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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 271 records · Page 15
All sourcesNASA NTRSDOE OSTI
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↗
DOE OSTI2025

A model to assess Zircaloy’s mechanical property changes following a transient beyond critical heat flux

Maintaining the integrity of nuclear fuel rods is essential for ensuring public health and safety in nuclear power generation. During reactor operation, this integrity is confirmed by demonstrating compliance with established regulatory acceptance criteria. For moderate-frequency events, such as limiting transients and anticipated operational occurrences (AOOs), the current fuel integrity criterion is based on preventing boiling transition. This criterion assumes that prevention of boiling transition will prevent excessive cladding heating and, thus, fuel failure during normal operations. While conservative, this approach places significant constraints on core design, fuel cycle economics, and a plant’s ability to perform major power uprates, leading to suboptimal fuel utilization and inefficient carbon-free energy production. A more efficient approach could be achieved by revising the failure criterion to a material-specific limit rather than strictly preventing the boiling transition, since boiling transition per se is not a cause of fuel cladding failure. Here, as a result, a new licensing framework based on material properties, termed time-at-temperature (t@T), is needed. This approach would allow for brief periods of post–critical heat flux operation during an AOO without compromising safety. Implementing the t@T licensing strategy requires a robust technical foundation in material properties, which must be established through comprehensive data collection on both unirradiated and irradiated fuel and cladding materials. This foundation would enable the development of a safety basis that ensures safe operation while providing greater flexibility and efficiency for reactor operation. This paper documents a thorough review of the available data to establish a baseline knowledge that can inform the development of cladding mechanical models, as well as identify experimental data gaps that need to be addressed in future research. Machine learning and data informatics were utilized to extract the importance of parameters on the t@T parameter. Industry tools were used to perform baseline analyses to define the relevant transient conditions for data analysis. The subsequent review successfully identified applicable experimental data, as well as sufficient data to evaluate changes in cladding mechanical properties following an AOO transient. Rather than developing new models, this work coupled existing irradiation annealing and recrystallization models to calculate changes in hardness, yield stress, and ultimate tensile stress following an AOO event. The findings from this review were summarized to highlight the experimental data needs required to fill remaining gaps and support the development of future t@T licensing methodologies.

Cladding performance↗
NASA NTRS1965

Postflight Evaluation of Atlas-Centaur AC-5 (Launched 2 March 1965)

The Atlas-Centaur AC-5 vehicle was launched from ETR Complex 36A on March 2., 1965 at 8:25.04 a.m. EST. Within about 1 second after launch the thrust of the Atlas booster engine decayed rapidly; the vehicle settled back on the launch pad and was quickly destroyed by fire and explosion. Considerable damage was sustained by the launch complex and its associated equipment. Loss of booster engine thrust was due to fuel depletion at the turbopump inlets, which is attributed to closure of the fuel prevalve or the staging valve. To preclude the recurrence of either of these fuel valving malfunctions, the following corrective action has been taken: The remote control actuator has been replaced by manual operation of the Atlas fuel prevalve; the internal passage dimensions in the staging valve have been increased to lessen the hydraulic load on the valve poppet. In addition to the Atlas fuel system malfunction, a failure in the power control circuitry of the Centaur guidance computer resulted in partial removal of power at umbilical ejection. To prevent such a guidance system failure on future flights some redundant circuitry has been eliminated and more rigorous checkout procedures have been adopted. No further anomalies were discovered in the telemetered data prior to the Atlas booster thrust decay. A prime objective of the AC-5 flight was to place a dynamic model of the Surveyor spacecraft in a simulated lunar transfer trajectory. An important facet of this problem is the demonstration of a launch-on-time capability in accordance with the proper Earth-moon relation. The window opening time was established at 8:25 a.m. EST; thus the actual launch occurred within 4 seconds of the planned time.

Source record↗
NASA NTRS1981

Lox/Gox related failures during Space Shuttle Main Engine development

Specific rocket engine hardware and test facility system failures are described which were caused by high pressure liquid and/or gaseous oxygen reactions. The failures were encountered during the development and testing of the space shuttle main engine. Failure mechanisms are discussed as well as corrective actions taken to prevent or reduce the potential of future failures.

