Results for “physics of failure” — Page 20

NASA NTRS2018

Electrodynamic Dust Shield (EDS) Preparation for MISSE-11 Launch

The dusty surfaces of the Moon, Mars, and various asteroids present a significant challenge to NASAâ€™s manned and unmanned space exploration efforts. The fine, electrostatically charged dust is difficult to remove and has resulted in vision obscuration, false instrument readings, contamination, elevated temperatures, performance reduction, and equipment failure. To alleviate these problems, NASA KSCâ€™s Electrostatics and Surface Physics Laboratory (ESPL) is developing active dust mitigation systems for solar system exploration and in situ resource utilization (ISRU). Part of KSCâ€™s Swamp Works system, the lab emphasizes fast-paced, hands-on, cost-effective, and collaborative innovation. The Electrodynamic Dust Shield (EDS) is an ESPL technology being developed to prevent dust accumulation on space components. It consists of a dielectric substrate embedded with parallel electrodes which, when applied with high voltage out-of-phase waveforms, produce a traveling electric field wave that scatters dust particles from its surface via dielectrophoretic and electrostatic forces. The EDS is currently fully functional and has been tested for scalability and endurance in reduced gravity/pressure flight. Next, it will be part of the May 2019 Materials International Space Station Experiment-11 (MISSE-11) payload, which will test small shield samples for performance durability with exposure to the harsh space environment. The summer objective was to test EDS functionality before active and passive dust shield samples launch on MISSE-11, in order to screen for good flight/control samples as well as to compare pre-flight and post-flight clearing efficiencies. I imaged glass and Kapton shields of 2-phase and 3-phase electrode configurations with the Keyence VHX-5000 digital microscope to check for damage before and after all testing for a qualitative pre-flight baseline; helped with vacuum testing of high-voltage shield breakdown; assembled shields and wires using Electrobond 004 silver epoxy; and helped with vacuum and cryogenic dust clearance testing of assembled EDS systems. I learned CAD (computer-aided design) and 3D printing skills to create parts for a shaker table/motor assembly, which will allow for repeatable experiments by evening out EDS dust distribution in a consistent manner prior to dust scattering testing. I will also be improving the interfacing with Alpha Spaceâ€™s prototype Data Communications Unit (DCU), a payload component to control power to the EDS and store data, by mapping the DCU structure upon power-up and writing shell scripts to improve various processes. Finally, I also CADed and 3D-printed plastic supports for three different geometries of the Electrostatic Precipitator (ESP), a project that aims to use high voltage electrodes to charge and filter out dust from the Martian atmosphere drawn for ISRU devices. This work on dust mitigation technologies will help to support future robotic and human space exploration missions, including NASAâ€™s Journey to Mars; the EDS has especially significant applications to spacecraft solar panels, thermal radiators, viewports, and astronaut visors. This opportunity has also allowed me to become more familiar with various lab equipment and hardware testing, develop key modeling skills in SolidWorks, explore past and present components critical to Americaâ€™s space program, work with inspiring peers and mentors, and ascertain my dream of working permanently for NASA.

space↗

NASA NTRSDate not supplied

TPSAS-NF1676L-25778-DND

Testing required to design and certify aircraft structures has increased dramatically with the growth in use of composite materials, and the development time and cost have become an issue as industry looks towards the next generation of aircraft. To help address this challenge, NASA has formed an industry-spanning consortium with the goal of cutting by 30% today's 10-year timeline for developing and certifying composite aircraft structures. This goal is to be achieved by infusing leading edge, physics-based tools to improve the prediction of the response and failure of composite aerospace structures. The plan for the public-private partnership of NASA, the FAA, airframe manufacturers, aircraft engine manufacturers, and several universities is to conduct joint research under the five-year Advanced Composites Program (ACP). The emphasis of the ACP project is the development of damage prediction and non-destructive inspection methods capabilities that are sufficiently reliable to enable a reduction in the element and subcomponent testing necessary for design and certification. ACP also is expected to create rapid design tools to speed preliminary design and improve safety and performance. A critical element of this research concerns the residual strength of postbuckled stiffened panels with impact damage. This presentation will discuss different aspects of ongoing research on the prediction of structural collapse due to skin/stiffener separation. In particular, the presentation will examine issues that must be addressed in the analysis, such as R-curve toughening, delamination migration, bridging, as well as some unexpected effects of ply orientation.

