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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 19 records

Initial Fermi orbital descriptors for FLOSIC calculations: The quick-FOD method

Fermi orbital descriptors (FODs) play a key role in Fermi-Löwdin orbital self-interaction correction (FLOSIC) calculations used to remove self-interaction from approximate density functionals. Optimal FODs are obtained by minimizing the self-interaction-corrected total energy, and, in this process, identifying initial sets of FODs becomes crucial. Here we propose, implement and test a novel method for automatically initializing FODs, quick-FOD, based on the minimization of an empirical energy expression that involves a Coulomb-like FOD-electron density attraction, an FOD-FOD short-range repulsion, and an exchange-like FOD-density repulsion. Quick-FOD successfully reproduces FOD arrangements in qualitatively good agreement with Lewis theory and with full-fledged FLOSIC calculations.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

In situ characterization of foreign object damage (FOD) in environmental-barrier-coated silicon carbide (SiC) ceramic

Environmental barrier coatings (EBCs) protect advanced ceramics and ceramic matrix composites (CMCs) from oxidation and corrosion in gas turbine engine environments. Foreign object damage (FOD), where debris impact the protective coatings, is a critical hazard which limits the turbine durability. Despite previous efforts to understand FOD in EBCs, a detailed understanding of the fundamental transient damage mechanisms is still lacking. In the current work, the real-time FOD behavior of a Mullite / Silicon EBC was visualized via a dynamic synchrotron X-ray source in phase contrast imaging (PCI) configuration. Prior to the in situ FOD experiments, the microstructure and composition of the coating were respectively characterized using a scanning electron microscope (SEM) and X-ray diffraction (XRD). The variation in the properties of the debris was modeled by ~ 1.5 mm diameter Partially Stabilized Zirconia (PSZ) and Silicon Nitride (Si 3 N 4 ) spheres. A modified light-gas gun setup, synchronized with the X-ray beam, was used to propel the projectiles at velocities ranging between 300 and 355 m·s -1 . Coated samples were impacted under a fully backed support configuration and at normal incidence. Coating penetration and delamination, as well as projectile deformation at the bond coat resulted for FOD by PSZ spheres. Comparatively, projectile fracture, with subsequent rebound of fragments, as well as complete coating penetration and delamination at the substrate interface occurred for FOD by Si 3 N 4 spheres. It should be noted that only cone cracking was observed for FOD by PSZ spheres while back surface cracking was present for both projectile types. Qualitative understanding of the driving forces for the observed damage mechanisms were provided.

36 MATERIALS SCIENCE↗

Using SPC and Trending to Reduce FOD

This paper presents viewgraphs showing the trends and Statistical Process Control (SPC) used by ATK-Thiokol to reduce Foreign Object Debris (FOD). Some of the topics include: 1) Amazing Little Known and Less Used Facts; 2) Critical Nature of Rocket Manufacturing; 3) ATK-Thiokol Foreign Object Debris (FOD) Philosophy; 4) FOD Trending and SPC at ATK-Thiokol Philosophy; 5) Trending and Statistical Process Control (SPC) Basic Philosophy; 6) Trending and Statistical Process Control (SPC); 7) FOD Trending and SPC at ATK-Thiokol Trending; 8) FOD Trending and SPC at ATK-Thiokol Specific Instances; 9) FOD Trending and SPC at ATK-Thiokol Contamination in Air; and 10) FOD Trending and SPC at ATK-Thiokol Nitrogen Dewpoint.

Wallentine, Mark↗

Reduced-Order Modeling and Wavelet Analysis of Turbofan Engine Structural Response Due to Foreign Object Damage (FOD) Events

The development of a wavelet-based feature extraction technique specifically targeting FOD-event induced vibration signal changes in gas turbine engines is described. The technique performs wavelet analysis of accelerometer signals from specified locations on the engine and is shown to be robust in the presence of significant process and sensor noise. It is envisioned that the technique will be combined with Kalman filter thermal/health parameter estimation for FOD-event detection via information fusion from these (and perhaps other) sources. Due to the lack of high-frequency FOD-event test data in the open literature, a reduced-order turbofan structural model (ROM) was synthesized from a finite element model modal analysis to support the investigation. In addition to providing test data for algorithm development, the ROM is used to determine the optimal sensor location for FOD-event detection. In the presence of significant noise, precise location of the FOD event in time was obtained using the developed wavelet-based feature.

