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At least 379 records · Page 21
All sourcesNASA NTRSDOE OSTI
NASA NTRS2000

Wormhole Formation in RSRM Nozzle Joint Backfill

The RSRM nozzle uses a barrier of RTV rubber upstream of the nozzle O-ring seals. Post flight inspection of the RSRM nozzle continues to reveal occurrence of "wormholes" into the RTV backfill. The term "wormholes", sometimes called "gas paths", indicates a gas flow path not caused by pre-existing voids, but by a little-understood internal failure mode of the material during motor operation. Fundamental understanding of the mechanics of the RSRM nozzle joints during motor operation, nonlinear viscoelastic characterization of the RTV backfill material, identification of the conditions that predispose the RTV to form wormholes, and screening of candidate replacement materials is being pursued by a joint effort between Thiokol Propulsion, NASA, and the Army Propulsion & Structures Directorate at Redstone Arsenal. The performance of the RTV backfill in the joint is controlled by the joint environment. Joint movement, which applies a tension and shear load on the material, coupled with the introduction of high pressure gas in combination create an environment that exceeds the capability of the material to withstand the wormhole effect. Little data exists to evaluate why the material fails under the modeled joint conditions, so an effort to characterize and evaluate the material under these conditions was undertaken. Viscoelastic property data from characterization testing will anchor structural analysis models. Data over a range of temperatures, environmental pressures, and strain rates was used to develop a nonlinear viscoelastic model to predict material performance, develop criteria for replacement materials, and quantify material properties influencing wormhole growth. Three joint simulation analogs were developed to analyze and validate joint thermal barrier (backfill) material performance. Two exploratory tests focus on detection of wormhole failure under specific motor operating conditions. A "validation" test system provides data to "validate" computer models and predictions. Finally, two candidate replacement materials are being screened and "validated" using the developed test systems.

Stevens, J.↗
NASA NTRS1991

The initiation, propagation, and effect of matrix microcracks in cross-ply and related laminates

Recently, a variational mechanics approach was used to determine the thermoelastic stress state in cracked laminates. Described here is a generalization of the variational mechanics techniques to handle other cross-ply laminates, related laminates, and to account for delaminations emanating from microcrack tips. Microcracking experiments on Hercules 3501-6/AS4 carbon fiber/epoxy laminates show a staggered cracking pattern. These results can be explained by the variational mechanics analysis. The analysis of delaminations emanating from microcrack tips has resulted in predictions about the structural and material variables controlling competition between microcracking and delamination failure modes.

Nairn, John A.↗
NASA NTRS1997

Correlation of Chemical and Physical Test Data For the Environment Ageing of Coflon (PVDF)

This report aims to identify correlations between mechanical property changes and chemical/morphological structure changes for Coflon. It is intended both to illustrate the overall methodology and to indicate the testing that needs to be undertaken in order to obtain correlations. Many fluid exposures have now been carried out on Coflon during the project and many data generated as a result. The report summarises the changes observed in mechanical and physical properties and relates these as well as possible to the chemistry thought to be occurring during ageing. For this purpose, data have been collated from already-issued MERL and TRI technical and progress reports. Most of the mechanical testing of aged testpieces has been performed soon after the completion of the exposure; however, there is of necessity a delay in obtaining chemical analysis of the same testpieces, so that more physical than chemical data are shown. Three fluids have so far caused measurable deterioration of Coflon, these being: methanol (Fluid A), a methanol and amine mixture (Fluid G), and a mixture of methane, carbon dioxide gas and hydrogen sulphide gas plus aqueous amine (Fluid F). Only the effects of these fluids will be dealt with in any detail in this report, although other fluids are assessed to give relevant background information. Relevant test data collated here include: tensile modulus and related properties, mode of sample failure at break, fracture toughness, fatigue crack growth rate and resistance, stress relaxation rate, permeation coefficients, % crystallinity and molecular weight distributions together with changes in fluorine levels, and other observations where appropriate. However, not all of these were obtained for every ageing condition. Because of the wide range of tests employed, and the different ways in which their results are obtained, the following section has been included to serve as a background for making comparisons.

