SEARCH · Engineering Papers

Results for “Disk failure”

Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

SourceResearch connectionFrom yearThrough year

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 73 records · Page 4

All sources NASA NTRS DOE OSTI

NASA NTRS1994

Evaluation of PS 212 Coatings Under Boundary Lubrication Conditions with an Ester-based Oil to 300 C

High friction and wear of turbine engine components occur during high temperature excursions above the oxidation threshold of the liquid lubricant. This paper reports on research to study the use of a high temperature self lubricating coating, PS 212 for back-up lubrication in the event of failure of the liquid lubricant. Pin on disk tests were performed under dry and boundary-lubricated conditions at disk temperatures up to 300 C. The liquid lubricant was a formulated polyol ester qualified under MIL L-23699. At test temperatures above the oil's thermal degradation level, the use of PS 212 reduced wear, providing a back-up lubricant effect.

Sliney, Harold E.↗

DOE OSTI2021

Durability of plasma sprayed Thermal Barrier Coatings with controlled properties part Ⅱ: Effects of geometrical curvature

The present investigation elucidates the effects of substrate curvature on the durability of Air Plasma Sprayed (APS) Thermal Barrier Coatings (TBCs). Traditionally, planar disk specimens are utilized in Furnace Cycle Testing (FCT). In most cases, delamination is initiated at the disk's free edge and then propagates along the TBC-bond coat interface. However, in turbine components (e.g., blades/vanes), they lack significant free edges and the coatings are deposited on non-flat surfaces of varying radii of curvature. These geometrical discrepancies imply significant differences in the stress states as compared to planar disk specimens. Therefore, the part geometry inevitably affects the TBC failure mechanisms in the turbine system, and consequently influences TBC durability. Nevertheless, these effects have not been fully explored in the past, despite the anecdotal knowledge which suggests the leading edge of turbine blades to be one of the most common failure/spallation locations. Here in this study, representative TBC systems were deposited onto superalloy disks with flat substrate and rods with curved substrate. The experimental results from FCT suggest TBC durability on rods is significantly lower than when sprayed on disks. Furthermore, the durability of TBCs on rods appears to increase with higher porosity, which is contradictory to reported trends for TBCs on disks. In addition, the effects of various bond coats are not consistent with those observed in disks. To clarify the underlying effects of curved geometries, detailed stress analyses were performed. They revealed a state of thermal stresses which is unique to curved geometries. It was found that TBC on rods experience tensile radial stresses as well as tensile hoop stresses during the cooling. These stresses result in a complex interplay in failure processes in rods, which explains the different observed trends in the durability from those obtained with disks.

36 MATERIALS SCIENCE↗

NASA NTRS2018

An Abrupt Transition to an Intergranular Failure Mode in the Near-Threshold Fatigue Crack Growth Regime in Ni-Based Superalloys

Cyclic near-threshold fatigue crack growth (FCG) behavior of two disk superalloys was evaluated and was shown to exhibit an unexpected sudden failure mode transition from a mostly transgranular failure mode at higher stress intensity factor ranges to an almost completely intergranular failure mode in the threshold regime. The change in failure modes was associated with a crossover of FCG resistance curves in which the conditions that produced higher FCG rates in the Paris regime resulted in lower FCG rates and increased Kth values in the threshold region. High-resolution scanning and transmission electron microscopy were used to carefully characterize the crack tips at these near-threshold conditions. Formation of stable Al-oxide followed by Cr-oxide and Ti-oxides was found to occur at the crack tip prior to formation of unstable oxides. To contrast with the threshold failure mode regime, a quantitative assessment of the role that the intergranular failure mode has on cyclic FCG behavior in the Paris regime was also performed. It was demonstrated that even a very limited intergranular failure content dominates the FCG response under mixed mode failure conditions.

Telesman, J.↗

NASA NTRS1981

The application of probabilistic design theory to high temperature low cycle fatigue

Metal fatigue under stress and thermal cycling is a principal mode of failure in gas turbine engine hot section components such as turbine blades and disks and combustor liners. Designing for fatigue is subject to considerable uncertainty, e.g., scatter in cycles to failure, available fatigue test data and operating environment data, uncertainties in the models used to predict stresses, etc. Methods of analyzing fatigue test data for probabilistic design purposes are summarized. The general strain life as well as homo- and hetero-scedastic models are considered. Modern probabilistic design theory is reviewed and examples are presented which illustrate application to reliability analysis of gas turbine engine components.

