategies for crashworthiness simulation; initial study of simulation of progressive failure of an aircraft component constructed of composite material; and research direction in composite characterization for impact analysis.
NASA Langley Research Center (LaRC) supported the National Transportation Safety Board (NTSB) in the American Airlines Flight 587 accident investigation due to LaRC's expertise in high-fidelity structural analysis and testing of composite structures and materials. A Global Analysis Team from LaRC reviewed the manufacturer s design and certification procedures, developed finite element models and conducted structural analyses, and participated jointly with the NTSB and Airbus in subcomponent tests conducted at Airbus in Hamburg, Germany. The Global Analysis Team identified no significant or obvious deficiencies in the Airbus certification and design methods. Analysis results from the LaRC team indicated that the most-likely failure scenario was failure initiation at the right rear main attachment fitting (lug), followed by an unstable progression of failure of all fin-to-fuselage attachments and separation of the VTP from the aircraft. Additionally, analysis results indicated that failure initiates at the final observed maximum fin loading condition in the accident, when the VTP was subjected to loads that were at minimum 1.92 times the design limit load condition for certification. For certification, the VTP is only required to support loads of 1.5 times design limit load without catastrophic failure. The maximum loading during the accident was shown to significantly exceed the certification requirement. Thus, the structure appeared to perform in a manner consistent with its design and certification, and failure is attributed to VTP loads greater than expected.
A research program is in progress to develop strain rate dependent deformation and failure models for the analysis of polymer matrix composites subject to high strain rate impact loads. Strain rate dependent inelastic constitutive equations have been developed to model the polymer matrix, and have been incorporated into a micromechanics approach to analyze polymer matrix composites. The Hashin failure criterion has been implemented within the micromechanics results to predict ply failure strengths. The deformation model has been implemented within LS-DYNA, a commercially available transient dynamic finite element code. The deformation response and ply failure stresses for the representative polymer matrix composite AS4/PEEK have been predicted for a variety of fiber orientations and strain rates. The predicted results compare favorably to experimentally obtained values.
The National Aeronautics and Space Administration (NASA) and other organizations have been performing U.S. Spacesuit Knowledge Capture (USSKC) since the beginning of space exploration through published reports, conference presentations, specialized seminars, and classes instructed by veterans in the field. The close physical interaction between spacesuit systems and human beings makes them among the most personally evocative pieces of space hardware. Consequently, spacesuit systems have required nearly constant engineering refinements to do their jobs without impinging on human activity. Since 2008, spacesuit knowledge capture has occurred through video recording, engaging both current and former specialists presenting technical scope specifically to educate individuals and preserve knowledge. These archives of spacesuit legacy reflect its rich history and will provide knowledge that will enhance the chances for the success of future and more ambitious spacesuit system programs. The scope and topics of USSKC have included lessons learned in spacesuit technology; experience from the Gemini, Apollo, Skylab, and Shuttle Programs; the process of hardware certification, design, development, and other program components; spacesuit evolution and experience; failure analysis and resolution; and aspects of program management. USSKC activities have progressed to a level where NASA, the National Air and Space Museum (NASM), Hamilton Sundstrand (HS) and the spacesuit community are now working together to provide a comprehensive way to organize and archive intra-agency information related to the development of spacesuit systems. These video recordings are currently being reviewed for public release using NASA export control processes. After a decision is made for either public or non-public release (internal NASA only), the videos and presentations will be available through the NASA Johnson Space Center Engineering Directorate (EA) Engineering Academy, the NASA Technical Reports Server (NTRS), the NASA Aeronautics & Space Database (NA&SD), or NASA YouTube. Event availability is duly noted in this catalog.
Space life cycle program - test parameters, cell failure analysis, and capacity tests
The Arecibo Observatory collapsed after a progressive structural failure stemming from the failure of a single socket joint cable termination. A failure investigation was conducted to identify the cause of the first failed cable termination socket. Due to the nature of the suspended observatory receiver, the dominant source of loading in the suspension cables was due to deadload, with secondary contributions coming from environmental effects and observatory operation. The high ratio of deadload vs. live load applied to the cable over many years resulted in a creep failure mode of the cast zinc within the socket which further induced stress into the highly stress wires at the entrance of the socket. The design of the socket joint did not explicitly consider socket constituent stress margins and time-dependent damage mechanisms such as creep. Lessons learned from this investigation led to recommendations for revising civil engineering cable standards, and recommendations for manufacturers and designers. The design of cables employing socket terminations should consider the cumulative damage effects from creep and cyclic loading identify their corresponding worst-case inspectable defects or establish a sufficiently high factor of safety so that the design is sufficiently robust to defects and time-dependent failure modes. The design should specify end-of-life capability and set service life inspection intervals with pass/fail inspection criteria. Finally, trial studies on design iterations were conducted to increase the reliability of cables with socket joints.