Morgan, G. J.↗
NASA NTRSDate not supplied

Material Variability Effects on Damage Development Within Composite Adhesively Bonded Joints

Use of composite adhesively bonded joints (ABJ) is of critical importance to the adoption of composite materials in the automotive industry, as ABJ enable lower stress concentrations as compared to conventional mechanically fastened joints. ABJ are better suited for joining composite materials as compared to fastened joints because fastened joints require drilling of holes which locally affect composite material structure. Composite materials and adhesives are subject to unavoidable stochastic local material variations which make different failure scenarios possible. An experimentally tested ABJ configuration is simulated using finite element analysis (FEA). Experimentally, under tension, the joints failed by three major failure modes, with peak loads ranging from 13.0-16.1 kips. Progressive failure analysis tools are used to simulate damage development within each material within the joint. The simulation agreed well with the average experimental peak load. Stochastically occurring adhesive porosity and matrix-fiber micro-disbonding were numerically simulated. The simulations revealed a similar trend as observed experimentally: joints which failed at higher peak loads had lower levels of damage within the face-sheets of the composite panels which were adhesively bonded; these joints which failed at higher peak loads also had greater damage in the doubler of the experimentally tested double lap joint configuration.

Richard Larson↗
NASA NTRS2011

Prognostics of Power Mosfets Under Thermal Stress Accelerated Aging Using Data-Driven and Model-Based Methodologies

An approach for predicting remaining useful life of power MOSFETs (metal oxide field effect transistor) devices has been developed. Power MOSFETs are semiconductor switching devices that are instrumental in electronics equipment such as those used in operation and control of modern aircraft and spacecraft. The MOSFETs examined here were aged under thermal overstress in a controlled experiment and continuous performance degradation data were collected from the accelerated aging experiment. Dieattach degradation was determined to be the primary failure mode. The collected run-to-failure data were analyzed and it was revealed that ON-state resistance increased as die-attach degraded under high thermal stresses. Results from finite element simulation analysis support the observations from the experimental data. Data-driven and model based prognostics algorithms were investigated where ON-state resistance was used as the primary precursor of failure feature. A Gaussian process regression algorithm was explored as an example for a data-driven technique and an extended Kalman filter and a particle filter were used as examples for model-based techniques. Both methods were able to provide valid results. Prognostic performance metrics were employed to evaluate and compare the algorithms.

Electrolytic capacitors↗
NASA NTRS2019

Experimental and Numerical Analysis of Skin-Stiffener Separation Using a Seven-Point Bend Configuration

Skin-stiffener separation in stiffened composite panels consists of a complex interaction between multiple scales of progressive damage and failure mechanisms. This work used a superposed cohesive element method of modeling resistance curve effects that represents the structural interface of a unidirectional tape skin and a fabric stiffener. Finite element models using cohesive elements with input properties obtained from tape-to-fabric interface characterization tests were compared to experimental results of a stable skin-stiffener separation characterization test using a seven-point bend fixture. This fixture deformed the stiffened panel specimens into a buckled configuration which induced mixed-mode interlaminar stress states at the skin-stiffener interface. The advantage of this fixture was the potential for more stable damage initiation and delamination growth compared to a stringer-stiffened panel under axial compression. Use of the superposed cohesive elements showed promise, but the characterization of interface material properties as input to the cohesive elements remains a crucial component to be investigated to ensure accurate prediction of skin-stiffener separation.

Kosztowny, Cyrus J. R.↗
NASA NTRS1979

Effect of moisture on the fatigue behavior of graphite/epoxy composite laminates

The form of the moisture distribution in the specimen (gradient and flat profile) was considered to establish the influence of accelerated moisture conditioning on fatigue behavior. For the gradient specimens having an average moisture content of 1.4 percent, fatigue life was reduced by a factor of 8 at all stress levels investigated. Corresponding reduction in fatigue life for the flat moisture profile specimens at the same average moisture content was comparatively smaller, being about a factor of 5 from the value in dry specimens. X-ray radiographic analysis of damage accumulation in compression-compression fatigue revealed interlaminar cracking to be the dominant mode of failure responsible for the observed enhanced cyclic degradation of moisture-conditioned specimens. This finding was corroborated by the observed systematic reduction in interlaminar shear strength as a function of moisture content, which, in turn, increased the propensity for delamination under cyclic compressive loads. Residual strength measurements on cycled specimens indicated significant strength reductions at long lives, particularly in moisture conditioned specimens.

Ramani, S. V.↗
NASA NTRS2011

Risk Acceptance Personality Paradigm: How We View What We Don't Know We Don't Know

The purpose of integrated hazard analyses, probabilistic risk assessments, failure modes and effects analyses, fault trees and many other similar tools is to give managers of a program some idea of the risks associated with their program. All risk tools establish a set of undesired events and then try to evaluate the risk to the program by assessing the severity of the undesired event and the likelihood of that event occurring. Some tools provide qualitative results, some provide quantitative results and some do both. However, in the end the program manager and his/her team must decide which risks are acceptable and which are not. Even with a wide array of analysis tools available, risk acceptance is often a controversial and difficult decision making process. And yet, today's space exploration programs are moving toward more risk based design approaches. Thus, risk identification and good risk assessment is becoming even more vital to the engineering development process. This paper explores how known and unknown information influences risk-based decisions by looking at how the various parts of our personalities are affected by what they know and what they don't know. This paper then offers some criteria for consideration when making risk-based decisions.