Cataldo, C. E.↗
NASA NTRS1999

Space Plasma Shown to Make Satellite Solar Arrays Fail

In 1997, scientists and engineers of the Photovoltaic and Space Environments Branch of the NASA Lewis Research Center, Maxwell Technologies, and Space Systems/Loral discovered a new failure mechanism for solar arrays on communications satellites in orbit. Sustained electrical arcs, initiated by the space plasma and powered by the solar arrays themselves, were found to have destroyed solar array substrates on some Space Systems/Loral satellites, leading to array failure. The mechanism was tested at Lewis, and mitigation strategies were developed to prevent such disastrous occurrences on-orbit in the future. Deep Space 1 is a solar-electric-powered space mission to a comet, launched on October 24, 1998. Early in 1998, scientists at Lewis and Ballistic Missile Defense Organization (BMDO) realized that some aspects of the Deep Space 1 solar arrays were nearly identical to those that had led to the failure of solar arrays on Space Systems/Loral satellites. They decided to modify the Deep Space 1 arrays to prevent catastrophic failure in space. The arrays were suitably modified and are now performing optimally in outer space. Finally, the Earth Observing System (EOS) AM1, scheduled for launch in mid-1999, is a NASA mission managed by the Goddard Space Flight Center. Realizing the importance of Lewis testing on the Loral arrays, EOS-AM1 management asked Lewis scientists to test their solar arrays to show that they would not fail in the same way. The first phase of plasma testing showed that sustained arcing would occur on the unmodified EOS-AM1 arrays, so the arrays were removed from the spacecraft and fixed. Now, Lewis scientists have finished plasma testing of the modified array configuration to ensure that EOS-AM1 will have no sustained arcing problems on-orbit.

Ferguson, Dale C.↗
NASA NTRS1979

Mathematical model for preventive maintenance scheduling

A model is formulated to describe the effect of the time interval chosen for preventive maintenance upon the frequency of failure and frequency of total maintenance. Trade-offs between these two frequencies are determined by computation of an optimal interval in the case where the failure distribution is known. For unknown distributions, an adaptive statistical technique is developed that converges to an optimal preventive maintenance interval. A numerical illustration is given.

Lorden, G.↗
NASA NTRS2010

Predicting Ares I Reaction Control System Performance by Utilizing Analysis Anchored with Development Test Data

The Ares I launch vehicle is an integral part of NASA s Constellation Program, providing a foundation for a new era of space access. The Ares I is designed to lift the Orion Crew Module and will enable humans to return to the Moon as well as explore Mars.1 The Ares I is comprised of two inline stages: a Space Shuttle-derived five-segment Solid Rocket Booster (SRB) First Stage (FS) and an Upper Stage (US) powered by a Saturn V-derived J-2X engine. A dedicated Roll Control System (RoCS) located on the connecting interstage provides roll control prior to FS separation. Induced yaw and pitch moments are handled by the SRB nozzle vectoring. The FS SRB operates for approximately two minutes after which the US separates from the vehicle and the US Reaction Control System (ReCS) continues to provide reaction control for the remainder of the mission. A representation of the Ares I launch vehicle in the stacked configuration and including the Orion Crew Exploration Vehicle (CEV) is shown in Figure 1. Each Reaction Control System (RCS) design incorporates a Gaseous Helium (GHe) pressurization system combined with a monopropellant Hydrazine (N2H4) propulsion system. Both systems have two diametrically opposed thruster modules. This architecture provides one failure tolerance for function and prevention of catastrophic hazards such as inadvertent thruster firing, bulk propellant leakage, and over-pressurization. The pressurization system on the RoCS includes two ambient pressure-referenced regulators on parallel strings in order to attain the required system level single Fault Tolerant (FT) design for function while the ReCS utilizes a blow-down approach. A single burst disk and relief valve assembly is also included on the RoCS to ensure single failure tolerance for must-not-occur catastrophic hazards. The Reaction Control Systems are designed to support simultaneously firing multiple thrusters as required

Stein, William B.↗
NASA NTRS1998

Creep of Uncoated and Cu-Cr Coated NARloy-Z

Stress rupture creep tests were performed on uncoated and Cu-30vol%Cr coated NARloy-Z copper alloy specimens exposed to air at 482 C to 704 C. The results showed that creep failure in air of unprotected NARloy-Z was precipitated by brittle intergranular surface cracking produced by strain assisted grain boundary oxidation (SAGBO) which in turn caused early onset of tertiary creep. For the protected specimens, the Cu-Cr coating remained adherent throughout the tests and was effective in slowing down the rate of oxygen absorption, particularly at the higher temperatures, by formation of a continuous chromium oxide scale. As the result of reducing oxygen ingress, the coating prevented SAGBO initiated early creep failure, extended creep deformation and increased the creep rupture life of NARloy-Z over the entire 482 C to 704 C test temperature range.

