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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 181 records · Page 10
All sourcesNASA NTRSDOE OSTI
NASA NTRS2011

Reliability Evaluation of Base-Metal-Electrode Multilayer Ceramic Capacitors for Potential Space Applications

Base-metal-electrode (BME) ceramic capacitors are being investigated for possible use in high-reliability spacelevel applications. This paper focuses on how BME capacitors construction and microstructure affects their lifetime and reliability. Examination of the construction and microstructure of commercial off-the-shelf (COTS) BME capacitors reveals great variance in dielectric layer thickness, even among BME capacitors with the same rated voltage. Compared to PME (precious-metal-electrode) capacitors, BME capacitors exhibit a denser and more uniform microstructure, with an average grain size between 0.3 and 0.5 m, which is much less than that of most PME capacitors. BME capacitors can be fabricated with more internal electrode layers and thinner dielectric layers than PME capacitors because they have a fine-grained microstructure and do not shrink much during ceramic sintering. This makes it possible for BME capacitors to achieve a very high capacitance volumetric efficiency. The reliability of BME and PME capacitors was investigated using highly accelerated life testing (HALT). Most BME capacitors were found to fail with an early avalanche breakdown, followed by a regular dielectric wearout failure during the HALT test. When most of the early failures, characterized with avalanche breakdown, were removed, BME capacitors exhibited a minimum mean time-to-failure (MTTF) of more than 105 years at room temperature and rated voltage. Dielectric thickness was found to be a critical parameter for the reliability of BME capacitors. The number of stacked grains in a dielectric layer appears to play a significant role in determining BME capacitor reliability. Although dielectric layer thickness varies for a given rated voltage in BME capacitors, the number of stacked grains is relatively consistent, typically around 12 for a number of BME capacitors with a rated voltage of 25V. This may suggest that the number of grains per dielectric layer is more critical than the thickness itself for determining the rated voltage and the life expectancy of the BME capacitor. The leakage current characterization and the failure analysis results suggest that most of these early avalanche failures are due to the extrinsic minor construction defects introduced during fabrication of BME capacitors. The concentration of the extrinsic defects must be reduced if the BME capacitors are considered for high reliability applications. There are two approaches that can reduce or prevent the occurrence of early failure in BME capacitors: (1) to reduce the defect concentration with improved processing control; (2) to prevent the use of BME capacitors under harsh external stress levels so that the extrinsic defects will never be triggered for a failure. In order to do so appropriate dielectric layer thickness must be determined for a given rated voltage.

Liu, David (Donhang)↗
NASA NTRS1973

Space shuttle orbiter fracture control plan

The criteria are presented for preventing space shuttle structural failure associated with crack initiation or propagation during fabrication, test, handling, and the operational life of the vehicle. The criteria discussed include: engineering responsibilities, assurance management, production, operation and test, procurement, critical parts selection, design, and structural analysis.

Space Division↗
NASA NTRS1976

Inspection of two Brayton rotating units after extensive endurance testing

A system was designed to produce 2-10 kW net continuous electric power for at least 5 years. The turbine-alternator-compressor power conversion unit in the system is designated Brayton Rotating Unit (BRU). Four BRU's were fabricated and extensively tested. One BRU has accumulated 11,000 hours of operation, and another has accumulated in excess of 21,000 hours. Testing has demonstrated that the BRU's have met or exceeded performance objectives. Two BRU's were disassembled and given a thorough post-test inspection. The inspection results show that after 21,000 hours of operation there is no apparent wear or failure mode that will prevent the attainment of the 5-year life objective.

Dunn, J. H.↗
NASA NTRS1980

Water-cooled insulated steam-injection wells

Water is used as insulated coolant and heat-transfer medium for steam-injection oil wells. Approach is somewhat analogous to cooling system in liquid-propellant rocket. In addition to trapping and delivering heat to steam-injection point, water will also keep casing cooler, preventing or reducing casing failures caused by thermal stresses.

