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At least 19 records

Lessons Learned from Recent Failure and Incident Investigations of Composite Structures

During the past few decades, NASA Langley Research Center (LaRC) has supported several large-scale failure and incident investigations and numerous requests for engineering consultations. Although various extenuating circumstances contributed to each of these incidents, in all cases, the failure resulted from accumulation and/or propagation of damage that reduced the load carrying capability of the structure to a level below that which was needed to sustain structural loads. A brief overview of various failure and incident investigations supported by LaRC, including some of the computational and experimental methodologies that have been applied, is presented. An important outcome of many of these failure and incident investigations is the development of an improved understanding of not only the state-of-the-art in experimental and analytical methods but also the state-of-the-art in the design and manufacturing processes that may contribute to such failures. In order to provide insight into such large-scale investigations, a series of lessons learned were captured. Awareness of these lessons learned is highly beneficial to engineers involved in similar investigations. Therefore, it is prudent that the lessons learned are disseminated such that they can be built upon in other investigations and in ensuing research and development activities.

Ransom, J. B.↗

Aerodynamic Investigation of Incidence Angle Effects in a Large Scale Transonic Turbine Cascade

Aerodynamic measurements showing the effects of large incidence angle variations on an HPT turbine blade set are presented. Measurements were made in NASA's Transonic Turbine Blade Cascade Facility which has been used in previous studies to acquire detailed aerodynamic and heat transfer measurements for CFD code validation. The current study supports the development of variable-speed power turbine (VSPT) speed-change technology for the NASA Large Civil Tilt Rotor (LCTR) vehicle. In order to maintain acceptable main rotor propulsive efficiency, the VSPT operates over a nearly 50 percent speed range from takeoff to altitude cruise. This results in 50deg or more variations in VSPT blade incidence angles. The cascade facility has the ability to operate over a wide range of Reynolds numbers and Mach numbers, but had to be modified in order to accommodate the negative incidence angle variation required by the LCTR VSPT operation. Using existing blade geometry with previously acquired aerodynamic data, the tunnel was re-baselined and the new incidence angle range was exercised. Midspan exit total pressure and flow angle measurements were obtained at seven inlet flow angles. For each inlet angle, data were obtained at five flow conditions with inlet Reynolds numbers varying from 6.83×10(exp 5) to 0.85×10(exp 5) and two isentropic exit Mach numbers of 0.74 and 0.34. The midspan flowfield measurements were acquired using a three-hole pneumatic probe located in a survey plane 8.6 percent axial chord downstream of the blade trailing edge plane and covering three blade passages. Blade and endwall static pressure distributions were also acquired for each flow condition.

McVetta, Ashlie B.↗

Aerodynamic Investigation of Incidence Angle Effects in a Large Scale Transonic Turbine Cascade

Aerodynamic measurements showing the effects of large incidence angle variations on an HPT turbine blade set are presented. Measurements were made in NASA's Transonic Turbine Blade Cascade Facility which has been used in previous studies to acquire detailed aerodynamic and heat transfer measurements for CFD code validation. The current study supports the development of variable-speed power turbine (VSPT) speed-change technology for the NASA Large Civil Tilt Rotor (LCTR) vehicle. In order to maintain acceptable main rotor propulsive efficiency, the VSPT operates over a nearly 50 percent speed range from takeoff to altitude cruise. This results in 50 deg or more variations in VSPT blade incidence angles. The cascade facility has the ability to operate over a wide range of Reynolds numbers and Mach numbers, but had to be modified in order to accommodate the negative incidence angle variation required by the LCTR VSPT operation. Using existing blade geometry with previously acquired aerodynamic data, the tunnel was re-baselined and the new incidence angle range was exercised. Midspan exit total pressure and flow angle measurements were obtained at seven inlet flow angles. For each inlet angle, data were obtained at five flow conditions with inlet Reynolds numbers varying from 6.83×10 (exp 5) to 0.85×10(exp 5) and two isentropic exit Mach numbers of 0.74 and 0.34. The midspan flowfield measurements were acquired using a three-hole pneumatic probe located in a survey plane 8.6 percent axial chord downstream of the blade trailing edge plane and covering three blade passages. Blade and endwall static pressure distributions were also acquired for each flow condition.