For the purpose of performing safety analysis and risk assessment for a potential off-nominal atmospheric reentry resulting in vehicle breakup, a synthesis of trajectory propagation coupled with thermal analysis and the evaluation of node failure is required to predict the sequence of events, the timeline, and the progressive demise of spacecraft components. To provide this capability, the Simulation for Prediction of Entry Article Demise (SPEAD) analysis tool was developed. The software and methodology have been validated against actual flights, telemetry data, and validated software, and safety/risk analyses were performed for various programs using SPEAD. This report discusses the capabilities, modeling, validation, and application of the SPEAD analysis tool.
Continuous fiber unidirectional polymer matrix composites (PMCs) can exhibit significant local variations in fiber volume fraction as a result of processing conditions that can lead to further local differences in material properties and failure behavior. In this work, the coupled effects of both local variations in fiber volume fraction and the empirically-based statistical distribution of fiber strengths on the predicted longitudinal modulus and local tensile strength of a unidirectional AS4 carbon fiber/ Hercules 3502 epoxy composite were investigated using the special purpose NASA Micromechanics Analysis Code with Generalized Method of Cells (MAC/GMC); local effective composite properties were obtained by homogenizing the material behavior over repeating units cells (RUCs). The predicted effective longitudinal modulus was relatively insensitive to small (~8%) variations in local fiber volume fraction. The composite tensile strength, however, was highly dependent on the local distribution in fiber strengths. The RUC-averaged constitutive response can be used to characterize lower length scale material behavior within a multiscale analysis framework that couples the NASA code FEAMAC and the ABAQUS finite element solver. Such an approach can be effectively used to analyze the progressive failure of PMC structures whose failure initiates at the RUC level. Consideration of the effect of local variations in constituent properties and morphologies on progressive failure of PMCs is a central aspect of the application of Integrated Computational Materials Engineering (ICME) principles for composite materials.
This contract reviewed the available literature on mechanisms of low velocity impact damage in filament wound rocket motor cases, MDE methods to quantify damage, critical coupon level test methods, manufacturing and material process variables and empirical and analytical modeling off impact damage. The critical design properties for rocket motor cases are biaxial hoop and axial tensile strength. Low velocity impact damage is insidious because it can create serious nonvisible damage at very low impact velocities. In thick rocket motor cases the prevalent low velocity impact damage is fiber fracture and matrix cracking adjacent to the front face. In contrast, low velocity loading of thin wall cylinders induces flexure, depending on span length and the flexure induces delamination and tensile cracking on the back face wall opposed to impact occurs due to flexural stresses imposed by impact loading. Important NDE methods for rocket motor cases are non-contacting methods that allow inspection from one side. Among these are vibrothermography, and pulse-echo methods based on acoustic-ultrasonic methods. High resolution techniques such as x-ray computed tomography appear to have merit for accurate geometrical characterization of local damage to support development of analytical models of micromechanics. The challenge of coupon level testing is to reproduce the biaxial stress state that the full scale article experiences, and to determine how to scale the composite structure to model full sized behavior. Biaxial tensile testing has been performed by uniaxially tensile loading internally pressurized cylinders. This is experimentally difficult due to gripping problems and pressure containment. Much prior work focused on uniaxial tensile testing of model filament wound cylinders. Interpretation of the results of some studies is complicated by the fact that the fabrication process did not duplicate full scale manufacturing. It is difficult to scale results from testing subscale cylinders since there are significant differences in out time of the resins relative to full scale cylinder fabrication, differences in hoop fiber tensioning and unsatisfactory coupon configurations. It appears that development of a new test method for subscale cylinders is merited. Damage tolerance may be improved by material optimization that uses fiber treatments and matrix modifications to control the fiber matrix interface bonding. It is difficult to develop process optimization in subscale cylinders without also modeling the longer out times resins experience in full scale testing. A major breakthrough in characterizing the effect of impact damage on residual strength, and understanding how to scale results of subscale evaluations, will be a sound micromechanical model that described progressive failure of the composite. Such models will utilize a three dimensional stress analysis due to the complex nature of low velocity impact stresses in thick composites. When these models are coupled with non-contact NDE methods that geometrically characterize the damage and acoustic methods that characterize the effective local elastic properties, accurate assessment of residual strength from impact damage may be possible. Directions for further development are suggested.
