Failure analysis and design report of Nimbus 1 solar array drive failure Final report
Postflight analysis data on Nimbus 1 solar array drive motor failure
Simpson, W. D.↗
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Quantifying Pilot Contribution to Flight Safety during Drive Shaft Failure
Accident statistics cite the flight crew as a causal factor in over 60% of large transport aircraft fatal accidents. Yet, a well-trained and well-qualified pilot is acknowledged as the critical center point of aircraft systems safety and an integral safety component of the entire commercial aviation system. The latter statement, while generally accepted, cannot be verified because little or no quantitative data exists on how and how many accidents/incidents are averted by crew actions. A joint NASA/FAA high-fidelity motion-base simulation experiment specifically addressed this void by collecting data to quantify the human (pilot) contribution to safety-of-flight and the methods they use in today's National Airspace System. A human-in-the-loop test was conducted using the FAA's Oklahoma City Flight Simulation Branch Level D-certified B-737-800 simulator to evaluate the pilot's contribution to safety-of-flight during routine air carrier flight operations and in response to aircraft system failures. These data are fundamental to and critical for the design and development of future increasingly autonomous systems that can better support the human in the cockpit. Eighteen U.S. airline crews flew various normal and non-normal procedures over a two-day period and their actions were recorded in response to failures. To quantify the human's contribution to safety of flight, crew complement was used as the experiment independent variable in a between-subjects design. Pilot actions and performance during single pilot and reduced crew operations were measured for comparison against the normal two-crew complement during normal and non-normal situations. This paper details the crew's actions, including decision-making, and responses while dealing with a drive shaft failure - one of 6 non-normal events that were simulated in this experiment.
Kramer, Lynda J.↗
Reliability on ISS Talk Outline
1. Overview of ISS 2. Space Environment and it effects a. Radiation b. Microgravity 3. How we ensure reliability a. Requirements b. Component Selection i. Note: I plan to stay away from talk about Rad Hardened components and talk about why we use older processors because they are less susceptible to SEUs. c. Testing d. Redundancy / Failure Tolerance e. Sparing strategies 4. Operational Examples a. Multiple MDM Failures on 6A due to hard drive failure In general, my plan is to only talk about data that is currently available via normal internet sources to ensure that I stay away from any topics that would be Export Controlled, ITAR, or NDA‐controlled. The operational example has been well‐reported on in the media and those are the details that I plan to cover. Additionally I am not planning on using any slides or showing any photos during the talk.
Misiora, Mike↗
Controlling dendrite propagation in solid-state batteries with engineered stress
Metal-dendrite penetration is a mode of electrolyte failure that threatens the viability of metal-anode-based solid-state batteries. Whether dendrites are driven by mechanical failure or electrochemical degradation of solid electrolytes remains an open question. If internal mechanical forces drive failure, superimposing a compressive load that counters internal stress may mitigate dendrite penetration. Here, we investigate this hypothesis by dynamically applying mechanical loads to growing dendrites in Li 6.6 La 3 Zr 1.6 Ta 0.4 O 12 solid electrolytes. Operando microscopy reveals marked deflection in the dendrite growth trajectory at the onset of compressive loading. For sufficient loading, this deflection averts cell failure. Using fracture mechanics, we quantify the impact of stack pressure and in-plane stresses on dendrite trajectory, chart the residual stresses required to prevent short-circuit failure, and propose design approaches to achieve such stresses. For the materials studied here, we show that dendrite propagation is dictated by electrolyte fracture, with electronic leakage playing a negligible role.
25 ENERGY STORAGE↗
Evaluating the Performance of the NASA LaRC CMF Motion Base Safety Devices
This paper describes the initial measured performance results of the previously documented NASA Langley Research Center (LaRC) Cockpit Motion Facility (CMF) motion base hardware safety devices. These safety systems are required to prevent excessive accelerations that could injure personnel and damage simulator cockpits or the motion base structure. Excessive accelerations may be caused by erroneous commands or hardware failures driving an actuator to the end of its travel at high velocity, stepping a servo valve, or instantly reversing servo direction. Such commands may result from single order failures of electrical or hydraulic components within the control system itself, or from aggressive or improper cueing commands from the host simulation computer. The safety systems must mitigate these high acceleration events while minimizing the negative performance impacts. The system accomplishes this by controlling the rate of change of valve signals to limit excessive commanded accelerations. It also aids hydraulic cushion performance by limiting valve command authority as the actuator approaches its end of travel. The design takes advantage of inherent motion base hydraulic characteristics to implement all safety features using hardware only solutions.