McVetta, Ashlie B.↗

Aerodynamic Investigation of Incidence Angle Effects in a Large Scale Transonic Turbine Cascade

Aerodynamic measurements showing the effects of large incidence angle variations on an HPT turbine blade set are presented. Measurements were made in NASA's Transonic Turbine Blade Cascade Facility which has been used in previous studies to acquire detailed aerodynamic and heat transfer measurements for CFD code validation. The current study supports the development of variable-speed power turbine (VSPT) speed-change technology for the NASA Large Civil Tilt Rotor (LCTR) vehicle. In order to maintain acceptable main rotor propulsive efficiency, the VSPT operates over a nearly 50% speed range from takeoff to altitude cruise. This results in 50 degrees or more variations in VSPT blade incidence angles. The cascade facility has the ability to operate over a wide range of Reynolds numbers and Mach numbers, but had to be modified in order to accommodate the negative incidence angle variation required by the LCTR VSPT operation. Using existing blade geometry with previously acquired aerodynamic data, the tunnel was re-baselined and the new incidence angle range was exercised. Midspan exit total pressure and flow angle measurements were obtained at seven inlet flow angles. For each inlet angle, data were obtained at five flow conditions with inlet Reynolds numbers varying from 6.83 × 10(exp 5) to 0.85 ×10(exp 5) and two isentropic exit Mach numbers of 0.74 and 0.34. The midspan flowfield measurements were acquired using a three-hole pneumatic probe located in a survey plane 8.6% axial chord downstream of the blade trailing edge plane and covering three blade passages. Blade and endwall static pressure distributions were also acquired for each flow condition

McVetta, Ashlie B.↗

Learning from Automation Surprises and "Going Sour" Accidents: Progress on Human-Centered Automation

Advances in technology and new levels of automation on commercial jet transports has had many effects. There have been positive effects from both an economic and a safety point of view. The technology changes on the flight deck also have had reverberating effects on many other aspects of the aviation system and different aspects of human performance. Operational experience, research investigations, incidents, and occasionally accidents have shown that new and sometimes surprising problems have arisen as well. What are these problems with cockpit automation, and what should we learn from them? Do they represent over-automation or human error? Or instead perhaps there is a third possibility - they represent coordination breakdowns between operators and the automation? Are the problems just a series of small independent glitches revealed by specific accidents or near misses? Do these glitches represent a few small areas where there are cracks to be patched in what is otherwise a record of outstanding designs and systems? Or do these problems provide us with evidence about deeper factors that we need to address if we are to maintain and improve aviation safety in a changing world? How do the reverberations of technology change on the flight deck provide insight into generic issues about developing human-centered technologies and systems (Winograd and Woods, 1997)? Based on a series of investigations of pilot interaction with cockpit automation (Sarter and Woods, 1992; 1994; 1995; 1997a, 1997 b), supplemented by surveys, operational experience and incident data from other studies (e.g., Degani et al., 1995; Eldredge et al., 1991; Tenney et al., 1995; Wiener, 1989), we too have found that the problems that surround crew interaction with automation are more than a series of individual glitches. These difficulties are symptoms that indicate deeper patterns and phenomena concerning human-machine cooperation and paths towards disaster. In addition, we find the same kinds of patterns behind results from studies of physician interaction with computer-based systems in critical care medicine (e.g., Moll van Charante et al., 1993; Obradovich and Woods, 1996; Cook and Woods, 1996). Many of the results and implications of this kind of research are synthesized and discussed in two comprehensive volumes, Billings (1996) and Woods et al. (1994). This paper summarizes the pattern that has emerged from our research, related research, incident reports, and accident investigations. It uses this new understanding of why problems arise to point to new investment strategies that can help us deal with the perceived "human error" problem, make automation more of a team player, and maintain and improve safety.

Woods, David D.↗

Shock wave-turbulent boundary layer interactions in rectangular channels.

Interaction regions created by the impingement of full span, externally generated, shock waves on a nozzle wall boundary layer were investigated. Incident shock strength was varied to produce unseparated, incipient, and fully separated flow fields. Significant departures from two-dimensionality were observed over the entire range of shock strengths tested and were identified with sidewall and corner boundary layer effects. However, comparisons of present centerline results with published two-dimensional data, obtained under similar test conditions and geometrical constraints, showed excellent agreement (e.g., incipient separation pressure levels, wall pressure distributions, free-interaction, and scale of the interaction region). This raises some question concerning the degree of two-dimensionality achieved in these previous investigations.

Reda, D. C.↗

Charge exchange of low-energy ions in thin carbon foils

In order to calibrate a time-of-flight mass spectrometer which is to be flown in the solar wind, the charge exchange properties of low-energy ions in thin carbon foils have been investigated. Incident ions of He, C, N, O, Ne, and Ar with energies in the range 0.5-2 keV/nucleon have been used to measure charge-state distribution, residual energy, and angular distribution after transmission through thin (1-6 microgram/sq cm) carbon foils. Within such foils, an equilibrium between ionization and recombination of the projectile is rapidly established, and, consequently, the charge state of the emerging particle depends essentially on its residual velocity. A comparison of the charge exchange properties of Ne-22 with Ne-20 demonstrates that indeed the velocity (and not the energy) of the emerging particle determines its final charge. A comparison of properties of different elements provides an indication of an electron shell effect. Predictions for the energy loss of ions within the carbon foils made with the TRIM code are in good agreement with the experimental results presented in this paper.