Back, L. H.↗
NASA NTRS1988

Fault-Tolerant Local-Area Network

Local-area network (LAN) for computers prevents single-point failure from interrupting communication between nodes of network. Includes two complete cables, LAN 1 and LAN 2. Microprocessor-based slave switches link cables to network-node devices as work stations, print servers, and file servers. Slave switches respond to commands from master switch, connecting nodes to two cable networks or disconnecting them so they are completely isolated. System monitor and control computer (SMC) acts as gateway, allowing nodes on either cable to communicate with each other and ensuring that LAN 1 and LAN 2 are fully used when functioning properly. Network monitors and controls itself, automatically routes traffic for efficient use of resources, and isolates and corrects its own faults, with potential dramatic reduction in time out of service.

Morales, Sergio↗
NASA NTRS1990

An evaluation of the pressure proof test concept for thin sheet 2024-T3

The concept of pressure proof testing of fuselage structures with fatigue cracks to insure structural integrity was evaluated from a fracture mechanics viewpoint. A generic analytical and experimental investigation was conducted on uniaxially loaded flat panels with crack configurations and stress levels typical of longitudinal lap splice joints in commercial transport aircraft fuselages. The results revealed that the remaining fatigue life after a proof test was longer than that without the proof test because of crack growth retardation due to increased crack closure. However, based on a crack length that is slightly less than the critical value at the maximum proof test stress, the minimum assured life or proof test interval must be no more than 550 pressure cycles for a 1.33 proof factor and 1530 pressure cycles for a 1.5 proof factor to prevent in-flight failures.

Dawicke, D. S.↗
NASA NTRS1989

First incremental buy for Increment 2 of the Space Transportation System (STS)

Thiokol manufactured and delivered 9 flight motors to KSC on schedule. All test flights were successful. All spent SRMs were recovered. Design, development, manufacture, and delivery of required transportation, handling, and checkout equipment to MSFC and to KSC were completed on schedule. All items of data required by DPD 400 were prepared and delivered as directed. In the system requirements and analysis area, the point of departure from Buy 1 to the operational phase was developed in significant detail with a complete set of transition documentation available. The documentation prepared during the Buy 1 program was maintained and updated where required. The following flight support activities should be continued through other production programs: as-built materials usage tracking on all flight hardware; mass properties reporting for all flight hardware until sample size is large enough to verify that the weight limit requirements were met; ballistic predictions and postflight performance assessments for all production flights; and recovered SRM hardware inspection and anomaly identification. In the safety, reliability, and quality assurance area, activities accomplished were assurance oriented in nature and specifically formulated to prevent problems and hardware failures. The flight program to date has adequately demonstrated the success of this assurance approach. The attention focused on details of design, analysis, manufacture, and inspection to assure the production of high-quality hardware has resulted in the absence of flight failures. The few anomalies which did occur were evaluated, design or manufacturing changes incorporated, and corrective actions taken to preclude recurrence.

Source record↗
NASA NTRS1990

An evaluation of the pressure proof test concept for thin sheet 2024-T3

The concept of pressure proof testing of fuselage structures with fatigue cracks to insure structural integrity was evaluated from a fracture mechanics viewpoint. A generic analytical and experimental investigation was conducted on uniaxially loaded flat panels with crack configurations and stress levels typical of longitudinal lap-splice joints in commercial transport aircraft fuselage. The results revealed that the remaining fatigue life after a proof test was longer than that without the proof test because of crack growth retardation due to increased crack closure. However, based on a crack length that is slightly less than the critical value at the maximum proof test stress, the minimum assured life or proof test interval must be no more than 550 pressure cycles for a 1.33 proof factor and 1530 pressure cycles for a 1.5 proof factor to prevent in-flight failures.