Gupton, Lawrence E.↗
Adaptive Stress Testing: Finding Likely Failure Events with Reinforcement Learning
Finding the most likely path to a set of failure states is important to the analysis of safety-critical systems that operate over a sequence of time steps, such as aircraft collision avoidance systems and autonomous cars. In many applications such as autonomous driving, failures cannot be completely eliminated due to the complex stochastic environment in which the system operates.As a result, safety validation is not only concerned about whether a failure can occur, but also discovering which failures are most likely to occur. This article presents adaptive stress testing (AST), a framework for finding the most likely path to a failure event in simulation. We consider a general black box setting for partially observable and continuous-valued systems operating in an environment with stochastic disturbances. We formulate the problem as a Markov decision process and use reinforcement learning to optimize it. The approach is simulation-based and does not require internal knowledge of the system, making it suitable for black-box testing of large systems. We present different formulations depending on whether the state is fully observable or partially observable. In the latter case, we present a modified Monte Carlo tree search algorithm that only requires access to the pseudorandom number generator of the simulator to overcome partial observability. We also present an extension of the framework, called differential adaptive stress testing (DAST), that can find failures that occur in one system but not in another. This type of differential analysis is useful in applications such as regression testing, where we are concerned with finding areas of relative weakness compared to a baseline. We demonstrate the effectiveness of the approach on an aircraft collision avoidance application, where a prototype aircraft collision avoidance system is stress tested to find the most likely scenarios of near mid-air collision.
Verification and Validation↗
Molten sodium batteries: advances in chemistries, electrolytes, and interfaces
The need for clean, renewable energy has driven the expansion of renewable energy generators, such as wind and solar. However, to achieve a robust and responsive electrical grid based on such inherently intermittent renewable energy sources, grid-scale energy storage is essential. The unmet need for this critical component has motivated extensive grid-scale battery research, especially exploring chemistries “beyond Li-ion”. Among others, molten sodium (Na) batteries, which date back to the 1960s with Na-S, have seen a strong revival, owing mostly to raw material abundance and the excellent electrochemical properties of Na metal. Recently, many groups have demonstrated important advances in battery chemistries, electrolytes, and interfaces to lower material and operating costs, enhance cyclability, and understand key mechanisms that drive failure in molten Na batteries. For widespread implementation of molten Na batteries, though, further optimization, cost reduction, and mechanistic insight is necessary. In this light, this work provides a brief history of mature molten Na technologies, a comprehensive review of recent progress, and explores possibilities for future advancements.
25 ENERGY STORAGE↗
RAID Disk Arrays for High Bandwidth Applications
High bandwidth applications require large amounts of data transferred to/from storage devices at extremely high data rates. Further, these applications often are 'real time' in which access to the storage device must take place on the schedule of the data source, not the storage. A good example is a satellite downlink - the volume of data is quite large and the data rates quite high (dozens of MB/sec). Further, a telemetry downlink must take place while the satellite is overhead. A storage technology which is ideally suited to these types of applications is redundant arrays of independent discs (RAID). Raid storage technology, while offering differing methodologies for a variety of applications, supports the performance and redundancy required in real-time applications. Of the various RAID levels, RAID-3 is the only one which provides high data transfer rates under all operating conditions, including after a drive failure.
