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At least 289 records · Page 16

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NASA NTRS1990

Probabilistic high cycle fatigue failure analysis with application to liquid propellant rocket engines

A probabilistic high cycle fatigue (HCF) failure analysis of a welded duct in a rocket engine of the Space Shuttle main engine class is described. A state-of-the-art HCF failure prediction method was used in a Monte Carlo simulation to generate a distribution of failure lives. A stochastic stress/life model is used for material characterization, and a composite stress history is generated for accurately deriving the stress cycles for the fatigue-damage calculations. The HCF failure model expresses fatigue life as a function of stochastic parameters including environment, loads, material properties, geometry, and model specification errors. A series of HCF failure life analyses were performed to study the impact of a fixed parameter and to assess the importance of each stochastic input parameter through marginal analyses.

Sutharshana, S.↗

NASA NTRS1990

Probabilistic low cycle fatigue failure analysis with application to liquid propellant rocket engines

A probabilistic Low Cycle Fatigue (LCF) failure analysis of a candidate turbine disk for use in a turbopump of a rocket engine of the Space Shuttle Main Engine class is described. A state-of-the-art LCF failure prediction method was used in a Monte Carlo simulation to generate a distribution of failure lives. A stochastic Stress/Life (S/N) model was used for materials characterization. The LCF failure model expresses fatigue life as a function of stochastic parameters including environmental parameters, loads, material properties, structural parameters, and model specification errors. The rationale for the particular characterization of each stochastic input parameter is described. The results and interpretation of the failure analysis are given.

Newlin, L.↗

NASA NTRS2000

Simulation of X-38 Landing Scenarios With Landing Gear Failures

Abnormal landing scenarios of the X-38 prototype Crew Rescue Vehicle (CRV) were modeled for three different cases involving non-deployment of landing gear with an explicit dynamic nonlinear finite element code, MSC/DYTRAN. The goal of this research was to develop models to predict the probability of crew injuries. The initial velocity conditions for the X-38 with chute deployed were 10 ft/s vertical and 57 ft/s longitudinal velocity. An MSC/NASTRAN structural model was supplied by JSC and was converted to a dynamic MSC/DYTRAN model. The MSC/NASTRAN model did not include seats or floor structure; thus, the acceleration of a lumped-mass attached to the bulkhead near each assumed occupant location was used to determine injury risk for each occupant. The worst case for injury was nondeployment of all gears. The mildest case was nondeployment of one main gear. Although a probability for minor injury was predicted for all cases, it is expected that the addition of energy-absorbing floor structure and seats would greatly diminish the probability of injury.

Fasanella, Edwin L.↗

DOE OSTI2025

Development of Predictive Model for Accurate Rupture Time from Multi-Axial Creep in Alloy 709 with Physics-Based Simulations

A physics-based model is developed to predict multiaxial creep behavior in Alloy 709 (A709), an advanced austenitic stainless steel intended for high-temperature applications such as Sodium Fast Reactors (SFRs). Compared to conventional stainless steels like 316H, A709 offers superior high-temperature performance; however, comprehensive data on its multiaxial creep response remain limited. To address this gap, a crystal plasticity finite element (CPFE) framework is used to simulate the deformation and failure mechanisms of A709 under multiaxial loading conditions. The model incorporates an extended Hu-Cocks dislocation creep formulation that accounts for precipitation effects, along with the Sham–Needleman model to capture grain boundary cavitation-driven failure. These advanced constitutive models enable a detailed understanding of the interplay between microstructural evolution and macroscopic creep response. Furthermore, the study evaluates the predictive accuracy of various effective stress measures in estimating creep rupture life, leveraging simulated multiaxial creep data. The findings provide critical insights into the applicability of different stress measures for engineering design and life prediction of A709 components operating under complex loading conditions. This work contributes to improving the reliability of high-temperature structural components by advancing predictive modeling capabilities for advanced austenitic steels.

