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NASA NTRS1961

Dynamic Stability and Control Problems of Piloted Reentry from Lunar Missions

A fixed-base simulator investigation has been made of stability and control problems during piloted reentry from lunar missions. Reentries were made within constraints of acceleration and skipping, in which the pilot was given simulated navigation tasks of altitude and heading angle commands. Vehicles considered included a blunt-face, high-drag capsule, and a low-drag lifting cone, each of which had a trim lift-drag ratio of 0.5. With the provision of three-axis automatic damping, both vehicles were easily controlled through reentry after a brief pilot-training period. With all dampers out, safe reentries could be made and both vehicles were rated satisfactory for emergency operation. In damper-failure conditions resulting in inadequate Dutch roll damping, the lifting-cone vehicle exhibited control problems due to excessive dihedral effect and oscillatory acceleration effects.

Moul, Martin T.↗

NASA NTRS1999

Diffusion Barriers to Increase the Oxidative Life of Overlay Coatings

Currently, most blades and vanes in the hottest section of aero gas turbine engines require some type of coating for oxidation protection. Newly developed single crystal superalloys have the mechanical potential to operate at increasingly higher component temperatures. However, at these elevated temperatures, coating/substrate interdiffusion can shorten the protective life of the coating. Diffusion barriers between overlay coatings and substrates are being examined to extend the protective life of the coating. A previously- developed finite-difference diffusion model has been modified to predict the oxidative life enhancement due to use of a diffusion barrier. The original diffusion model, designated COSIM, simulates Al diffusion in the coating to the growing oxide scale as well as Al diffusion into the substrate. The COSIM model incorporates an oxide growth and spalling model to provide the rate of Al consumption during cyclic oxidation. Coating failure is predicted when the Al concentration at the coating surface drops to a defined critical level. The modified COSIM model predicts the oxidative life of an overlay coating when a diffusion barrier is present eliminating diffusion of Al from the coating into the substrate. Both the original and the modified diffusion models have been used to predict the effectiveness of a diffusion barrier in extending the protective life of a NiCrAl overlay coating undergoing cyclic oxidation at 1100 C.

Nesbitt, James A.↗

NASA NTRS2021

Application of a Developmental Composite Material Model to Predict the Crush Response of Two Energy Absorbers

In 2012, a consortium was formed with the goal of creating a new composite material model capable of predicting the wide range of properties, accumulated damage behavior, and the many different types of failure in composites under impact loading. The material model was developed for execution in the commercially available nonlinear, explicit transient dynamic finite element code, LS-DYNA®. This material model incorporates three sub-models: deformation, damage, and failure. In addition, the model accounts for strain rate and temperature effects and relies heavily on the input of tabulated material response data. The model is designated *MAT_COMPOSITE_TABULATED_PLASTICITY_DAMAGE, or *MAT_213. Initially, *MAT_213 was developed for use with solid elements only; however, a thin shell element formulation for *MAT_213 has been adapted recently. The objective of this project was to find a suitable modeling example to investigate the capabilities and performance of *MAT_213. In 2012, two composite energy absorbers were designed and evaluated at NASA Langley Research Center through multi-level testing and simulation. The first was a conical-shaped energy absorber, designated the conusoid, which consisted of four layers of hybrid carbon-Kevlar® plain-weave fabric oriented at [+45°/-45°/-45°/+45°] with respect to the vertical direction. The second was a sinusoidal-shaped energy absorber, designated the sinusoid, which consisted of hybrid carbon-Kevlar® plain-weave fabric face sheets, two layers for each face sheet oriented at ±45° with respect to the vertical direction, and a closed-cell ELFOAM® P200 polyisocyanurate foam core. Finite element models were developed of the energy absorbers and simulations were performed using LS-DYNA®. In this paper, the development of a *MAT_213 model of a hybrid carbon-Kevlar® plain-weave fabric is presented. Next, comparisons with material characterization tests are presented. Then, test-analysis results are documented for each energy absorber as comparisons of time-history responses, as well as predicted and experimental structural deformations and progressive damage under impact loading using the *MAT_213 material model. Since a prior *MAT_58, or *MAT_LAMINATED_COMPOSITE_FABRIC material model was used in previous simulations of the energy absorbers, comparisons are made between *MAT_58 and *MAT_213 model predictions with test data. Finally, the paper includes a comprehensive list of “lessons learned,” in which a series of parametric studies are documented that were performed to investigate specific issues related to the material model. These “lessons learned” are included in hopes that they may help future *MAT_213 users.