Fracture mechanics applications in stress analysis and structural design, considering rocket motor case failure
A diagnostic tool for detecting damage to gears was developed. Two different measurement technologies, oil debris analysis and vibration were integrated into a health monitoring system for detecting surface fatigue pitting damage on gears. This integrated system showed improved detection and decision-making capabilities as compared to using individual measurement technologies. This diagnostic tool was developed and evaluated experimentally by collecting vibration and oil debris data from fatigue tests performed in the NASA Glenn Spur Gear Fatigue Rig. An oil debris sensor and the two vibration algorithms were adapted as the diagnostic tools. An inductance type oil debris sensor was selected for the oil analysis measurement technology. Gear damage data for this type of sensor was limited to data collected in the NASA Glenn test rigs. For this reason, this analysis included development of a parameter for detecting gear pitting damage using this type of sensor. The vibration data was used to calculate two previously available gear vibration diagnostic algorithms. The two vibration algorithms were selected based on their maturity and published success in detecting damage to gears. Oil debris and vibration features were then developed using fuzzy logic analysis techniques, then input into a multi sensor data fusion process. Results show combining the vibration and oil debris measurement technologies improves the detection of pitting damage on spur gears. As a result of this research, this new diagnostic tool has significantly improved detection of gear damage in the NASA Glenn Spur Gear Fatigue Rigs. This research also resulted in several other findings that will improve the development of future health monitoring systems. Oil debris analysis was found to be more reliable than vibration analysis for detecting pitting fatigue failure of gears and is capable of indicating damage progression. Also, some vibration algorithms are as sensitive to operational effects as they are to damage. Another finding was that clear threshold limits must be established for diagnostic tools. Based on additional experimental data obtained from the NASA Glenn Spiral Bevel Gear Fatigue Rig, the methodology developed in this study can be successfully implemented on other geared systems.
Life predictions of regeneratively cooled rocket thrust chambers are normally derived from classical material fatigue principles. The failures observed in experimental thrust chambers do not appear to be due entirely to material fatigue. The chamber coolant walls in the failed areas exhibit progressive bulging and thinning during cyclic firings until the wall stress finally exceeds the material rupture stress and failure occurs. A preliminary analysis of an oxygen free high conductivity (OFHC) copper cylindrical thrust chamber demonstrated that the inclusion of cumulative cyclic plastic effects enables the observed coolant wall thinout to be predicted. The thinout curve constructed from the referent analysis of 10 firing cycles was extrapolated from the tenth cycle to the 200th cycle. The preliminary OFHC copper chamber 10-cycle analysis was extended so that the extrapolated thinout curve could be established by performing cyclic analysis of deformed configurations at 100 and 200 cycles. Thus the original range of extrapolation was reduced and the thinout curve was adjusted by using calculated thinout rates at 100 and 100 cycles. An analysis of the same underformed chamber model constructed of half-hard Amzirc to study the effect of material properties on the thinout curve is included.
Life cycle tests of space cell packs - test parameters, cell failure analysis, and capacity tests
The program focuses on predicting the lives of two types of strain-tolerant and oxidation-resistant thermal barrier coating (TBC) systems that are produced by commercial coating suppliers to the gas turbine industry. The plasma-sprayed TBC system, composed of a low-pressure plasma-spray (LPPS) or an argon shrouded plasma-spray (ASPS) applied oxidation resistant NiCrAlY or (CoNiCrAlY) bond coating and an air-plasma-sprayed yttria partially stabilized zirconia insulative layer, is applied by both Chromalloy, Klock, and Union Carbide. The second type of TBS is applied by the electron beam-physical vapor deposition (EB-PVD) process by Temescal. The second year of the program was focused on specimen procurement, TMC system characterization, nondestructive evaluation methods, life prediction model development, and TFE731 engine testing of thermal barrier coated blades. Materials testing is approaching completion. Thermomechanical characterization of the TBC systems, with toughness, and spalling strain tests, was completed. Thermochemical testing is approximately two-thirds complete. Preliminary materials life models for the bond coating oxidation and zirconia sintering failure modes were developed. Integration of these life models with airfoil component analysis methods is in progress. Testing of high pressure turbine blades coated with the program TBS systems is in progress in a TFE731 turbofan engine. Eddy current technology feasibility was established with respect to nondestructively measuring zirconia layer thickness of a TBC system.
The Videogrammetric Model Deformation (VMD) technique, developed at NASA Langley Research Center, was recently used to measure displacements and local surface angle changes on a static aeroelastic wind-tunnel model. The results were assessed for consistency, accuracy and usefulness. Vertical displacement measurements and surface angular deflections (derived from vertical displacements) taken at no-wind/no-load conditions were analyzed. For accuracy assessment, angular measurements were compared to those from a highly accurate accelerometer. Shewhart's Variables Control Charts were used in the assessment of consistency and uncertainty. Some bad data points were discovered, and it is shown that the measurement results at certain targets were more consistent than at other targets. Physical explanations for this lack of consistency have not been determined. However, overall the measurements were sufficiently accurate to be very useful in monitoring wind-tunnel model aeroelastic deformation and determining flexible stability and control derivatives. After a structural model component failed during a highly loaded condition, analysis of VMD data clearly indicated progressive structural deterioration as the wind-tunnel condition where failure occurred was approached. As a result, subsequent testing successfully incorporated near- real-time monitoring of VMD data in order to ensure structural integrity. The potential for higher levels of consistency and accuracy through the use of statistical quality control practices are discussed and recommended for future applications.