Alloy 709↗

DOE OSTI2020

Mechanical failure of fresh nuclear grade iron–chromium–aluminum (FeCrAl) cladding under simulated hot zero power reactivity initiated accident conditions

The reactivity initiated accident (RIA) is a postulated accident in light water reactors initiated by a rapid increase in reactivity which causes an increase in fission rate and fuel temperature. One potential mode of fuel system failure during RIA is pellet cladding mechanical interaction (PCMI) due to the rapid thermal expansion of the fuel pellet. Simulated PCMI experiments were performed by rapidly pressurizing iron-chromium-aluminum (FeCrAl) cladding tube samples using a hydraulic modified burst test system, causing the specimens to burst under a biaxial loading path. Deformation and rupture of the specimens were tracked with a telecentric lens and high-speed camera system. Outer surface strains were calculated using digital image correlation (DIC) on speckle patterns painted on the specimens’ outer surfaces. Experiments were conducted at approximately 275 °C, representative of hot zero power RIA conditions. The failure hoop strain was DIC-calculated between approximately 1.8–3.4%, corresponding to quasi-static energy depositions of approximately 110–260 calories per gram UO 2 assuming initial pellet-cladding contact. These conditions are very similar to the proposed energy deposition limit of 150 calories per gram UO 2 for unirradiated zirconium-based cladding in US Nuclear Regulatory Commission (NRC) Draft Regulatory Guide 1327. A very small strain rate dependence was observed in the data, with the magnitude of the failure hoop strain decreasing slightly with increasing strain rate. This observed dependence may be relevant because the FeCrAl cladding strain rate will be approximately 20% higher than in zirconium-based cladding due to the harder neutron spectrum and resultant shorter neutron generation time.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2023

Large deformation and brittle failure calculated using the dual-domain material point method

The dual domain material point (DDMP) method is explored as a candidate to be implemented in a general purpose code to perform simulations of materials with complex geometry that undergo large history-dependent deformation and failure. To test its candidacy, we study its mesh convergence, its sensitivity to mesh orientation, and its ability to handle softening and failure of a material. Simulations of large deformation and simulations of mechanical failure are performed using both DDMP and the material point method (MPM). When cell-crossing of material points is not an issue and when there are a sufficient number of material points in each computation cell, the numerical error decreases with the square of the cell size as expected for both MPM and DDMP. DDMP has reduced error compared with MPM when there are many instances of material points crossing cell boundaries due to the continuous nature of the modified gradient of the shape functions. Simulations of a specimen under tension are also performed where the background mesh is aligned and misaligned with the tension direction. MPM displays a significant mesh-dependent stress field, DDMP shows negligible mesh dependency. Despite a mesh orientation-dependent stress field from MPM, the critical tension and failure mode from both MPM and DDMP calculations have negligible mesh dependency when using a non-local failure model. If only the failure mode is important (i.e., local stresses are unimportant), MPM with a non-local failure model is a suitable method for modeling failure with small deformations. However, if local stresses are also important or if there are large deformations with many cell-crossings before failure, DDMP should be the method that is used. A needed improvement for DDMP is identified from our numerical simulations.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Subdiffusive High-Pressure Hydrogen Gas Dynamics in Elastomers

We report elastomeric rubber materials serve a vital role as sealing materials in the hydrogen storage and transport infrastructure. With applications including O-rings and hose liners, these components are exposed to pressurized hydrogen at a range of temperatures, cycling rates, and pressure extremes. High-pressure exposure and subsequent rapid decompression often lead to cavitation and stress-induced damage of the elastomer due to localization of the hydrogen gas. Here, we use all-atom classical molecular dynamics simulations to assess the impact of compositional variations on gas diffusion within the commonly used elastomer ethylene–propylene–diene monomer (EPDM). With the aim to build a predictive understanding of precursors to cavitation and to motivate material formulations that are less sensitive to hydrogen-induced failure, we perform systematic simulations of gas dynamics in EPDM as a function of temperature, gas concentration, and cross-link density. Our simulations reveal anomalous, subdiffusive hydrogen motion at pressure and intermediate times. We identify two groups of gas with different mobilities: one group exhibiting high mobility and one group exhibiting low mobility due to their motion being impeded by the polymer. With decreasing temperatures, the low-mobility group shows increased gas localization, the necessary precursor for cavitation damage in these materials. At lower temperatures, increasing cross-link density led to greater hydrogen gas mobility and a lower fraction of caged hydrogen, indicating that increasing cross-link density may reduce precursors to cavitation. Finally, we use a two-state kinetic model to determine the energetics associated with transitions between these two mobility states.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Transmission Capacity Allocation in Zonal Electricity Markets