Dawicke, D. S.↗
NASA NTRS1991

An evaluation of the pressure proof test concept for 2024-T3 aluminium alloy sheet

The concept of pressure proof testing of fuselage structures with fatigue cracks to insure structural integrity was evaluated from a fracture mechanics viewpoint. A generic analytical and experimental investigation was conducted on uniaxially loaded flat panels with crack configurations and stress levels typical of longitudinal lap splice joints in commercial transport aircraft fuselages. The results revealed that the remaining fatigue life after a proof cycle was longer than that without the proof cycle because of crack growth retardation due to increased crack closure. However, based on a crack length that is slightly less than the critical value at the maximum proof stress, the minimum assured life or proof test interval must be no more than 550 pressure cycles for a 1.33 proof factor and 1530 pressure cycles for a 1.5 proof factor to prevent in-flight failures.

Dawicke, D. S.↗
NASA NTRS1996

Simulated 'On-Line' Wear Metal Analysis of Lubricating Oils by X-Ray Fluorescence Spectroscopy

The objective of this project was to assess the sensitivity of X-ray Fluorescence Spectroscopy (XFS) for quantitative evaluation of metal particle content in engine oil suspensions and the feasibility of real-time, dynamic wear metal analysis. The study was focused on iron as the majority wear metal component. Variable parameters were: particle size, particle concentration and oil velocity. A commercial XFS spectrometer equipped with interchangeable static/dynamic (flow cell) sample chambers was used. XFS spectra were recorded for solutions of Fe-organometallic standard and for a series of DTE oil suspensions of high purity spherical iron particles of 2g, 4g, and 8g diameter, at concentrations from 5 ppm to 5,000 ppm. Real contaminated oil samples from Langley Air Force Base aircraft engines and NASA Langley Research Center wind tunnels were also analyzed. The experimental data conform the reliability of XFS as the analytical method of choice for this project. Intrinsic inadequacies of the instrument for precise analytic work at low metal concentrations were identified as being related to the particular x-ray beam definition, system geometry, and flow-cell materials selection. This work supports a proposal for the design, construction and testing of a conceptually new, miniature XFS spectrometer with superior performance, dedicated to on-line, real-time monitoring of lubricating oils in operating engines. Innovative design solutions include focalization of the incident x-ray beam, non-metal sample chamber, and miniaturization of the overall assembly. The instrument would contribute to prevention of catastrophic engine failures. A proposal for two-year funding has been presented to NASA Langley Research Center Internal Operation Group (IOG) Management, to continue the effort begun by this summer's project.

Kelliher, Warren C.↗
NASA NTRS2001

Gear Crack Propagation Path Studies: Guidelines for Ultra-Safe Design

Design guidelines have been established to prevent catastrophic rim fracture failure modes when considering gear tooth bending fatigue. Analysis was performed using the finite element method with principles of linear elastic fracture mechanics. Crack propagation paths were predicted for a variety of gear tooth and rim configurations. The effects of rim and web thicknesses, initial crack locations, and gear tooth geometry factors such as diametral pitch, number of teeth, pitch radius, and tooth pressure angle were considered. Design maps of tooth/rim fracture modes including effects of gear geometry, applied load, crack size, and material properties were developed. The occurrence of rim fractures significantly increased as the backup ratio (rim thickness divided by tooth height) decreased. The occurrence of rim fractures also increased as the initial crack location was moved down the root of the tooth. Increased rim and web compliance increased the occurrence of rim fractures. For gears with constant pitch radii, coarser-pitch teeth increased the occurrence of tooth fractures over rim fractures. Also, 25 deg pressure angle teeth had an increased occurrence of tooth fractures over rim fractures when compared to 20 deg pressure angle teeth. For gears with constant number of teeth or gears with constant diametral pitch, varying size had little or no effect on crack propagation paths.