Carlos G Davila↗

NASA NTRSDate not supplied

A Prognostics Framework for Battery Health Monitoring Integrated with Thermal Modeling

Urban Air Mobility (UAM) promises to revolutionize transportation in major cities, offering passenger travel, cargo delivery, and emergency medical services through a network of electric vertical takeoff and landing (eVTOL) aircraft. However, the limited range of current eVTOLs, due to the low specific energy of lithium-ion batteries along with a possibility of thermal runaway conditions poses significant safety concerns, leading to potentially compromising operational safety. To address this critical challenge, researchers are actively evaluating the impact of flight and environmental conditions on onboard lithium-ion battery health. This involves carefully assessing the performance of battery packs under laboratory and operational conditions for developing models to estimate future health using prognostics framework. This study examines the effectiveness of evaluating battery degradation leading to catastrophic failures under varying operational conditions in laboratory. These are captured using physics based models of underlying phenomenons and integrated into the prognostics framework. A fully charged battery undergoes controlled discharge cycles at varying C-rates based on the simulated power draw profile, with current and voltage, temperature data recorded throughout the experiment. The observed data provides valuable insights into how different operating conditions and mission profiles affect battery performance. This information is crucial for developing strategies to optimize battery systems, enhance range, and ultimately ensure the safe and reliable operation of UAM vehicles.

Thermal Modeling↗

NASA NTRSDate not supplied

A Prognostics Framework for Battery Health Monitoring Integrated with Thermal Modeling

Urban Air Mobility (UAM) promises to revolutionize transportation in major cities, offering passenger travel, cargo delivery, and emergency medical services through a network of electric vertical takeoff and landing (eVTOL) aircraft. However, the limited range of current eVTOLs, due to the low specific energy of lithium-ion batteries along with a possibility of thermal runaway conditions poses significant safety concerns, leading to potentially compromising operational safety. To address this critical challenge, researchers are actively evaluating the impact of flight and environmental conditions on onboard lithium-ion battery health. This involves carefully assessing the performance of battery packs under laboratory and operational conditions for developing models to estimate future health using prognostics framework. This study examines the effectiveness of evaluating battery degradation leading to catastrophic failures under varying operational conditions in laboratory. These are captured using physics based models of underlying phenomenons and integrated into the prognostics framework. A fully charged battery undergoes controlled discharge cycles at varying C-rates based on the simulated power draw profile, with current and voltage, temperature data recorded throughout the experiment. The observed data provides valuable insights into how different operating conditions and mission profiles affect battery performance. This information is crucial for developing strategies to optimize battery systems, enhance range, and ultimately ensure the safe and reliable operation of UAM vehicles.

Thermal Modeling↗

NASA NTRSDate not supplied

A Prognostics Framework for Battery Health Monitoring Integrated with Thermal Modeling

Urban Air Mobility (UAM) promises to revolutionize transportation in major cities, offering passenger travel, cargo delivery, and emergency medical services through a network of electric vertical takeoff and landing (eVTOL) aircraft. However, the limited range of current eVTOLs, due to the low specific energy of lithium-ion batteries along with a possibility of thermal runaway conditions poses significant safety concerns, leading to potentially compromising operational safety. To address this critical challenge, researchers are actively evaluating the impact of flight and environmental conditions on onboard lithium-ion battery health. This involves carefully assessing the performance of battery packs under laboratory and operational conditions for developing models to estimate future health using prognostics framework. This study examines the effectiveness of evaluating battery degradation leading to catastrophic failures under varying operational conditions in laboratory. These are captured using physics based models of underlying phenomenons and integrated into the prognostics framework. A fully charged battery undergoes controlled discharge cycles at varying C-rates based on the simulated power draw profile, with current and voltage, temperature data recorded throughout the experiment. The observed data provides valuable insights into how different operating conditions and mission profiles affect battery performance. This information is crucial for developing strategies to optimize battery systems, enhance range, and ultimately ensure the safe and reliable operation of UAM vehicles.