In this work, we propose a novel framework for modeling zonal electricity markets, based on projecting the constraints of the nodal network onto the space of the zonal aggregation of the network. The framework avoids circular definitions and discretionary parameters, which are recurrent in the implementation and study of zonal markets. Using this framework, we model and analyze two zonal market designs currently present in Europe: flow-based market coupling (FBMC) and available-transfer-capacity market coupling (ATCMC). We develop cutting-plane algorithms for simulating FBMC and ATCMC while accounting for the robustness of imports/exports to single element failures, and we conduct numerical simulations of FBMC and ATCMC on a realistic instance of the Central Western European system under the equivalent of 100 years of operating conditions. We find that FBMC and ATCMC are unable to anticipate the congestion of branches interconnecting zones and branches within zones and that both zonal designs achieve similar overall cost efficiencies (0.01% difference), whereas a nodal market design largely outperforms both of them (5.09% better than FBMC). These findings raise the question of whether it is worth it for more European countries to switch from ATCMC to FBMC, instead of advancing directly toward a nodal market design.

24 POWER TRANSMISSION AND DISTRIBUTION↗

NASA NTRS2018

Differential Adaptive Stress Testing of Airborne Collision Avoidance Systems

The next-generation Airborne Collision Avoidance System (ACAS X) is currently being developed and tested to replace the Traffic Alert and Collision Avoidance System (TCAS) as the next international standard for collision avoidance. To validate the safety of the system, stress testing in simulation is one of several approaches for analyzing near mid-air collisions (NMACs). Understanding how NMACs can occur is important for characterizing risk and informingdevelopment of the system. Recently, adaptive stress testing (AST) has been proposed as a way to find the most likely path to a failure event. The simulation-based approach accelerates search by formulating stress testing as a sequential decision process then optimizing it using reinforcement learning. The approach has been successfully applied to stress test a prototype of ACAS Xin various simulated aircraft encounters. In some applications, we are not as interestedin the system's absolute performance as its performance relative to another system. Such situations arise, for example, during regression testing or when deciding whether a new system should replace an existing system. In our collision avoidance application, we are interested in finding cases where ACAS X fails but TCAS succeeds in resolving a conflict. Existing approaches do not provide an efficient means to perform this type of analysis. This paper extends the AST approach to differential analysis by searching two simulators simultaneously and maximizing the difference between their outcomes. We call this approach differential adaptive stress testing (DAST). We apply DAST to compare a prototype of ACAS X against TCAS and show examples of encounters found by the algorithm.

Lee, Ritchie↗

NASA NTRS2017

Incorporation of Failure Into an Orthotropic Three-Dimensional Model with Tabulated Input Suitable for Use in Composite Impact Problems

The need for accurate material models to simulate the deformation, damage and failure of polymer matrix composites under impact conditions is becoming critical as these materials are gaining increased use in the aerospace and automotive communities. The aerospace community has identified several key capabilities which are currently lacking in the available material models in commercial transient dynamic finite element codes. To attempt to improve the predictive capability of composite impact simulations, a next generation material model is being developed for incorporation within the commercial transient dynamic finite element code LS-DYNA. The material model, which incorporates plasticity, damage and failure, utilizes experimentally based tabulated input to define the evolution of plasticity and damage and the initiation of failure as opposed to specifying discrete input parameters such as modulus and strength. The plasticity portion of the orthotropic, three-dimensional, macroscopic composite constitutive model is based on an extension of the Tsai-Wu composite failure model into a generalized yield function with a non-associative flow rule. For the damage model, a strain equivalent formulation is used to allow for the uncoupling of the deformation and damage analyses. In the damage model, a semi-coupled approach is employed where the overall damage in a particular coordinate direction is assumed to be a multiplicative combination of the damage in that direction resulting from the applied loads in various coordinate directions. For the failure model, a tabulated approach is utilized in which a stress or strain based invariant is defined as a function of the location of the current stress state in stress space to define the initiation of failure. Failure surfaces can be defined with any arbitrary shape, unlike traditional failure models where the mathematical functions used to define the failure surface impose a specific shape on the failure surface. In the current paper, the complete development of the failure model is described and the generation of a tabulated failure surface for a representative composite material is discussed.