Massie, Michael J.↗
NASA NTRS1979

Nonlinear temperature dependent failure analysis of finite width composite laminates

A quasi-three dimensional, nonlinear elastic finite element stress analysis of finite width composite laminates including curing stresses is presented. Cross-ply, angle-ply, and two quasi-isotropic graphite/epoxy laminates are studied. Curing stresses are calculated using temperature dependent elastic properties that are input as percent retention curves, and stresses due to mechanical loading in the form of an axial strain are calculated using tangent modulii obtained by Ramberg-Osgood parameters. It is shown that curing stresses and stresses due to tensile loading are significant as edge effects in all types of laminate studies. The tensor polynomial failure criterion is used to predict the initiation of failure. The mode of failure is predicted by examining individual stress contributions to the tensor polynomial.

Nagarkar, A. P.↗
NASA NTRS2002

Effect of Environment on Stress-Rupture Behavior of a Carbon Fiber-Reinforced Silicon Carbide (C/SiC) Ceramic Matrix Composite

Stress-rupture tests were conducted in air, vacuum, and steam-containing environments to identify the failure modes and degradation mechanisms of a carbon fiber-reinforced silicon carbide (C/SiC) composite at two temperatures, 600 and 1200 C. Stress-rupture lives in air and steam containing environments (50 - 80% steam with argon) are similar for a composite stress of 69 MPa at 1200 C. Lives of specimens tested in a 20% steam/argon environment were about twice as long. For tests conducted at 600 C, composite life in 20% steam/argon was 20 times longer than life in air. Thermogravimetric analysis of the carbon fibers was conducted under similar conditions to the stress-rupture tests. The oxidation rate of the fibers in the various environments correlated with the composite stress-rupture lives. Examination of the failed specimens indicated that oxidation of the carbon fibers was the primary damage mode for specimens tested in air and steam environments at both temperatures.

Verrilli, Michael J.↗
NASA NTRS1978

An analysis of delamination in angle-ply fiber reinforced composites

An analytical investigation of the mechanics and failure modes of delamination initiated from a service-induced surface flaw in angle-ply fiber reinforced composites is presented. The analysis employs a hybrid-stress finite element method including a crack-tip singular element with its field variables expressed by Muskhelishvili's complex stress functions. Solutions are obtained for delaminated composites with various laminate parameters. The results elucidate unique and important characteristics of delamination crack-tip response and interlaminar stress transfer mechanisms. Of particular interest are the mixed-mode stress intensity factors associated with the delamination crack. The influence of ply orientation on KI and KII and their effects on subsequent crack extension are discussed.

Wang, S. S.↗
NASA NTRS1989

Fracture characteristics of balloon films

An attempt was made to determine the failure modes of high altitude scientific balloons through an investigation of the fracture characteristics of the thin polyethylene films. Two films were the subject of the evaluation, Winzen Int.'s Stratafilm SF-85 and Raven Industries' Astro-E. Research began with an investigation of the film's cold brittleness point and it's effect on the ultimate strength and elasticity of the polyethylene film. A series of preliminary investigations were conducted to develop an understanding of the material characteristics. The primary focus of this investigation was on the notch sensitivity of the films. Simple stress strain tests were also conducted to enable analysis employing fracture toughness parameters. Studies were conducted on both film types at 23 C (room temperature), -60 C, -90 C, and -120 C.

Portanova, Marc A.↗
NASA NTRS1980

An analysis of delamination in angle-ply fiber-reinforced composites

A study of the mechanics and failure modes of delamination initiated from a surface flaw in angle-ply fiber-reinforced composites is presented. The analysis employs a hybrid-stress finite-element method including a crack-tip singular element with its field variables expressed by Muskhelishvili's complex stress functions. Solutions are obtained for the delaminated composites with various laminate parameters. The results elucidate unique and important characteristics of delamination crack-tip response and interlaminar stress transfer mechanisms. Of particular interest are the mixed-mode stress-intensity factors associated with the delamination crack. The influence of ply orientation on KI and KII and their effects on subsequent crack extension are discussed.