Wirsching, P. H.↗

NASA NTRS2005

Rotordynamic Analysis and Feasibility Study of a Disk Spin Test Facility for Rotor Health Monitoring

Recently, National Aeronautics and Space Administration (NASA) initiated a program to achieve the significant improvement in aviation safety. One of the technical challenges is the design and development of accelerated experiments that mimic critical damage cases encountered in engine components. The Nondestructive Evaluation (NDE) Group at the NASA Glenn Research Center (GRC) is currently addressing the goal concerning propulsion health management and the development of propulsion system specific technologies intended to detect potential failures prior to catastrophe. For this goal the unique disk spin simulation system was assembled at NASA GRC, which allows testing of rotors with the spinning speeds up to 10K RPM, and at the elevated temperature environment reaching 540 C (1000 F). It is anticipated that the facility can be employed for detection of Low Cycle Fatigue disk cracking and further High Cycle Fatigue blade vibration. The controlled crack growth studies at room and elevated temperatures can be conducted on the turbine wheels, and various NDE techniques can be integrated and assessed as in-situ damage monitoring tools. Critical rotating parts in advanced gas turbine engines such as turbine disks frequently operate at high temperature and stress for long periods of time. The integrity of these parts must be proven by non-destructive evaluation (NDE) during various machining steps ranging from forging blank to finished shape, and also during the systematic overhaul inspections. Conventional NDE methods, however, have unacceptable limits. Some of these techniques are time-consuming and inconvenient for service aircraft testing. Almost all of these techniques require that the vicinity of the damage is known in advance. These experimental techniques can provide only local information and no indication of the structural strength at a component and/or system level. The shortcomings of currently available NDE methods lead to the requirement of new damage detection techniques that can provide global information on the rotating components/system, and, in addition, they do not require direct human access to the operating system. During this period of research considerable effort was directed towards the further development of experimental facility and development of the vibration-based crack detection methodology for rotating disks and shafts. A collection of papers and reports were written to describe the results of this work. The attached captures that effort and represents the research output during the grant period.

Sawicki, Jerzy T.↗

NASA NTRS1974

Adhesive fracture mechanics

In studies of fracture mechanics the adhesive fracture energy is regarded as a fundamental property of the adhesive system. It is pointed out that the value of the adhesive fracture energy depends on surface preparation, curing conditions, and absorbed monolayers. A test method reported makes use of a disk whose peripheral part is bonded to a substrate material. Pressure is injected into the unbonded central part of the disk. At a certain critical pressure value adhesive failure can be observed. A numerical stress analysis involving arbitrary geometries is conducted.

Bennett, S. J.↗

NASA NTRS1990

Compendium of fracture mechanics problems

Fracture mechanics analysis results are presented from the following structures/components analyzed at Marshall Space Flight Center (MSFC) between 1982 and 1989: space shuttle main engine (SSME), Hubble Space Telescope (HST), external tank attach ring, B-1 stand LOX inner tank, and solid rocket booster (SRB). Results from the SSME high pressure fuel turbopump (HPFTP) second stage blade parametric analysis determine a critical flaw size for a wide variety of stress intensity values. The engine 0212 failure analysis was a time dependent fracture life assessment. Results indicated that the disk ruptured due to an overspeed condition. Results also indicated that very small flaws in the curvic coupling area could propagate and lead to failure under normal operating conditions. It was strongly recommended that a nondestructive evaluation inspection schedule be implemented. The main ring of the HST, scheduled to launch in 1990, was analyzed by safe-life and fail-safe analyses. First safe-life inspection criteria curves for the ring inner and outer skins and the fore and aft channels were derived. Afterwards the skins and channels were determined to be fail-safe by analysis. A conservative safe-life analysis was done on the 270 redesign external tank attach ring. Results from the analysis were used to determine the nondestructive evaluation technique required.

Stallworth, R.↗

NASA NTRS2001

The Tensile Properties of Advanced Nickel-Base Disk Superalloys During Quenching Heat Treatments

There is a need to increase the temperature capabilities of superalloy turbine disks. This would allow full utilization of higher temperature combustor and airfoil concepts under development. One approach to meet this goal is to modify the processing and chemistry of advanced alloys, while preserving the ability to use rapid cooling supersolvus heat treatments to achieve coarse grain, fine gamma prime microstructures. An important step in this effort is to understand the key high temperature tensile properties of advanced alloys as they exist during supersolvus heat treatments. This could help in projecting cracking tendencies of disks during quenches from supersolvus heat treatments. The objective of this study was to examine the tensile properties of two advanced disk superalloys during simulated quenching heat treatments. Specimens were cooled from the solution heat treatment temperatures at controlled rates, interrupted, and immediately tensile tested at various temperatures. The responses and failure modes were compared and related to the quench cracking tendencies of disk forgings.