Turso, James↗

Reduced-Order Modeling and Wavelet Analysis of Turbofan Engine Structural Response Due to Foreign Object Damage "FOD" Events

The development of a wavelet-based feature extraction technique specifically targeting FOD-event induced vibration signal changes in gas turbine engines is described. The technique performs wavelet analysis of accelerometer signals from specified locations on the engine and is shown to be robust in the presence of significant process and sensor noise. It is envisioned that the technique will be combined with Kalman filter thermal/ health parameter estimation for FOD-event detection via information fusion from these (and perhaps other) sources. Due to the lack of high-frequency FOD-event test data in the open literature, a reduced-order turbofan structural model (ROM) was synthesized from a finite-element model modal analysis to support the investigation. In addition to providing test data for algorithm development, the ROM is used to determine the optimal sensor location for FOD-event detection. In the presence of significant noise, precise location of the FOD event in time was obtained using the developed wavelet-based feature.

Turso, James A.↗

FOD Prevention at NASA-Marshall Space Flight Center

NASA-MSFC directive MID 5340.1 requires FOD prevention for all flight hardware projects, and requires all support organizations to comply. MSFC-STD-3598 implements a standard approach for FOD prevention, tailored from NAS 412. Three levels of FOD Sensitive Area are identified, adopting existing practices at other NASA facilities. Additional emphasis is given to prevention of impact damage and mitigation of facility FOD sources, especially leaks and spills. Impact Damage Susceptible (IDS) items are identified as FOD-sensitive as well as hardware vulnerable to entrapment of small items.

Lowrey, Nikki M.↗

Impact damage of narrow silicon carbide (SiC) ceramics with and without environmental barrier coatings (EBCs) by various foreign object debris (FOD) simulants

The leading and trailing edges of turbine airfoils are highly susceptible to impact by foreign object debris (FOD) entrained in the gas stream of turbine engines. In this study, a narrow specimen geometry is implemented to study the FOD impact behavior of low curvature airfoil edges. Silicon carbide (SiC) ceramic specimens with and without an environmental barrier coating (EBC) are used as target materials. The EBC consists of an air plasma sprayed mullite topcoat (~ 166 µm) and silicon bond coat (~ 58 µm). Spherical (∅ 1.5 mm) FOD simulants of silicon nitride (Si3N4), partially stabilized zirconia (PSZ), and steel are used as impactors. Additionally, a modified gas gun is used to generate impact damage at normal incidence and velocities ranging between 300 to 400 m/s. In situ phase contrast X-ray radiographs, which render 2D representations of the internal transient damage, are captured during the impact experiments. Impactor hardness and toughness are found to primarily influence damage in the coating. Relative to wide specimens, the narrow specimens experience a greater level of cracking and this is postulated to result from reduced self-confinement. Irrespective of specimen geometry and impactor material type, limited cracking (i.e. enhanced shielding) is observed for the coated condition.

36 MATERIALS SCIENCE↗

FOD Prevention at NASA-Marshall Space Flight Center

NASA now requires all flight hardware projects to develop and implement a Foreign Object Damage (FOD) Prevention Program. With the increasing use of composite and bonded structures, NASA now also requires an Impact Damage Protection Plan for these items. In 2009, Marshall Space Flight Center released an interim directive that required all Center organizations to comply with FOD protocols established by on-site Projects, to include prevention of impact damage. The MSFC Technical Standards Control Board authorized the development of a new MSFC technical standard for FOD Prevention.

Lowrey, Nikki M.↗

TRUST Sensors in Environments: Fiber Optic Displacement (SE-FOD) Report, Release FY24

The objective of the Delivery Environments (DE) Testbeds to Reduce Uncertainty in Simulations and Tests (TRUST) project is to quantify and help increase confidence in specific areas of computational and experimental capabilities that are applicable to the development, on-target assessment, and qualification of current and future delivery environments. More complete quantification of confidence in experimental and computational capabilities and the sufficient increase of confidence in those capabilities is critical to improving weapons engineering design, qualification, and assessment efforts that are critical to the current and future stockpile. This work uses and provides feedback on analysis tools and experimental results databases for efficient and responsive engineering which are currently under development. Under the TRUST work package, there are five testbeds and their associated engineering analysis baseline models (EABMs): 1. Contact Thermal Conductivity (CTC), 2. Nonlinear Dynamics (ND), 3. Sensors in Environments: Accelerometers (SE-A), 4. Sensors in Environments: Fiber Optic Displacement Gauges (SE-FOD), and 5. Sensors in Environments: Thermocouples (SE-TC). The TRUST project uses single-feature testbeds to quantify uncertainties in specific models and experiments and to identify capability development needs that can help to reduce these uncertainties. Each testbed is designed, configured, and tested in collaboration with groups with design and experimental capability: E-14 and MPA-CINT. The complementary simulations are conducted using W-13 analysis tools and stored in model repositories with plans for incremental progress toward EABM requirements. W-13 extends and exercises the testbed simulations in collaboration with experimentalists for uncertainty quantification of current and future materials, geometries, and environments. Additionally, TRUST is intended to provide engineers in W-13 and E-14 with experience in both numerical simulations and experimental methods through cross-discipline collaborations. Following the introduction to the TRUST project, the remainder of this report focuses on experimental, modeling and simulation, and analysis efforts conducted in FY24 relevant to the TRUST Sensors in Environments: Fiber Optic Displacement (SE-FOD) testbed.