Wang, S. S.↗
NASA NTRS2009

The Development of Directional Decohesion Finite Elements for Multiscale Failure Analysis of Metallic Polycrystals

Atomistic simulations of intergranular fracture have indicated that grain-scale crack growth in polycrystalline metals can be direction dependent. At these material length scales, the atomic environment greatly influences the nature of intergranular crack propagation, through either brittle or ductile mechanisms, that are a function of adjacent grain orientation and direction of crack propagation. Methods have been developed to obtain cohesive zone models (CZM) directly from molecular dynamics simulations. These CZMs may be incorporated into decohesion finite element formulations to simulate fracture at larger length scales. A new directional decohesion element is presented that calculates the direction of Mode I opening and incorporates a material criterion for dislocation emission based on the local crystallographic environment to automatically select the CZM that best represents crack growth. The simulation of fracture in 2-D and 3-D aluminum polycrystals is used to illustrate the effect of parameterized CZMs and the effectiveness of directional decohesion finite elements.

Saether, Erik↗
NASA NTRS1990

KOH concentration effect on the cycle life of nickel-hydrogen cells. IV - Results of failure analysis

Potassium hydroxide concentration effects on the cycle life of a Ni/H2 cell have been studied by carrying out a cycle life test on ten Ni/H2 boiler plate cells which contain electrolytes of various KOH concentrations. Failure analyses of these cells were carried out after completion of the life test, which accumulated up to 40,000 cycles at an 80-percent depth of discharge over a period of 3.7 years. These failure analyses included studies on changes of electrical characteristics of test cells, and component analyses after disassembly of the cell. The component analyses included visual inspections, dimensional changes, capacity measurements of nickel electrodes, scanning electron microscopy, surface area measurements, and chemical analyses. Results have indicated that failure mode and change in the nickel electrode varied as the concentration was varied, especially when the concentration was changed from 31 percent or higher to 26 percent or lower.

Lim, H. S.↗
NASA NTRS2007

Cohesive Elements for Shells

A cohesive element for shell analysis is presented. The element can be used to simulate the initiation and growth of delaminations between stacked, non-coincident layers of shell elements. The procedure to construct the element accounts for the thickness offset by applying the kinematic relations of shell deformation to transform the stiffness and internal force of a zero-thickness cohesive element such that interfacial continuity between the layers is enforced. The procedure is demonstrated by simulating the response and failure of the Mixed Mode Bending test and a skin-stiffener debond specimen. In addition, it is shown that stacks of shell elements can be used to create effective models to predict the inplane and delamination failure modes of thick components. The results indicate that simple shell models can retain many of the necessary predictive attributes of much more complex 3D models while providing the computational efficiency that is necessary for design.

Davila, Carlos G.↗
NASA NTRS2010

Solving Component Structural Dynamic Failures Due to Extremely High Frequency Structural Response on the Space Shuttle Program

For many years, the capabilities to determine the root-cause failure of component failures have been limited to the analytical tools and the state of the art data acquisition systems. With this limited capability, many anomalies have been resolved by adding material to the design to increase robustness without the ability to determine if the design solution was satisfactory until after a series of expensive test programs were complete. The risk of failure and multiple design, test, and redesign cycles were high. During the Space Shuttle Program, many crack investigations in high energy density turbomachines, like the SSME turbopumps and high energy flows in the main propulsion system, have led to the discovery of numerous root-cause failures and anomalies due to the coexistences of acoustic forcing functions, structural natural modes, and a high energy excitation, such as an edge tone or shedding flow, leading the technical community to understand many of the primary contributors to extremely high frequency high cycle fatique fluid-structure interaction anomalies. These contributors have been identified using advanced analysis tools and verified using component and system tests during component ground tests, systems tests, and flight. The structural dynamics and fluid dynamics communities have developed a special sensitivity to the fluid-structure interaction problems and have been able to adjust and solve these problems in a time effective manner to meet budget and schedule deadlines of operational vehicle programs, such as the Space Shuttle Program over the years.

Frady, Greg↗
NASA NTRS1974

Unsteady aerodynamics could dominate the space shuttle booster aeroelastic stability

Quasi-steady techniques are used in a preliminary, order of magnitude, analysis of the aeroelastic stability of a number of space shuttle boost configurations. The configurations analyzed all have at least one low frequency free-free bending mode that is aerodynamically undamped due to aerodynamic interference effects. Typically, the aerodynamic interference effects involve flow conditions at one vehicle station influencing the loads at another. Due to the finite flow convection velocity and the aerodynamic coupling of flow conditions at different locations on the vehicle, these interference loads result in aerodynamic undamping of one or more of the low frequency free-free elastic modes. The implication of these results, i.e., the possibility of undamped, divergent, oscillations leading to structural failure, (if the aerodynamic undamping should dominate the structural damping) is serious enough to warrant further analytic and experimental investigations.

Reding, J. P.↗