Moren, Bill↗
A Passive fuel-Cell Surface power System (PaCeSS)
This effort produces a fully-passive surface power generation capability for fuel cell technology. The concept replaces the actively pumped thermal management of a state of the art (SOA) fuel cell/electrolyzer stack with a passive 2-phase thermosyphon for heat transport and a passive shape memory actuating radiator for temperature management. The concept addresses NASA fuel cell technology roadmap needs for greater reliability and longer operating life by eliminating life limiting elements of SOA fuel cell system design that drive failure modes associated with moving parts and control complexity. Applications map to surface power (primary fuel cell), surface energy storage (regenerable fuel cell) and in-situ resource utilization (electrolyzer/unitized reversible fuel cell). The first year of this effort concluded with independent demonstrations of 2-phase thermosyphon heat transport from a simulated fuel cell and temperature driven actuation of a shape memory actuating radiator. Results are in-character with underlying physics and demonstrate the potential to realize the objectives of this concept. his effort produces a fully-passive surface power generation capability for fuel cell technology. The concept replaces the actively pumped thermal management of a state of the art (SOA) fuel cell/electrolyzer stack with a passive 2-phase thermosyphon for heat transport and a passive shape memory actuating radiator for temperature management.
deionized water↗
Alpine disk failure dataset
This dataset consists of 4114 disk failure events collected from Alpine from 07/01/2019 to 04/18/2022. Individual events are identified by their timestamp in ISO 8601 format, rack and enclosure where the failed disk is located.
97 MATHEMATICS AND COMPUTING↗
Redundant control system for X-wing valve actuators
The capability of compensating automatically for a failure in an actuator and the associated drive circuit is enhanced by providing a dual channel actuator, each channel having a drive coil and a position sensor tracking the position of the actuator output shaft. A separate circuit is provided for each actuator channel to detect drive loop failures and hydraulic failures. When the drive loop of one channel fails, it is disengaged, and the gain in the remaining drive loop is doubled to maintain authority. In an embodiment, the remaining drive loop cannot disengage when certain criteria, relating to the failure of associated actuators, are met. The invention is particularly useful for aerospace applications.
Arifian, Kenneth C.↗
Influence of Thermally-Grown Oxide (TGO) Layer on the Driving Forces Associated with Failure in Environmental Barrier Coating (EBC) Systems
Environmental barrier coatings (EBC) is an enabling technology for the successful application of ceramic matrix composites (CMCs) in air-breathing gas turbine engines. Spallation of environmental barrier coating (EBC) induced by thermally grown oxide (TGO) layer is a key EBC failure mode. The TGO layer, resulting from steam oxidation, grows either from a silicon bond coat layer (if present) or from the silicon carbide (SiC) based substrate itself. Critical thickness of the TGO layer for failure is in the range of 20-30 microns but it can vary due to exposure temperature, microstructure etc. Current work at NASA Glenn Research Center, under the Revolutionary Tools and Methods (RTM) project is aimed at addressing associated failure modes in EBC systems and developing robust analysis tools to aid in the design/analysis of these systems. The objective of the current work is to conduct a sensitivity study to examine the influence of uniformly and non-uniformly grown oxide layers with or without damage on the associated driving forces leading to spallation of the EBC when subjected to isothermal loading. Initial results indicate that the presence of damage (vertical cracks caused by in-plane stresses) enhances the stresses that are present due to non-uniformity. However, the presence of non-uniformity itself is still the main factor influencing the magnitude of peel and shear stresses in the TGO layer.
Mital, Subodh K.↗
Spacecraft Parachute Recovery System Testing from a Failure Rate Perspective
Spacecraft parachute recovery systems, especially those with a parachute cluster, require testing to identify and reduce failures. This is especially important when the spacecraft in question is human-rated. Due to the recent effort to make spaceflight affordable, the importance of determining a minimum requirement for testing has increased. The number of tests required to achieve a mature design, with a relatively constant failure rate, can be estimated from a review of previous complex spacecraft recovery systems. Examination of the Apollo parachute testing and the Shuttle Solid Rocket Booster recovery chute system operation will clarify at which point in those programs the system reached maturity. This examination will also clarify the risks inherent in not performing a sufficient number of tests prior to operation with humans on-board. When looking at complex parachute systems used in spaceflight landing systems, a pattern begins to emerge regarding the need for a minimum amount of testing required to wring out the failure modes and reduce the failure rate of the parachute system to an acceptable level for human spaceflight. Not only a sufficient number of system level testing, but also the ability to update the design as failure modes are found is required to drive the failure rate of the system down to an acceptable level. In addition, sufficient data and images are necessary to identify incipient failure modes or to identify failure causes when a system failure occurs. In order to demonstrate the need for sufficient system level testing prior to an acceptable failure rate, the Apollo Earth Landing System (ELS) test program and the Shuttle Solid Rocket Booster Recovery System failure history will be examined, as well as some experiences in the Orion Capsule Parachute Assembly System will be noted.