42 ENGINEERING↗

Foreign Object Debris: FOD Prevention QS210LSK-REV

Housekeeping in the space industry? You may think the idea isn't technical enough for the shuttle program. Yet, eliminating Foreign Object Debris or FOD is an important goal for USA and NASA. The justification for this effort is based on data from the aeronautics industry. Experience has shown that if debris is not controlled, it may later cause a variety of in-flight issues. FOD can result in material damage, or make systems and equipment inoperable unsafe, or less efficient

Randolph, Sherry↗

TA-55 FOD Waste Management Requirements

Virtually all activities conducted in the TA-55 FOD (Facility Operations Division) (TA-55, TA-50,RLWTF[Radioactive Liquid Waste Treatment Facility], RLUOB[Radiological Laboratory/Utilities/Office Building], TWF, TA-63 [Transuranic Waste Facility], RANT, TA-54 West [Radioassay Nondestructive Testing Facility], WCRRF [Waste Characterization, Reduction, and Repackaging Facility]and CMR[Chemistry and Metallurgy Research])facilities generate waste. Generation and management of waste arecomplex activitiessubject toFederal and State regulations as well as DOE(Department of Energy)and Laboratory requirements. Improper management of waste can result in civiland/or criminal penalties as well as potential significant impacts to operations.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

NASA FOD – KARI Operations

Presentation outlining the cooperation between NASA FOD (Flight Operations Directorate) and KARI (Korea Pathfinder Lunar Orbiter) for spaceflight operations of KARI's KPLO spacecraft.

Shane Fuller↗

TRUST Sensors in Environments: Fiber Optic Displacement (SE-FOD)

The objective of the Delivery Environments (DE) Testbeds to Reduce Uncertainty in Simulations and Tests (TRUST) project is to quantify and help increase confidence in specific areas of computational and experimental capabilities that are applicable to the development, on-target assessment, and qualification of current and future delivery environments. More complete quantification of confidence in experimental and computational capabilities and the sufficient increase of confidence in those capabilities is critical to improving weapons engineering design, qualification, and assessment efforts that are critical to the current and future stockpile. Under the TRUST work package, engineers use and provide feedback on analysis tools and experimental results and create databases for efficient and responsive engineering which are currently under development.

42 ENGINEERING↗

FOD impact testing of composite fan blades

The results of impact tests on large, fiber composite fan blades for aircraft turbofan engine applications are discussed. Solid composite blades of two different sizes and designs were tested. Both graphite/epoxy and boron/epoxy were evaluated. In addition, a spar-shell blade design was tested that had a boron/epoxy shell bonded to a titanium spar. All blades were tested one at a time in a rotating arm rig to simulate engine operating conditions. Impacting media included small gravel, two inch diameter ice balls, gelatin and RTV foam-simulated birds, as well as starlings and pigeons. The results showed little difference in performance between the graphite and boron/epoxy blades. The results also indicate that composite blades may be able to tolerate ice ball and small bird impacts but need improvement to tolerate birds in the small duck and larger category.

Johns, R. H.↗

FOD impact testing of composite fan blades

The results of impact tests on large, fiber composite fan blades for aircraft turbofan engine applications are discussed. Solid composite blades of two different sizes and designs were tested. Both graphite/epoxy and boron/epoxy were evaluated. In addition, a spar-shell blade design was tested that had a boron/epoxy shell bonded to a titanium spar. All blades were tested one at a time in a rotating arm rig to simulate engine operating conditions. Impacting media included small gravel, two inch diameter ice balls, gelatin, and RTV foam-simulated birds, as well as starlings and pigeons. The results showed little difference in performance between the graphite and boron/epoxy blades. The results also indicate that composite blades may be able to tolerate ice ball and small bird impacts but need improvement to tolerate birds in the small duck and larger category.

Johns, R. H.↗

Increasing the FOD tolerance of composites

An experimental program was conducted for the purpose of increasing the foreign object damage tolerance of resin matrix composites in gas turbine engine fan blade applications. The superhybrid concept consisting of a resin matrix composite core surrounded by a sheath of boron/aluminum and titanium was found to be the most promising approach.

Novak, R. C.↗

Environmental effects on FOD resistance of composite fan blade

The sensitivity of the impact characteristics of typical polymeric composite fan blade materials to potential limiting combinations of moisture, temperature level and temperature transients was established. The following four technical tasks are reported: (1) evaluation and characterization of constituent blade materials; (2) ballistic impact tests; (3) leading edge impact protection systems; and (4) simulated blade spin impact tests.

Murphy, G. C.↗