Walter, R. J.↗
NASA NTRS2002

A Multilayered Thin Film Insulator for Harsh Environments

The status of work to develop a reliable high temperature dielectric thin film for use with thin film sensors is presented. The use of thin films to electrically insulate thin film sensors on engine components minimizes the intrusiveness of the sensor and allows a more accurate measurement of the environment. A variety of insulating films were investigated for preventing electrical shorting caused by insulator failure between the sensor and the component. By alternating layers of sputtered high temperature ceramics, a sequence of insulating layers was devised that prevents pinholes from forming completely through the insulator and maintains high electrical resistivity at high temperatures. The major technical challenge remaining is to optimize the fabrication of the insulator with respect to composition to achieve a reliable high temperature insulating film. Data from the testing of various potentially insulating thin film systems is presented and their application to thin film sensors is also discussed.

Wrbanek, John D.↗
NASA NTRS2003

Collaboration of the NASA Glenn Research Center and Rolls-Royce Developed Thin Film Multilayered Dielectrics for Harsh Environments

The use of thin films to electrically insulate thin film sensors on engine components minimizes the intrusiveness of the sensors and allows a more accurate measurement of the environment. A variety of insulating films were investigated for preventing electrical shorting caused by insulator failure between the sensor and the component. By alternating layers of sputtered high-temperature ceramics, a sequence of insulating layers was devised that (1) prevents pinholes from forming completely through the insulator and (2) maintains high electrical resistivity at high temperatures. The total thickness is only a fraction of that needed for conventional insulating techniques. The Sensors and Electronics Technology Branch of the NASA Glenn Research Center has an in-house effort to develop thin film sensors for surface measurement in propulsion system research. Thin film sensors do not require special machining of the components on which they are mounted, and they are considerably thinner (less than 10 mm thick) than wire or foil sensors. The thin film sensors are thus much less disturbing to the operating environment and have a minimal impact on the physical characteristics of the supporting component. To further this research, NASA Glenn and Rolls-Royce (Derby, UK), with assistance from the Ohio Aerospace Institute (OAI) and the Akima Corporation, pursued a joint investigation using multilayered thin film dielectrics as a reliable insulator in harsh environments. The use of a multilayered scheme is thought to be promising for the fabrication of electrically insulating thin films. A major cause of conduction in thin film dielectrics is the presence of defects, such as pinholes, that propagate through the film to the underlying substrate surface. By alternating the insulating material, each new growth pattern would deviate from the previous one, eliminating direct pathways for conduction to the substrate. The film depositions and testing were conducted in the Instrument Research Laboratory at Glenn. The multilayered insulator test samples were made from alumina and stainless steel shims that were first covered with a sputtered underlayer of either yttria-stabilized zirconia or chromium carbide, and then overcoated with a sputtered top layer of alumina. An example of a test sample is shown in the following photograph. Each multilayered insulator sample was 5 mm thick, at least an order of magnitude thinner than conventional insulators. The insulating properties of the samples were tested in a high-temperature air oven to determine their suitability. The multilayer insulators tested showed a stabilized film at temperatures in excess of 800 C (1472 F). The underlying materials in these multilayers allow thermal expansion stresses produced during the heating to be graded. The chromium carbide-alumina multilayer had the best adhesion at high temperatures, presumably from the induced chemical bonding between the substrate and the chromium carbide underlayer. However, the zirconia-alumina multilayer proved to have slightly better insulating properties when adhering. The application of the zirconia-alumina insulator has been demonstrated on a nickel-alloy fan blade, as shown. The insulators using thin film sensors still need to be tested in a relevant high-temperature combustion environment.

Wrbanek, John D.↗