Buergi, Alfred↗

Response of a piezoelectric pressure transducer to IR laser beam impingement

The non-pressure response of a PCB Model 113A transducer to a far infrared radiation impulse from a carbon dioxide laser was investigated. Incident radiation was applied both to the bare transducer diaphragm and to coated diaphragms. Coatings included two common ablative materials and a reflective gold coating. High-flux radiation impulses induced an immediate brief negative output followed by a longer-duration positive output. Both timing and amplitude of the responses will be discussed, and the effects of coatings will be compared. Bursts of blackbody radiation from a 1500 K source produced qualitatively similar responses.

Smith, William C.↗

USAF single-event sonic boom prediction model: PCBoom3

The Air Force has developed PCBoom3, a general-purpose, single-event sonic boom prediction model. The model operates on an IBM PC or compatible, under DOS or Windows. It is accessed via an integrated environment which controls building of input cases, running boom calculations, displaying contours and signatures, and managing all associated data. The primary boom calculation is via a variation of FOBOOM, the focus-boom extension of Thomas's program. Aircraft input is either via a user-provided F-function, or simple N-wave F-functions tabulated for about 20 current aircraft. A fast boom calculation, based on Plotkin's SBORT algorithms, is included for simple N-wave F-functions in a windless atmosphere and flight altitudes up to 60,000 feet. After a run is complete, the user can access an index identifying significant events (focal zones, beginning of footprint, etc.), then plot boom amplitude contours and signatures or spectra at any point in the footprint. The primary uses of this program are expected to be operational planning and boom incident investigation. However, because of the commonality between FOBOOM and the MDBOOM program currently being used for low boom configuration design, this program is of interest to the HSCT community, especially as supersonic route planning activity increases. The Air Force recently conducted a flight test program to evaluate the focal zone capabilities of PCBoom3. Initial results of that program validate the prediction of focal zone geometry, amplitudes, and waveforms.

Plotkin, Kenneth J.↗

Effects of Modality on Interrupted Flight Deck Performance: Implications for Data Link

Externally-imposed tasks frequently interrupt ongoing task performance in the commercial flight deck. While normally managed without consequence, basic research as well as aviation accident and incident investigations show that interruptions can negatively affect performance and safety. This research investigates the influence of interruption and interrupted task modality on pilot performance in a simulated commercial flight deck. Fourteen current commercial airline pilots performed approach scenarios in a fixed-base flight simulator. Air traffic control instructions, conveyed either aurally or visually (via a data link system) interrupted a visual task (obtaining information from the Flight Management System) and an auditory task (listening to the automated terminal information service recording). Some results confirm the hypothesized performance advantage of cross-modality conditions, more compelling nature of auditory interruptions, and interruption-resistance of auditory ongoing tasks. However, taken together, results suggest the four interaction conditions had different effects on pilot performance. These results have implications for the design of data link systems, and for facilitating interruption management through interface design, aiding, and training programs.

Latorella, Kara A.↗

An Investigation of Turbulence Incidents

This is the final report for a cooperative research project which was initiated over 12 years ago in collaboration with Ralph Bach and the late Rodney Wingrove of NASA-Ames. This successful endeavor has resulted in many journal and conference publications describing research into the causes and characteristics of aviation turbulence. This Cooperative agreement also gave students access to a leading research facility and the chance to work with internationally, recognized researchers while supporting senior and master's thesis research work. The data set used in the study were unique quantitative measurements of microscale turbulence derived from commercial aircraft. A significant result of the study was the development of a standard turbulence metric based on those available on-board measurements.

Lester, Peter F.↗

Investigation of High Incidence Angle Propeller Aerodynamics for Subscale eVTOL Aircraft

Propellers used for electric vertical takeoff and landing (eVTOL) aircraft propulsion systems experience a wide range of aerodynamic conditions, including significant incidence angles relative to oncoming airflow. Propellers in oblique flow exhibit deviations in thrust and torque oriented along their axis of rotation, as well as significant off-axis forces and moments. Although important for understanding eVTOL aircraft aerodynamics, sparse experimental data exist for propellers operating at incidence. This report describes an experimental wind tunnel study of isolated propeller aerodynamics across a wide range of flight conditions expected to be experienced by the LA-8 tandem tilt-wing, eVTOL aircraft. The experimental data obtained from the study are graphically presented and a discussion of observed aerodynamic phenomena is compared to theoretical expectations and past experimental work. The content of this report is intended to provide guidance to future propeller testing efforts and describe pertinent propeller aerodynamic behavior expected to be experienced by eVTOL vehicles.

propeller aerodynamics↗

An experimental investigation of blade-vortex interaction at normal incidence

An experimental investigation has been conducted for the blade-vortex interaction (BVI) of a rotor at normal incidence, where the vortex is generally parallel to the rotor axis. Tip Mach number, radial BVI station, and free stream velocity were varied during measurements of fluctuating blade pressures, far field sound pressure levels and directivity, incident vortex velocity field, and blade-vortex interaction angles. The experimental setup is representative of the chopping of helicopter main rotor tip vortices by the tail rotor. This interaction is found to generate impulsive noise which radiates primarily ahead of the blade.

Ahmadi, A. R.↗