Thermal Modeling↗

NASA NTRS2020

Application of Fault Containment Principles to EMC

A hardware fault in aerospace is an undesired response to a designed engineering function in hardware. Therefore, in aerospace systems fault management is of prime importance. An important aspect of hardware faults is fault propagation. Fault propagation (also known as failure propagation) is a condition where a fault will not only produce an undesired hardware response, at its location of origin, but the fault will also propagate to other interfaced hardware and cause additional faults, or failures. Fault containment is necessary to avoid fault propagation. A fault containment region is an electronic or electromechanical region within a given hardware assembly where a fault in that region will not physically propagate to other regions of the assembly, and beyond. Rather, the fault will cause a functional failure of the hardware, where the fault occurred, without causing any additional propagated failures. Electromagnetic Compatibility (EMC) is a desired state in aerospace hardware. Electromagnetic Interference (EMI) in aerospace hardware is a fault condition of EMC. Like other faults EMI can also propagate to other aerospace hardware unless it occurs inside an EMI containment region. The paper addresses the concepts of fault containment region and introduces the concept of EMI containment region with examples of both.

Perez, Reinaldo↗

DOE OSTI2021

Machine Learning Predicts the Timing and Shear Stress Evolution of Lab Earthquakes Using Active Seismic Monitoring of Fault Zone Processes

Abstract Machine learning (ML) techniques have become increasingly important in seismology and earthquake science. Lab‐based studies have used acoustic emission data to predict time‐to‐failure and stress state, and in a few cases, the same approach has been used for field data. However, the underlying physical mechanisms that allow lab earthquake prediction and seismic forecasting remain poorly resolved. Here, we address this knowledge gap by coupling active‐source seismic data, which probe asperity‐scale processes, with ML methods. We show that elastic waves passing through the lab fault zone contain information that can predict the full spectrum of labquakes from slow slip instabilities to highly aperiodic events. The ML methods utilize systematic changes in P‐wave amplitude and velocity to accurately predict the timing and shear stress during labquakes. The ML predictions improve in accuracy closer to fault failure, demonstrating that the predictive power of the ultrasonic signals improves as the fault approaches failure. Our results demonstrate that the relationship between the ultrasonic parameters and fault slip rate, and in turn, the systematically evolving real area of contact and asperity stiffness allow the gradient boosting algorithm to “learn” about the state of the fault and its proximity to failure. Broadly, our results demonstrate the utility of physics‐informed ML in forecasting the imminence of fault slip at the laboratory scale, which may have important implications for earthquake mechanics in nature.

58 GEOSCIENCES↗

NASA NTRS2009

Explosion/Blast Dynamics for Constellation Launch Vehicles Assessment

An assessment methodology is developed to guide quantitative predictions of adverse physical environments and the subsequent effects on the Ares-1 crew launch vehicle associated with the loss of containment of cryogenic liquid propellants from the upper stage during ascent. Development of the methodology is led by a team at Sandia National Laboratories (SNL) with guidance and support from a number of National Aeronautics and Space Administration (NASA) personnel. The methodology is based on the current Ares-1 design and feasible accident scenarios. These scenarios address containment failure from debris impact or structural response to pressure or blast loading from an external source. Once containment is breached, the envisioned assessment methodology includes predictions for the sequence of physical processes stemming from cryogenic tank failure. The investigative techniques, analysis paths, and numerical simulations that comprise the proposed methodology are summarized and appropriate simulation software is identified in this report.

Baer, Mel↗

DOE OSTI2020

Prognosis of Wind Turbine Gearbox Bearing Failures Using SCADA and Modeled Data

Predictive maintenance and condition monitoring systems for wind turbines have seen increased adoption to minimize downtime, reducing operation and maintenance costs. On today’s wind power plants, the integrated supervisory control and data acquisition (SCADA) system provides low- frequency operational data that can be leveraged to quantify a wind turbine’s health. The aim of this study is to utilize machine-learning techniques to predict axial cracking failures in wind turbine gearbox bearings up to 1 month ahead of time. The failures are assumed to have occurred when the investigated bearing was replaced. While current SCADA systems show the overall condition of a wind turbine, often they do not allow for the investigation of specific gearbox bearings’ health. To enrich bearing fault signatures, additional data are computed through physics-based models using gearbox design information. Based on SCADA data, modeled data, and bearing failure log data from an actual wind plant, the performances of different machine-learning models on unseen data are then evaluated using industry-standard metrics such as precision, recall, and F1 score. Results show the overall system performance enhancement in predicting bearing failure when modeled data are included with SCADA data. The reduction in terms of false alarms is about 50%, and improvement in terms of precision and F1 score is about 33% and 12% respectively, based on the best modeling case in this study.