crashworthiness, LS-DYNA transient dynamic simulat↗

NASA NTRS2008

Practical Application of a Subscale Transport Aircraft for Flight Research in Control Upset and Failure Conditions

Over the past decade, the goal of reducing the fatal accident rate of large transport aircraft has resulted in research aimed at the problem of aircraft loss-of-control. Starting in 1999, the NASA Aviation Safety Program initiated research that included vehicle dynamics modeling, system health monitoring, and reconfigurable control systems focused on flight regimes beyond the normal flight envelope. In recent years, there has been an increased emphasis on adaptive control technologies for recovery from control upsets or failures including damage scenarios. As part of these efforts, NASA has developed the Airborne Subscale Transport Aircraft Research (AirSTAR) flight facility to allow flight research and validation, and system testing for flight regimes that are considered too risky for full-scale manned transport airplane testing. The AirSTAR facility utilizes dynamically-scaled vehicles that enable the application of subscale flight test results to full scale vehicles. This paper describes the modeling and simulation approach used for AirSTAR vehicles that supports the goals of efficient, low-cost and safe flight research in abnormal flight conditions. Modeling of aerodynamics, controls, and propulsion will be discussed as well as the application of simulation to flight control system development, test planning, risk mitigation, and flight research.

Cunningham, Kevin↗

NASA NTRS1993

Tensile creep and creep-recovery behavior of a SiC-fiber-Si3N4-matrix composite

The tensile creep and creep-recovery behavior of a hot-pressed unidirectional SiC-fiber/Si3N4-matrix composite was investigated at 1200 C in air, in order to determine how various sustained and cyclic creep loading histories would influence the creep rate, accumulated creep strain, and the amount of strain recovered upon specimen unloading. The data accumulated indicate that the fundamental damage mode for sustained tensile creep at stresses of 200 and 250 MPa was periodic fiber fracture and that the creep life and the failure mode at 250 MPa were strongly influenced by the rate at which the initial creep stress was applied. Cyclic loading significantly lowered the duration of primary creep and the overall creep-strain accumulation. The implications of the results for microstructural and component design are discussed.

Holmes, John W.↗

NASA NTRS1973

Failure detection and isolation methods for redundant gimballed inertial measurement units.

Skewed alignment of two redundant conventional inertial measuring units permits nonambiguous detection and isolation of hard and soft failures in real time by an airborne computer. Accelerometer outputs and gimbal readouts are monitored periodically, and attitude rate and velocity error vectors are computed from these data. Magnitudes of these vectors provide failure detection, and projection of these error vectors onto the coordinate axes of the two clusters permits isolation. A detailed Monte Carlo simulation of one version of the mechanization as applied to Space Shuttle boost trajectories demonstrates effectiveness down to very low levels of inertial instrument performance failures. The results indicate that worst case overall navigation performance occurs when accelerometer failures are of the order of 20 sigma and gyro failures are about 100 sigma for conventional state-of-the-art IMU instruments.

Solov, E. G.↗

NASA NTRS1997

Composite Interlaminar Shear Fracture Toughness, G(sub 2c): Shear Measurement of Sheer Myth?