Lewicki, David G.↗
NASA NTRS2008

Scintillation Breakdowns in Chip Tantalum Capacitors

Scintillations in solid tantalum capacitors are momentarily local breakdowns terminated by a self-healing or conversion to a high-resistive state of the manganese oxide cathode. This conversion effectively caps the defective area of the tantalum pentoxide dielectric and prevents short-circuit failures. Typically, this type of breakdown has no immediate catastrophic consequences and is often considered as nuisance rather than a failure. Scintillation breakdowns likely do not affect failures of parts under surge current conditions, and so-called "proofing" of tantalum chip capacitors, which is a controllable exposure of the part after soldering to voltages slightly higher than the operating voltage to verify that possible scintillations are self-healed, has been shown to improve the quality of the parts. However, no in-depth studies of the effect of scintillations on reliability of tantalum capacitors have been performed so far. KEMET is using scintillation breakdown testing as a tool for assessing process improvements and to compare quality of different manufacturing lots. Nevertheless, the relationship between failures and scintillation breakdowns is not clear, and this test is not considered as suitable for lot acceptance testing. In this work, scintillation breakdowns in different military-graded and commercial tantalum capacitors were characterized and related to the rated voltages and to life test failures. A model for assessment of times to failure, based on distributions of breakdown voltages, and accelerating factors of life testing are discussed.

Teverovsky, Alexander↗
NASA NTRS2010

A Near-Term Concept for Trajectory Based Operations with Air/Ground Data Link Communication

An operating concept and required system components for trajectory-based operations with air/ground data link for today's en route and transition airspace is proposed. Controllers are fully responsible for separation as they are today, and no new aircraft equipage is required. Trajectory automation computes integrated solutions to problems like metering, weather avoidance, traffic conflicts and the desire to find and fly more time/fuel efficient flight trajectories. A common ground-based system supports all levels of aircraft equipage and performance including those equipped and not equipped for data link. User interface functions for the radar controller's display make trajectory-based clearance advisories easy to visualize, modify if necessary, and implement. Laboratory simulations (without human operators) were conducted to test integrated operation of selected system components with uncertainty modeling. Results are based on 102 hours of Fort Worth Center traffic recordings involving over 37,000 individual flights. The presence of uncertainty had a marginal effect (5%) on minimum-delay conflict resolution performance, and windfavorable routes had no effect on detection and resolution metrics. Flight plan amendments and clearances were substantially reduced compared to today s operations. Top-of-descent prediction errors are the largest cause of failure indicating that better descent predictions are needed to reliably achieve fuel-efficient descent profiles in medium to heavy traffic. Improved conflict detections for climbing flights could enable substantially more continuous climbs to cruise altitude. Unlike today s Conflict Alert, tactical automation must alert when an altitude amendment is entered, but before the aircraft starts the maneuver. In every other failure case tactical automation prevented losses of separation. A real-time prototype trajectory trajectory-automation system is running now and could be made ready for operational testing at an en route Center in 1-2 years.

McNally, David↗
NASA NTRS2011

Spacecraft Testing Programs: Adding Value to the Systems Engineering Process

Testing has long been recognized as a critical component of spacecraft development activities - yet many major systems failures may have been prevented with more rigorous testing programs. The question is why is more testing not being conducted? Given unlimited resources, more testing would likely be included in a spacecraft development program. Striking the right balance between too much testing and not enough has been a long-term challenge for many industries. The objective of this paper is to discuss some of the barriers, enablers, and best practices for developing and sustaining a strong test program and testing team. This paper will also explore the testing decision factors used by managers; the varying attitudes toward testing; methods to develop strong test engineers; and the influence of behavior, culture and processes on testing programs. KEY WORDS: Risk, Integration and Test, Validation, Verification, Test Program Development

Britton, Keith J.↗
NASA NTRS1974

Space Shuttle Orbiter Fracture Control Plan

The criteria are presented for preventing space shuttle structural failure associated with crack initiation or propagation during fabrication, test, handling, and the operational life of the vehicle. The criteria discussed include: engineering responsibilities, assurance management, production, operation and test, procurement, critical parts selection, design, and structural analysis.