Gabb, Timothy P.↗

NASA NTRS1993

Performance of redundant disk array organizations in transaction processing environments

A performance evaluation is conducted for two redundant disk-array organizations in a transaction-processing environment, relative to the performance of both mirrored disk organizations and organizations using neither striping nor redundancy. The proposed parity-striping alternative to striping with rotated parity is shown to furnish rapid recovery from failure at the same low storage cost without interleaving the data over multiple disks. Both noncached systems and systems using a nonvolatile cache as the controller are considered.

Mourad, Antoine N.↗

NASA NTRS1977

Rotor burst protection program: Statistics on aircraft gas turbine engine rotor failures that occurred in US commercial aviation during 1975

Statistics on gas turbine rotor failures that have occurred in U.S. commercial aviation during 1975 are presented. The compiled data were analyzed to establish: (1) The incidence of rotor failures and the number of contained and uncontained rotor bursts; (2) The distribution of rotor bursts with respect to engine rotor component; i.e., fan, compressor or turbine; (3) The type of rotor fragment (disk, rim or blade) typically generated at burst; (4) The cause of failure; (5) The type of engines involved; and (6) The flight condition at the time of failure.

Delucia, R. A.↗

NASA NTRS2009

Health Monitoring of a Rotating Disk Using a Combined Analytical-Experimental Approach

Rotating disks undergo rigorous mechanical loading conditions that make them subject to a variety of failure mechanisms leading to structural deformities and cracking. During operation, periodic loading fluctuations and other related factors cause fractures and hidden internal cracks that can only be detected via noninvasive types of health monitoring and/or nondestructive evaluation. These evaluations go further to inspect material discontinuities and other irregularities that have grown to become critical defects that can lead to failure. Hence, the objectives of this work is to conduct a collective analytical and experimental study to present a well-rounded structural assessment of a rotating disk by means of a health monitoring approach and to appraise the capabilities of an in-house rotor spin system. The analyses utilized the finite element method to analyze the disk with and without an induced crack at different loading levels, such as rotational speeds starting at 3000 up to 10 000 rpm. A parallel experiment was conducted to spin the disk at the desired speeds in an attempt to correlate the experimental findings with the analytical results. The testing involved conducting spin experiments which, covered the rotor in both damaged and undamaged (i.e., notched and unnotched) states. Damaged disks had artificially induced through-thickness flaws represented in the web region ranging from 2.54 to 5.08 cm (1 to 2 in.) in length. This study aims to identify defects that are greater than 1.27 cm (0.5 in.), applying available means of structural health monitoring and nondestructive evaluation, and documenting failure mechanisms experienced by the rotor system under typical turbine engine operating conditions.

Abdul-Aziz, Ali↗

DOE OSTI2021

Mechanical and Thermophysical Properties of 3D-Printed SiC before and after Neutron Irradiation – FY21

This report presents the mechanical and thermophysical properties of 3D-printed SiC before and after neutron irradiation that have been evaluated to assess the fuel matrix material for the Transformational Challenge Reactor (TCR). The TCR fuel form consists of an additively-manufactured silicon carbide (SiC) matrix and uranium nitride tristructural isotropic (UN TRISO) fuel particles, which is manufactured through a newly developed processing route combining binderjet 3D printing, TRISO fuel particle loading, and chemical vapor infiltration (CVI). Because the fuel matrix is a primary component of the TCR core and its response to mechanical and thermal loads during operation is one of the most influential factors on the integrity of TCR core, testing and evaluation have focused on producing mechanical and thermophysical properties data for the binderjet/CVI SiC. Baseline mechanical and thermophysical properties were measured from the disk specimens printed for different and sizes orientations, which included equibiaxial flexural failure strength, elastic constants, thermal diffusivity and conductivity, density, and the coefficient of thermal expansion. Flexural failure strength datasets showed similar Weibull distributions regardless of sample variants including different orientations. The mean failure strengths of the 3D-printed SiC variants were in the range of 280–310 MPa, which are slightly lower than that of the chemical vapor deposition (CVD) SiC. Thermophysical test results showed that specific heat and thermal expansion are not sensitive to the build direction of SiC samples, while thermal conductivity is highly dependent on the build direction and can be correlated to the anisotropic character of the 3D-printed SiC. Neutron irradiation tests were carried out on the 3D-printed 6-mm diameter SiC disk specimens. Irradiation was carried to 2.3 dpa over a temperature range of 360–880°C. No significant degradation in strength was observed in SiC after irradiations in various conditions and with different orientations. Anisotropy that had been observed in the thermal conductivity of 3D-printed SiC prior to irradiation vanished after irradiation as the irradiation defect thermal resistivity accumulated in the material. Electron microscopy of the microstructure after neutron irradiation showed distinct defect morphologies in the heterogenous material, but no evidence for irradiation-induced cracking or degradation in the microstructure was observed.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