49 EE - Wind and Water Power Program - Wind (EE-4W↗

DOE OSTI2025

Investigation of the temperature-dependent failure processes in PVD Cr-coated ZIRLO nuclear fuel cladding using in situ X-ray micro-tomography imaging

In this work, an accident tolerant fuel cladding system with Cr coating deposited using physical vapour deposition (PVD) method onto commercial Optimized ZIRLO™ was studied. The cladding tubes were machined into C-rings and loaded to failure under compression with real-time synchrotron micro-X-ray computed tomography (XCT) imaging at room temperature (RT), 345 °C, 650 °C and 950 °C in argon (Ar) atmosphere. The mechanical behaviour and failure processes were found strongly temperature-dependent where the Cr coating showed brittle fracture at RT and 345 °C, ductile fracture at 650 °C and a reversion to brittle fracture at 950 °C. Nanoindentation measurements and scanning electron microscopy (SEM) imaging were conducted on the materials after high temperature testing. It was found that recrystallisation of the Cr coating occurred at elevated temperatures, which significantly affected its local properties hence the failure behaviour at different temperatures. This work represents the first in situ 3D XCT observation of progressive failure processes in PVD Cr-coated ZIRLO claddings up to 950 °C providing critical insights into its brittle-to-ductile transition (BDTT) behaviour and subsequent ductile-to-brittle reversion with the increase in temperature. Moreover, results are compared with other PVD Cr-coated Zircaloy materials from open literature; the influences of the coating microstructure and local properties on the failure stress/strain and fracture processes are discussed.

Yuan, Guanjie↗

NASA NTRS2015

Overview of Threats and Failure Models for Safety-Relevant Computer-Based Systems

This document presents a high-level overview of the threats to safety-relevant computer-based systems, including (1) a description of the introduction and activation of physical and logical faults; (2) the propagation of their effects; and (3) function-level and component-level error and failure mode models. These models can be used in the definition of fault hypotheses (i.e., assumptions) for threat-risk mitigation strategies. This document is a contribution to a guide currently under development that is intended to provide a general technical foundation for designers and evaluators of safety-relevant systems.

Torres-Pomales, Wilfredo↗

DOE OSTI2026

Atomic- and Molecular-Scale Interphase Engineering for High-Performance Solid-State Batteries

Solid-state batteries (SSBs) promise a decisive advance beyond conventional Li-ion systems, yet their development remains constrained by persistent solid–solid interfacial instabilities that degrade performance and durability. Interfaces between solid electrolytes and both cathodes and Li metal often exhibit poor wettability, limited physical contact, and high charge–transfer resistance, leading to chemical decomposition, mechanical failure, and impedance growth. Overcoming these limitations requires interphase engineering with atomic-scale precision—capabilities that conventional coating methods cannot reliably deliver. Atomic layer deposition (ALD) and molecular layer deposition (MLD) uniquely meet this need by enabling ultrathin, conformal, and composition-tunable films that stabilize reactive surfaces, suppress parasitic reactions, and regulate Li-metal morphology. Importantly, this Perspective highlights ALD/MLD systems that have already demonstrated effectiveness in liquid-electrolyte cells and discusses how these validated strategies can be deliberately translated to solid-state architectures. By grounding future directions in experimentally proven concepts rather than speculative hypotheses, we outline how atomic- and molecular-scale design principles can accelerate the development of robust, high-performance SSB technologies.

atomic and molecular layer deposition↗

DOE OSTI2026

Multiscale fatigue crack initiation in hierarchical additively manufactured alloys