Fracture control↗
NASA NTRSDate not supplied

Comparisons of Artemis I and Wind Tunnel Buffet Environments and Induced Structural Responses

This paper presents comparisons of buffet forcing functions (BFFs) and associated structural responses for the Space Launch System from two data sources: 1) Artemis I (AR01) Developmental Flight Instrumentation (DFI) and 2) transonic wind-tunnel (WT) tests. Failures of DFI sensors prevented the development of a complete set of flight-based BFFs, where each BFF is based on azimuthal integration over 360-degrees of unsteady pressures acquired by sensor rings placed at many longitudinal stations along the vehicle. Instead, a set of equivalent flight- and WT-based BFFs was developed based on functional DFI and WT sensors that share the same locations. Root-mean-square (rms) levels of equivalent BFFs from flight and WT data are in-family for most of the cardinal Mach numbers. However, at stations downstream of the booster forward attachment (FA) protuberance, the rms of flight-based BFFs exceed their WT counterparts. Strikingly, vortex-shedding off the FA protuberance occurs at lower frequencies during flight than in WT experiments. This frequency shift propagates onto the spectrum of flight-measured vs. WT-based structural responses. Aside from vortex-shedding frequency mismatch, a generally good agreement between AR01 and WT-based responses is an indirect indication that WT buffet environments are fairly well representative of their AR01 counterpart.

transonic buffet↗
NASA NTRSDate not supplied

Comparisons of Artemis I and Wind Tunnel Buffet Environments and Induced Structural Responses

This paper presents comparisons of buffet forcing functions (BFFs) and associated structural responses for the Space Launch System from two data sources: 1) Artemis I (AR01) Developmental Flight Instrumentation (DFI) and 2) transonic wind-tunnel (WT) tests. Failures of DFI sensors prevented the development of a complete set of flight-based BFFs, where each BFF is based on azimuthal integration over 360-degrees of unsteady pressures acquired by sensor rings placed at many longitudinal stations along the vehicle. Instead, a set of equivalent flight- and WT-based BFFs was developed based on functional DFI and WT sensors that share the same locations. Root-mean-square (rms) levels of equivalent BFFs from flight and WT data are in-family for most of the cardinal Mach numbers. However, at stations downstream of the booster forward attachment (FA) protuberance, the rms of flight-based BFFs exceed their WT counterparts. Strikingly, vortex-shedding off the FA protuberance occurs at lower frequencies during flight than in WT experiments. This frequency shift propagates onto the spectrum of flight-measured vs. WT-based structural responses. Aside from vortex-shedding frequency mismatch, a generally good agreement between AR01 and WT-based responses is an indirect indication that WT buffet environments are fairly well representative of their AR01 counterpart.

transonic buffet↗
NASA NTRS2024

Extended Investigation into Fault-Tolerant Integrated Motor Drive for a Quadrotor Urban Air Mobility (UAM) Aircraft

Electric propulsor machines and their associated power electronics have been identified in past studies as low-reliability components in emerging Urban Air Mobility (UAM) Vertical Takeoff and Landing (VTOL) vehicles that raise their predicted catastrophic failure rates. This research effort extends previously presented work investigating the use of fault-tolerant (FT) motor drives in quadrotor aircraft as a promising approach to significantly increase their mean-time-to-failure (MTTF). In particular, fault-tolerant modular motor drives (FT-MMDs) are identified as strong candidates for closing the electric propulsor reliability gap. These FT-MMDs divide a machine drive into multiple redundant modules, each consisting of three phase stator windings and power electronics units, enabling continued machine operation after a module failure. Achieving the highest possible isolation between modules (physical, magnetic, thermal, electrical) is critically important in FT-MMDs to prevent the propagation of any failure between modules. Key additional requirements for achieving the highest possible reliability characteristics with FT-MMDs are high repair rates and aggressive suppression of all single-point failures.

quadrotor↗