Stewart, Christine E.↗
Analysis of the failure of a polyester peripheral drive belt on the Mariner Mars 1971 flight tape recorder
A peripheral drive belt on the Mariner Mars 1971 tape recorder failed when a thin longitudinal strip separated off one edge. Analysis showed that the most probable cause of failure occurred from flexural fatigue initiating in mechanically weak locations which are introduced into the belt during fabrication. Methyl ethyl ketone, which is employed as a cleaning solvent during fabrication, was found to cause permanent reduction in engineering properties of polyester and could have contributed to the reduction of the fatigue resistance. Fatigue properties of the polyester drive belt are reviewed for the operating condition, as well as the sensitivity of polyester to cleaning solvents and the origin of mechanically weak locations.
Cuddihy, E. F.↗
Oxidation Embrittlement Observed in SiC/SiC Composites
As part of a comprehensive materials characterization program at the NASA Lewis Research Center, tensile creep-rupture tests were performed on a SiC-fiber-reinforced SiC-matrix composite. The results of these tests and subsequent analysis revealed an oxidation embrittlement phenomena that occurs readily at a discreet temperature range below the maximum use temperature. The graph shows rupture lives for a creep stress of 83 MPa as a function of temperature. Note that the rupture time is constant at an intermediate temperature range of 700 to 982 C. This graph also shows the failure location, as measured from the center of the specimen. Whereas for temperatures of 500 to 700 C, failure occurred in the specimen gage section; at higher temperatures, the failure location migrated toward the cooled grip ends. Although the results initially suggested that the test procedure was influencing the measured creep rupture lives and driving the failure location out of the gage section, subsequent experiments and thermal stress analyses verified the robustness of the test method employed.
Verrilli, Michael J.↗
Turntable mechanism
In vacuum plasma spraying a turntable must be provided which not only makes it possible to rotate and tilt a heavy workpiece, but to operate at vacuum plasma temperatures to do so. In the vacuum plasma coating of large parts such as combustion chambers of rocket engines, the workpiece must not only be rotated, but it must be tilted. Hence, the turntable must be capable not only of supporting heavy parts, but of angulating such heavy workpieces. And this must be done without drive means failure due to extremely high temperatures under which the turntable mechanism is operated. A turntable mechanism is provided which is capable of operating under such conditions. For cooling the turntable drive mechanism, internal cooling means are included.
Myers, William Neill↗
Modelling early failures in Space Station Freedom
A major problem encountered in planning for Space Station Freedom is the amount of maintenance that will be required. To predict the failure rates of components and systems aboard Space Station Freedom, the logical approach is to use data obtained from previously flown spacecraft. In order to determine the mechanisms that are driving the failures, models can be proposed, and then checked to see if they adequately fit the observed failure data obtained from a large variety of satellites. For this particular study, failure data and truncation times were available for satellites launched between 1976 and 1984; no data past 1984 was available. The study was limited to electrical subsystems and assemblies, which were studied to determine if they followed a model resulting from a mixture of exponential distributions.
Navard, Sharon E.↗
Using real-time data analysis to conduct next-generation synchrotron fatigue studies
Next-generation experimental techniques, like high energy X-ray diffraction microscopy (HEDM), usher in new opportunities to collect the grain-scale data necessary for understanding the evolving processes that drive fatigue failure. In this study, we present a framework for monitoring the evolution of a deforming polycrystal, in real-time, by applying principal component analysis (PCA) to raw X-ray diffraction image data. We applied this framework to inform in-situ HEDM measurements of a cyclically loaded Inconel-718 superalloy. Further, we discovered correlations between PCA of the diffraction data and the physical processes in the polycrystal. Lastly, we discuss extending this framework in future HEDM fatigue studies.
36 MATERIALS SCIENCE↗