The ability to learn from both the mistakes and successes of the past is vital to assuring success in the future. Due to the close physical interaction between spacesuit systems and human beings as users, spacesuit technology and usage lends itself rather uniquely to the benefits realized from the skillful organization of historical information; its dissemination; the collection and identification of artifacts; and the education of individuals and groups working in the field. The National Aeronautics and Space Administration (NASA), other organizations and individuals have been performing United States (U.S.) spacesuit knowledge capture since the beginning of space exploration. Avenues used to capture the knowledge have included publication of reports; conference presentations; specialized seminars; and classes usually given by veterans in the field. Recently, the effort has been more concentrated and formalized whereby a new avenue of spacesuit knowledge capture has been added to the archives through which videotaping occurs, engaging both current and retired specialists in the field presenting technical scope specifically for education and preservation of knowledge. Now with video archiving, all these avenues of learning can be brought to life with the real experts presenting their wealth of knowledge on screen for future learners to enjoy. U.S. spacesuit knowledge capture topics have included lessons learned in spacesuit technology, experience from the Gemini, Apollo, Skylab and Shuttle programs, hardware certification, design, development and other program components, spacesuit evolution and experience, failure analysis and resolution, and aspects of program management. Concurrently, U.S. spacesuit knowledge capture activities have progressed to a level where NASA, the National Air and Space Museum (NASM), Hamilton Sundstrand (HS) and the spacesuit community are now working together to provide a rather closed-looped spacesuit knowledge capture system which includes specific attention to spacesuit system artifacts as well. A NASM report has recently been created that allows the cross reference of history to the artifacts and the artifacts to the history including spacesuit manufacturing details with current condition and location. NASA has examined spacesuits in the NASM collection for evidence of wear during their operational life. NASA s formal spacesuit knowledge capture efforts now make use of both the NASM spacesuit preservation collection and report to enhance its efforts to educate NASA personnel and contribute to spacesuit history. Be it archiving of human knowledge or archiving of the actual spacesuit legacy hardware with its rich history, the joining together of spacesuit system artifact history with that of development and use during past programs will provide a wealth of knowledge which will greatly enhance the chances for the success of future and more ambitious spacesuit system programs.
The ability to learn from both the mistakes and successes of the past is vital to assuring success in the future. Due to the close physical interaction between spacesuit systems and human beings as users, spacesuit technology and usage lends itself rather uniquely to the benefits realized from the skillful organization of historical information; its dissemination; the collection and identification of artifacts; and the education of those in the field. The National Aeronautics and Space Administration (NASA), other organizations and individuals have been performing United States (U.S.) Spacesuit Knowledge Capture since the beginning of space exploration. Avenues used to capture the knowledge have included publication of reports; conference presentations; specialized seminars; and classes usually given by veterans in the field. More recently the effort has been more concentrated and formalized whereby a new avenue of spacesuit knowledge capture has been added to the archives in which videotaping occurs engaging both current and retired specialists in the field presenting technical scope specifically for education and preservation of knowledge. With video archiving, all these avenues of learning can now be brought to life with the real experts presenting their wealth of knowledge on screen for future learners to enjoy. Scope and topics of U.S. spacesuit knowledge capture have included lessons learned in spacesuit technology, experience from the Gemini, Apollo, Skylab and Shuttle programs, hardware certification, design, development and other program components, spacesuit evolution and experience, failure analysis and resolution, and aspects of program management. Concurrently, U.S. spacesuit knowledge capture activities have progressed to a level where NASA, the National Air and Space Museum (NASM), Hamilton Sundstrand (HS) and the spacesuit community are now working together to provide a comprehensive closed-looped spacesuit knowledge capture system which includes
FANTASTIC is an acronym for Failure Analysis Nonlinear Thermal and Structural Integrated Code. This program was developed by Failure Analysis Associates, Palo Alto, Calif., for MSFC to improve the accuracy of solid rocket motor nozzle analysis. FANTASTIC has three modules: FACT - thermochemical analysis; FAHT - heat transfer analysis; and FAST - structural analysis. All modules have keywords for data input. Work is in progress for the verification of the FAHT module, which is done by using data for various problems with known solutions as inputs to the FAHT module. The information obtained is used to identify problem areas of the code and passed on to the developer for debugging purposes. Failure Analysis Associates have revised the first version of the FANTASTIC code and a new improved version has been released to the Thermal Systems Branch.