The concept of G2c as a measure of the interlaminar shear fracture toughness of a composite material is critically examined. In particular, it is argued that the apparent G2c as typically measured is inconsistent with the original definition of shear fracture. It is shown that interlaminar shear failure actually consists of tension failures in the resin rich layers between plies followed by the coalescence of ligaments created by these failures and not the sliding of two planes relative to one another that is assumed in fracture mechanics theory. Several strain energy release rate solutions are reviewed for delamination in composite laminates and structural components where failures have been experimentally documented. Failures typically occur at a location where the mode 1 component accounts for at least one half of the total G at failure. Hence, it is the mode I and mixed-mode interlaminar fracture toughness data that will be most useful in predicting delamination failure in composite components in service. Although apparent G2c measurements may prove useful for completeness of generating mixed-mode criteria, the accuracy of these measurements may have very little influence on the prediction of mixed-mode failures in most structural components.

OBrien, T. Kevin↗

NASA NTRS1984

Failure Analysis of Nickel-hydrogen Cell Subjected to Simulated Low Earth Orbit Cycling

A nickel-hydrogen cell completed 10,080 simulated low earth orbit charge/discharge cycles at depths-of-discharge ranging from 50 to 80 percent prior to failure. The cell is of the Air Force design, rated at 50 ampere-hours, 8.9 cm (3.5 inches) in diameter. Upon disassembly, the end of the polysulfone core supporting the electrode stack was found to have fractured. This allowed the electrode stack to expand. A massive short was found at the inner diameter of the electrodes centered roughly at plate set 34 to 37 from the positive end of the electrode stack. The damaged area extended through approximately one third of the electrode stack, with the effect becoming progressively less with distance from plate set 34 to 37. Measured thicknesses of the positive plates were significantly greater than the initial specification values. The postulated cause of failure is that positive plate growth caused fracture of the shoulder from the end of the polysulfone core on which the electrodes are mounted. The electrode stack relieved and pressure points were created at the area near the inner diameter of the plates at the tab attachment. A short occurred at a pressure point between opposing plates and propagated to other electrode sets due to thermal and mechanical stresses caused by the short.

Mueller, V. C.↗

NASA NTRS2000

Testing and Analysis of Composite Skin/Stringer Debonding Under Multi-Axial Loading

A consistent step-wise approach is presented to investigate the damage mechanism in composite bonded skin/stringer constructions under uniaxial and biaxial (in-plane/out-of-plane) loading conditions. The approach uses experiments to detect the failure mechanism, computational stress analysis to determine the location of first matrix cracking and computational fracture mechanics to investigate the potential for delamination growth. In a first step, tests were performed on specimens, which consisted of a tapered composite flange, representing a stringer or frame, bonded onto a composite skin. Tests were performed under monotonic loading conditions in tension, three-point bending, and combined tension/bending to evaluate the debonding mechanisms between the skin and the bonded stringer. For combined tension/bending testing, a unique servohydraulic load frame was used that was capable of applying both in-plane tension and out-of-plane bending loads simultaneously. Specimen edges were examined on the microscope to document the damage occurrence and to identify typical damage patterns. For all three load cases, observed failure initiated in the flange, near the flange tip, causing the flange to almost fully debond from skin. In a second step, a two dimensional plane-strain finite element model was developed to analyze the different test cases using a geometrically nonlinear solution. For all three loading conditions, computed principal stresses exceeded the transverse strength of the material in those areas of the flange where the matrix cracks had developed during the tests. In a third step, delaminations of various lengths were simulated in two locations where delaminations were observed during the tests. The analyses showed that at the loads corresponding to matrix ply crack initiation computed strain energy release rates exceeded the values obtained from a mixed mode failure criterion in one location, Hence. Unstable delamination propagation is likely to occur as observed in the experiments.