Bioinspired hierarchical microstructures offer a route toward engineered fatigue resistance in additively manufactured alloys. However, it remains unclear how discrete structural constituents independently govern damage accumulation, particularly during the critical fatigue initiation regime where short cracks strongly interact with local microstructure. Here, we investigate multiscale fatigue initiation in a dual-phase, nanolamellar AlCoCrFeNi 2.1 high-entropy alloy. By comparing microscale specimens that isolate the nanolamellar structure against macroscale specimens containing the full melt-pool architecture, we identify size-dependent fatigue initiation mechanisms. We find that failure is dictated by nanolamellar interfaces at the microscale, whereas mesoscale melt pool boundaries serve to initiate fatigue at the macroscale. This mechanistic shift is accompanied by a transition from macroscale quasi-brittle failure to microscale plasticity-driven crack extension. Our results provide a physical framework for understanding how structural hierarchy governs the transition from discrete microstructural deformation to continuum fatigue fracture behavior, informing the design of damage-tolerant, additively manufactured alloys.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Exploring uranium oxidation in glue vapor to help avoid catastrophic slivers on NIF targets

Depleted uranium (DU) hohlraums are utilized for indirect drive fusion experiments at Lawrence Livermore National Laboratory. The production process for DU hohlraums is intricate, involving complex sputtering, machining, and leaching techniques. Achieving low-stress and defect-free hohlraums presents significant challenges. Recent failures have revealed that some uranium flakes, known as slivers, detach from the diagnostic windows and fall onto the capsule. These catastrophic failures were observed only after target assembly, leading to the hypothesis that oxidation of the DU by glue vapor might be the cause. A study investigating the impact of glue vapor on DU hohlraums found that spallation occurred in three out of seven sample hohlraums after three weeks. The slivers observed in these samples were consistent with those seen in assembled targets. This marks the first experimental reproduction of such catastrophic slivering failures. Consequently, future studies can now focus on sliver mitigation and the precise diagnosis of the failure mode.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

NASA NTRS1973

Blood electrolytes and exercise in relation to temperature regulation in man.

It is shown that the body temperature rise during physical exercise is a regulated process and is not due to a failure of heat-dissipating mechanisms. Core and skin temperatures do not provide sufficient information to account for the control of sweating during exercise. Evidence is presented that suggests an association between equilibrium levels of rectal temperature and the osmotic concentration of the blood with essentially no influence from variations in plasma volume.-

Greenleaf, J. E.↗

NASA NTRS1973

Blood electrolytes and exercise in relation to temperature regulation in man

Current knowledge and theories about the relation of blood electrolytes and exercise to thermoregulation in man are reviewed. It is shown that the elevation of body temperature during physical exercise is a regulated process and is not due to a failure of the heat dissipating mechanisms. Core and skin temperatures do not provide sufficient information to account for the control of sweating during exercise. Evidence is presented that suggests an association between equilibrium levels of rectal temperature and the osmotic concentration of the blood with essentially no influence of variations in plasma volume.

Greenleaf, J. E.↗

NASA NTRS2009

An Overview of the State of the Art in Atomistic and Multiscale Simulation of Fracture

The emerging field of nanomechanics is providing a new focus in the study of the mechanics of materials, particularly in simulating fundamental atomic mechanisms involved in the initiation and evolution of damage. Simulating fundamental material processes using first principles in physics strongly motivates the formulation of computational multiscale methods to link macroscopic failure to the underlying atomic processes from which all material behavior originates. This report gives an overview of the state of the art in applying concurrent and sequential multiscale methods to analyze damage and failure mechanisms across length scales.

Saether, Erik↗

NASA NTRS2017

Extension of HCDstruct for Transonic Aeroservoelastic Analysis of Unconventional Aircraft Concepts

A substantial effort has been made to implement an enhanced aerodynamic modeling capability in the Higher-fidelity Conceptual Design and structural optimization tool. This additional capability is needed for a rapid, physics-based method of modeling advanced aircraft concepts at risk of structural failure due to dynamic aeroelastic instabilities. To adequately predict these instabilities, in particular for transonic applications, a generalized aerodynamic matching algorithm was implemented to correct the doublet-lattice model available in Nastran using solution data from a priori computational fluid dynamics anal- ysis. This new capability is demonstrated for two tube-and-wing aircraft configurations, including a Boeing 737-200 for implementation validation and the NASA D8 as a first use case. Results validate the current implementation of the aerodynamic matching utility and demonstrate the importance of using such a method for aircraft configurations featuring fuselage-wing aerodynamic interaction.

Quinlan, Jesse R.↗