NASA NTRS1997

Fatigue Reliability of Gas Turbine Engine Structures

The results of an investigation are described for fatigue reliability in engine structures. The description consists of two parts. Part 1 is for method development. Part 2 is a specific case study. In Part 1, the essential concepts and practical approaches to damage tolerance design in the gas turbine industry are summarized. These have evolved over the years in response to flight safety certification requirements. The effect of Non-Destructive Evaluation (NDE) methods on these methods is also reviewed. Assessment methods based on probabilistic fracture mechanics, with regard to both crack initiation and crack growth, are outlined. Limit state modeling techniques from structural reliability theory are shown to be appropriate for application to this problem, for both individual failure mode and system-level assessment. In Part 2, the results of a case study for the high pressure turbine of a turboprop engine are described. The response surface approach is used to construct a fatigue performance function. This performance function is used with the First Order Reliability Method (FORM) to determine the probability of failure and the sensitivity of the fatigue life to the engine parameters for the first stage disk rim of the two stage turbine. A hybrid combination of regression and Monte Carlo simulation is to use incorporate time dependent random variables. System reliability is used to determine the system probability of failure, and the sensitivity of the system fatigue life to the engine parameters of the high pressure turbine. 'ne variation in the primary hot gas and secondary cooling air, the uncertainty of the complex mission loading, and the scatter in the material data are considered.

Cruse, Thomas A.↗

NASA NTRS2009

X-38 Advanced Sublimator

A document discusses a heat rejection device for transferring heat from a space vehicle by venting water into space through the use of a novel, two-stage water distribution system. The system consists of two different, porous media that stop water-borne contaminants from clogging the system and causing operational failures. Feedwater passes through a small nozzle, then into a porous disk made of sintered stainless steel, and then finally into large-pore aluminum foam. The smaller pore layer of the steel disk controls the pressure drop of the feedwater. The ice forms in the foam layer, and then sublimates, leaving any contaminants behind. The pore-size of the foam is two orders of magnitude larger than the current porous plate sublimators, allowing for a greater tolerance for contaminants. Using metallic fibers in the foam also negates problems with compression seen in the use of poly(tetrafluoroethylene) felt.

Dingell, Chuck↗

NASA NTRS2017

Relationship Between Unusual High-Temperature Fatigue Crack Growth Threshold Behavior in Superalloys and Sudden Failure Mode Transitions

An investigation of high temperature cyclic fatigue crack growth (FCG) threshold behavior of two advanced nickel disk alloys was conducted. The focus of the study was the unusual crossover effect in the near-threshold region of these type of alloys where conditions which produce higher crack growth rates in the Paris regime, produce higher resistance to crack growth in the near threshold regime. It was shown that this crossover effect is associated with a sudden change in the fatigue failure mode from a predominant transgranular mode in the Paris regime to fully intergranular mode in the threshold fatigue crack growth region. This type of a sudden change in the fracture mechanisms has not been previously reported and is surprising considering that intergranular failure is typically associated with faster crack growth rates and not the slow FCG rates of the near-threshold regime. By characterizing this behavior as a function of test temperature, environment and cyclic frequency, it was determined that both the crossover effect and the onset of intergranular failure are caused by environmentally driven mechanisms which have not as yet been fully identified. A plausible explanation for the observed behavior is proposed.

Fatigue Crack Growth Thresholds; Grain boundary ox↗

NASA NTRS2017

Relationship Between Unusual High-Temperature Fatigue Crack Growth Threshold Behavior in Superalloys and Sudden Failure Mode Transitions

Fatigue Crack Growth Thresholds; Grain boundary ox↗

NASA NTRS2010

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

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

Stein, William B.↗

NASA NTRS1972

Angular velocity and acceleration meter

Meter uses a liquid crystalline film which changes coloration due to shear-stresses produced by a rotating disk. Device is advantageous in that it is not subject to bearing failure or electrical burnouts as are conventional devices.

Melamed, L.↗