Krueger, Ronald↗

NASA NTRS2000

Testing and Analysis of Composite Skin/Stringer Debonding under Multi-Axial Loading

A consistent step-wise approach is presented to investigate the damage mechanism in composite bonded skin/stringer constructions under uniaxial and biaxial (in-plane/out-of-plane) loading conditions. The approach uses experiments to detect the failure mechanism, computational stress analysis to determine the location of first matrix cracking and computational fracture mechanics to investigate the potential for delamination growth. In a first step, tests were performed on specimens, which consisted of a tapered composite flange, representing a stringer or frame, bonded onto a composite skin. Tests were performed under monotonic loading conditions in tension, three-point bending, and combined tension/bending to evaluate the debonding mechanisms between the skin and the bonded stringer. For combined tension/bending testing, a unique servohydraulic load frame was used that was capable of applying both in-plane tension and out-of-plane bending loads simultaneously. Specimen edges were examined on the microscope to document the damage occurrence and to identify typical damage patterns. For all three load cases, observed failure initiated in the flange, near the flange tip, causing the flange to almost fully debond from the skin. In a second step, a two-dimensional plane-strain finite element model was developed to analyze the different test cases using a geometrically nonlinear solution. For all three loading conditions, computed principal stresses exceeded the transverse strength of the material in those areas of the flange where the matrix cracks had developed during the tests. In a third step, delaminations of various lengths were simulated in two locations where delaminations were observed during the tests. The analyses showed that at the loads corresponding to matrix ply crack initiation computed strain energy release rates exceeded the values obtained from a mixed mode failure criterion in one location. Hence, unstable delamination propagation is likely to occur as observed in the experiments.

Krueger, Ronald↗

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 NTRS1969

Coatings decrease metal fatigue failure

Metal test specimens were coated with suitable materials to limit the rate of attack of fresh metal surfaces by the atmosphere. The fatigue properties of coated metals were superior to those which were uncoated and approached the properties observable in vacuum.

Sumsion, H. T.↗

NASA NTRSDate not supplied

Quantitative Analysis of Spaceflight Drug Stability Data to Support a Predictive Pharmaceutical Testing Strategy

To systematically quantify the time-dependent effect of spaceflight on active pharmaceutical ingredient (API) degradation, data were extracted from available published and unpublished spaceflight drug stability studies. Seven studies were identified that investigated the stability of individual medications following storage aboard crewed spacecraft. Medications stored for up to 2.4 years in low earth orbit (LEO) show limited change in API potency that, in all cases, falls within 10% of matched terrestrial controls, and within 5% of controls for the most drugs. This investigation shows that spaceflight is associated with a ~1.5-fold increase in the degradation rate relative to lot-matched terrestrial controls. Spaceflight is associated with an increased probability of drug failure over time; however, the incremental increase in degradation risk associated with spaceflight is minor compared to the baseline risk associated with terrestrial controls. Since most drugs across all NASA-supported studies were repackaged solid oral formulations that had been removed from protective manufacturer packaging, it is likely that prolonged exposure to atmospheric factors during both terrestrial and spaceflight treatments is a key contributor to degradation. Unique spaceflight environmental factors, particularly ionizing radiation and elevated CO2, may contribute to the additional cumulative effect of spaceflight. The results of this study show that the effect of spaceflight on drug stability is minor relative to the terrestrial baseline; however, the degradation rate and time-dependent failure of terrestrial controls highlights an extremely critical need to evaluate the effect of current repackaging methods and development of operationally appropriate methods to protected repackaged solid oral medications from environmental factors that mediate degradation.

J F Reichard↗

NASA NTRS2001

Effect of Load Rate on Tensile Strength of Various CFCCs at Elevated Temperatures: An Approach to Life Prediction Testing

Strength of three continuous fiber-reinforced ceramic composites, including SiC/CAS-11, SiC/MAS-5 and SiC/SiC, was determined as a function of test rate in air at 1100 - 1200 C. All three composite materials exhibited a strong dependency of strength on test rate, similar to the behavior observed in many advanced monolithic ceramics at elevated temperatures. The application of the preloading technique as well as the prediction of life from one loading configuration (constant stress-rate) to another (constant stress loading) suggested that the overall macroscopic failure mechanism of the composites would be the one governed by a power-law tyw of damage evolution/accumulation, analogous to slow crack growth commonly observed in advanced monolithic ceramics. It was further found that constant stress-rate testing could be used as an alternative to life prediction test methodology even for the composite materials at least for the short range of lifetime.