Impact↗

NASA NTRS1999

A Gas-Actuated Projectile Launcher for High-Energy Impact Testing of Structures

A gas-act,uated penetration device has been developed for high-energy impact testing of structures. The high-energy impact. t,estiiig is for experimental simulation of uncontained engine failures. The non-linear transient finite element, code LS-DYNA3D has been used in the numerical simula.tions of a titanium rectangular blade with a.n aluminum target, plate. Threshold velocities for different combinations of pitch and yaw angles of the impactor were obtained for the impactor-target, t8est configuration in the numerica.1 simulations. Complet,e penet,ration of the target plate was also simulat,ed numerically. Finally, limited comparison of analytical and experimental results is presented for complete penetration of the target by the impactor.

Ambur, Damodar R.↗

NASA NTRS1998

Ground-Based Testing of Replacement Thermal Control Materials for the Hubble Space Telescope

The mechanical and optical properties of the metallized Teflon FEP thermal control materials on the Hubble Space Telescope (HST) have degraded over the nearly seven years the telescope has been in orbit. Given the damage to the outer layer of the multi-layer insulation (MLI) that was apparent during the second servicing mission (SM2), the decision was made to replace the outer layer during subsequent servicing missions. A Failure Review Board was established to investigate the damage to the MLI and identify a replacement material. The replacement material had to meet the stringent thermal requirements of the spacecraft and maintain mechanical integrity for at least ten years. Ten candidate materials were selected and exposed to ten-year HST-equivalent doses of simulated orbital environments. Samples of the candidates were exposed sequentially to low and high energy electrons and protons, atomic oxygen, x-ray radiation, ultraviolet radiation and thermal cycling. Following the exposures, the mechanical integrity and optical properties of the candidates were investigated using Optical Microscopy, Scanning Electron Microscopy (SEM), a Laboratory Portable Spectroreflectometer (LPSR) and a Lambda 9 Spectroreflectometer. Based on the results of these simulations and analyses, the Failure Review Board selected a replacement material and two alternates that showed the highest likelihood of providing the requisite thermal properties and surviving for ten years in orbit.

Townsend, Jacqueline A.↗

NASA NTRS1980

Modeling a maintenance simulation of the geosynchronous platform

A modeling technique used to conduct a simulation study comparing various maintenance routines for a space platform is dicussed. A system model is described and illustrated, the basic concepts of a simulation pass are detailed, and sections on failures and maintenance are included. The operation of the system across time is best modeled by a discrete event approach with two basic events - failure and maintenance of the system. Each overall simulation run consists of introducing a particular model of the physical system, together with a maintenance policy, demand function, and mission lifetime. The system is then run through many passes, each pass corresponding to one mission and the model is re-initialized before each pass. Statistics are compiled at the end of each pass and after the last pass a report is printed. Items of interest typically include the time to first maintenance, total number of maintenance trips for each pass, average capability of the system, etc.

Kleiner, A. F., Jr.↗

DOE OSTI2024

Simulated signatures of ignition

Ignition on the National Ignition Facility (NIF) provides a novel opportunity to evaluate past data to identify signatures of capsule failure mechanisms. We have used new simulations of high-yield implosions as well as some from past studies in order to identify unique signatures of different ignition failure mechanisms: jetting due to the presence of voids or defects, jetting due to the capsule fill tube, interfacial mixing due to instabilities or due to plasma transport, radiative cooling due to the presence of contaminant in the hot spot, long-wavelength drive asymmetry, and preheat. Many of these failure mechanisms exhibit unique trajectories that can be distinguished through variations in experimental observables such as neutron yield, down-scattered ratio (DSR), and burn width. Our simulations include capsules using both plastic and high-density carbon ablators and span all high-yield designs considered since the beginning of the National Ignition Campaign in 2011. We observe that the variability in trajectories through the space of neutron yield, DSR, and burn width varies little across capsule design yet are unique to the failure mechanism. The experimental trajectories are most consistent with simulated preheat and jetting due to voids and defects, which are the only failure mechanisms that are indistinguishable in our analysis. This suggests that improvements to capsule compression due to improved capsule quality or reduced preheat have played a primary role in enabling high yields on NIF. Furthermore, our analysis suggests that further improvements have the potential to increase yields further.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