Choi, Sung R.↗

NASA NTRS2006

Life Limiting Behavior in Interlaminar Shear of Continuous Fiber-Reinforced Ceramic Matrix Composites at Elevated Temperatures

Interlaminar shear strength of four different fiber-reinforced ceramic matrix composites was determined with doublenotch shear test specimens as a function of test rate at elevated temperatures ranging from 1100 to 1316 C in air. Life limiting behavior, represented as interlaminar shear strength degradation with decreasing test rate, was significant for 2-D crossplied SiC/MAS-5 and 2-D plain-woven C/SiC composites, but insignificant for 2-D plain-woven SiC/SiC and 2-D woven Sylramic (Dow Corning, Midland, Michigan) SiC/SiC composites. A phenomenological, power-law delayed failure model was proposed to account for and to quantify the rate dependency of interlaminar shear strength of the composites. Additional stress rupture testing in interlaminar shear was conducted at elevated temperatures to validate the proposed model. The model was in good agreement with SiC/MAS-5 and C/SiC composites, but in poor to reasonable agreement with Sylramic SiC/SiC. Constant shear stress-rate testing was proposed as a possible means of life prediction testing methodology for ceramic matrix composites subjected to interlaminar shear at elevated temperatures when short lifetimes are expected.

Choi, Sung R.↗

NASA NTRS1994

Lossless Compression and Rate Control for the Galileo NIMS Experiment

The Galileo Near-Infrared Mapping Spectrometer (NIMS) is a sophisticated multi-spectral instrument that was developed to study the spatial/compositional aspects of the atmosphere of Jupiter and the surfaces of it's satellites. Since its original development, the communication capability of the Galileo spacecraft has been severly reduced as the result of a failure of ground controllers to open the main antenna. The data rate which will be available for all instruments at the first Jupiter encounter in 1995 has been reduced by several orders of magnitude (even after recent numerous improvements to data link efficiency.).

data compression NIMS instrument Galileo↗

NASA NTRS2009

Meteoroid and Orbital Debris Threats to NASA's Docking Seals: Initial Assessment and Methodology

The Crew Exploration Vehicle (CEV) will be exposed to the Micrometeoroid Orbital Debris (MMOD) environment in Low Earth Orbit (LEO) during missions to the International Space Station (ISS) and to the micrometeoroid environment during lunar missions. The CEV will be equipped with a docking system which enables it to connect to ISS and the lunar module known as Altair; this docking system includes a hatch that opens so crew and supplies can pass between the spacecrafts. This docking system is known as the Low Impact Docking System (LIDS) and uses a silicone rubber seal to seal in cabin air. The rubber seal on LIDS presses against a metal flange on ISS (or Altair). All of these mating surfaces are exposed to the space environment prior to docking. The effects of atomic oxygen, ultraviolet and ionizing radiation, and MMOD have been estimated using ground based facilities. This work presents an initial methodology to predict meteoroid and orbital debris threats to candidate docking seals being considered for LIDS. The methodology integrates the results of ground based hypervelocity impacts on silicone rubber seals and aluminum sheets, risk assessments of the MMOD environment for a variety of mission scenarios, and candidate failure criteria. The experimental effort that addressed the effects of projectile incidence angle, speed, mass, and density, relations between projectile size and resulting crater size, and relations between crater size and the leak rate of candidate seals has culminated in a definition of the seal/flange failure criteria. The risk assessment performed with the BUMPER code used the failure criteria to determine the probability of failure of the seal/flange system and compared the risk to the allotted risk dictated by NASA's program requirements.

deGroh, Henry C., III↗

NASA NTRS2009

Meteoroid and Orbital Debris Threats to NASA's Docking Seals: Initial Assessment and Methodology

deGroh, Henry C., III↗