NASA NTRS1975

Operations analysis (study 2.1): Program manual and users guide for the LOVES computer code

Information is provided necessary to use the LOVES Computer Program in its existing state, or to modify the program to include studies not properly handled by the basic model. The Users Guide defines the basic elements assembled together to form the model for servicing satellites in orbit. As the program is a simulation, the method of attack is to disassemble the problem into a sequence of events, each occurring instantaneously and each creating one or more other events in the future. The main driving force of the simulation is the deterministic launch schedule of satellites and the subsequent failure of the various modules which make up the satellites. The LOVES Computer Program uses a random number generator to simulate the failure of module elements and therefore operates over a long span of time typically 10 to 15 years. The sequence of events is varied by making several runs in succession with different random numbers resulting in a Monte Carlo technique to determine statistical parameters of minimum value, average value, and maximum value.

Wray, S. T., Jr.↗

DOE OSTI2021

Success of digital adiabatic simulation with large Trotter step

The simulation of adiabatic evolution has deep connections with adiabatic quantum computation, the quantum approximate optimization algorithm, and adiabatic state preparation. Here we address the error analysis problem in quantum simulation of adiabatic process using Trotter formulas. Here we show that with additional conditions, the circuit depth can be linear in simulation time T. The improvement comes from the observation that the fidelity error here can't be estimated by the norm distance between evolution operators. This phenomenon is termed the robustness of discretization in digital adiabatic simulation. It can be explained in three steps, from analytical and numerical evidence: (1) The fidelity error should be estimated by applying adiabatic theorem on the effective Hamiltonian instead. (2) Because of the specialty of Riemann-Lebesgue lemma, most adiabatic process is naturally robust against discretization. (3) As the Trotter step gets larger, the spectral gap of effective Hamiltonian tends to close, which results in the failure of digital adiabatic simulation.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

NASA NTRS1988

An Investigation of the Ability to Recover from Transients Following Failures for Single-Pilot Rotorcraft

A moving-base simulation was conducted to investigate a pilot's ability to recover from transients following single-axis hard-over failures of the flight-control system. The investigation was performed in conjunction with a host simulation that examined the influence of control modes on a single pilot's ability to perform various mission elements under high-workload conditions. The NASA Ames large-amplitude-motion Vertical Motion Simulator (VMS) was utilized, and the experimental variables were the failure axis, the severity of the failure, and the airspeed at which the failure occurred. Other factors, such as pilot workload and terrain and obstacle proximity at the time of failure, were kept as constant as possible within the framework of the host simulation task scenarios. No explicit failure warnings were presented to the pilot. Data from the experiment are shown, and pilot ratings are compared with the proposed handling-qualities requirements for military rotorcraft. Results indicate that the current proposed failure transient requirements may need revision.

Mansur, M. Hossein↗

NASA NTRSDate not supplied

Modeling and Characterization of Crushable Composite Structures

The crushing response and the energy absorption capacity of a quasi-isotropic C-shaped composite panel is presented to simulate the progressive damage and failure mechanisms involved in the component testing. Crushable composite structures are widely used for impact applications, as because of their great high-energy absorption capability and lower weight. Simulating the crush characteristics of composite structures is challenging, as the conventional tools fail to accurately represent the failure mechanisms at the component level. Here, a cost-effective predictive tool ‘CZone’ is applied for simulating the crushing response of composite materials. CZone for Abaqus (CZA) is an add-on capability for Abaqus/Explicit and combines with the commercially available impact modeling capabilities included within the Abaqus finite element software package.

crush zone↗