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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.

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At least 73 records · Page 4
All sourcesNASA NTRSDOE OSTI
NASA NTRS1981

Failure analysis of a tool steel torque shaft

A low design load drive shaft used to deliver power from an experimental exhaust heat recovery system to the crankshaft of an experimental diesel truck engine failed during highway testing. An independent testing laboratory analyzed the failure by routine metallography and attributed the failure to fatigue induced by a banded microstructure. Visual examination by NASA of the failed shaft plus the knowledge of the torsional load that it carried pointed to a 100 percent ductile failure with no evidence of fatigue. Scanning electron microscopy confirmed this. Torsional test specimens were produced from pieces of the failed shaft and torsional overload testing produced identical failures to that which had occurred in the truck engine. This pointed to a failure caused by a high overload and although the microstructure was defective it was not the cause of the failure.

Reagan, J. R.↗
NASA NTRS1983

Failure analysis of a tool steel torque shaft

A low design load drive shaft used to deliver power from an experimental exhaust heat recovery system to the crankshaft of an experimental diesel truck engine failed during highway testing. An independent testing laboratory analyzed the failure by routine metallography and attributed the failure to fatigue induced by a banded microstructure. Visual examination by NASA of the failed shaft plus the knowledge of the torsional load that it carried pointed to a 100 percent ductile failure with no evidence of fatigue. Scanning electron microscopy confirmed this. Previously announced in STAR as N82-11184

Reagan, J. R.↗
NASA NTRS2000

Lubrication System Failure Baseline Testing on an Aerospace Quality Gear Mesh

Aerospace drive systems are required to survive a loss-of-lubrication test for qualification. In many cases emergency lubrication systems need to be designed and utilized to permit the drive system to pass this difficult requirement. The weight of emergency systems can adversely affect the mission capabilities of the aircraft. The possibility to reduce the emergency system weight through the use of mist lubrication will be described. Mist lubrication involves the delivery of a minute amount of an organic liquid as a vapor or fine mist in flowing compressed air to rubbing surfaces. At the rubbing surface, the vapor or mist reacts to form a solid lubricating film. The aim of this study was to establish a baseline for gear behavior under oil depleted conditions. A reactive vapor-mist lubrication method is described and proposed as a candidate emergency lubrication system.

Handschuh, Robert F.↗
NASA NTRS2003

Surface Cracking and Interface Reaction Associated Delamination Failure of Thermal and Environmental Barrier Coatings

In this paper, surface cracking and interface reactions of a BSAS coating and a multi-layer ZTO2-8wt%Y2O3 and mullite/BSAS/Si thermal and environmental barrier coating system on SiC/SiC ceramic matrix composites were characterized after long-term combined laser thermal gradient and furnace cyclic tests in a water vapor containing environment. The surface cracking was analyzed based on the coating thermal gradient sintering behavior and thermal expansion mismatch stress characteristics under the thermal cyclic conditions. The interface reactions, which were largely enhanced by the coating surface cracking in the water vapor environment, were investigated in detail, and the reaction phases were identified for the coating system after the long- term exposure. The accelerated coating delamination failure was attributed to the increased delamination driving force under the thermal gradient cyclic loading and the reduced interface adhesion due to the detrimental interface reactions.

Zhu, Dongming↗
NASA NTRS2003

Surface Cracking and Interface Reaction Associated Delamination Failure of Thermal and Environmental Barrier Coatings

In this paper, surface cracking and interface reactions of a BSAS coating and a multi-layer ZrO2-8wt%Y2O3 and mullite/BSAS/Si thermal and environmental barrier coating system on SiC/SiC ceramic matrix composites were characterized after long-term combined laser thermal gradient and furnace cyclic tests in a water vapor containing environment. The surface cracking was analyzed based on the coating thermal gradient sintering behavior and thermal expansion mismatch stress characteristics under the thermal cyclic conditions. The interface reactions, which were largely enhanced by the coating surface cracking in the water vapor environment, were investigated in detail, and the reaction phases were identified for the coating system after the long-term exposure. The accelerated coating delamination failure was attributed to the increased delamination driving force under the thermal gradient cyclic loading and the reduced interface adhesion due to the detrimental interface reactions.

Zhu, Dong-Ming↗
NASA NTRS2003

Single Event Effects Testing of the Linfinity SG1525A Pulse Width Modulator Controller

Pulse Width Modulator (PWM) Controllers are the heart of switching power supply systems in development today. The PWMs considered here have the same integration advantages as many other controllers but it also includes the interface drivers for the follow-on power Field Effect Transistors (FET). Previous work on these types of devices looked into the required test methodologies [ 11 and the impact of radiation on the soft start and shutdown circuits of typically incorporated in the technology [2]. Taking advantage of this previous work this study was undertaken to determine the single event destructive and transient susceptibility of the Linfinity SG1525A Pulse Width Modulator Controller. The device was monitored for transient interruptions in the output signals and for destructive events induced by exposing it to a heavy ion beam at the Texas A&M University Cyclotron Single Event Effects Test Facility. After exposing these devices to the beam, a new upset mode has been identified that can lead to catastrophic power supply system failure if this event would occur while drive power FETs off the two device outputs. The devices and the test methods used will be described first. This will be followed by a brief description of the data collected to date (not all data can be presented with the length constraints of the summary) and a summary of the key results.

Howard, J. W., Jr.↗
NASA NTRS2014

An Integrated Reliability and Physics-Based Risk Modeling Approach for Assessing Human Spaceflight Systems

This paper presents an integrated reliability and physics-based risk modeling approach for assessing human spaceflight systems. The approach is demonstrated using an example, end-to-end risk assessment of a generic-crewed space transportation system during a reference mission to the International Space Station. The behavior of the system is modeled using analysis techniques from multiple disciplines in order to properly capture the dynamic time- and state- dependent consequences of failures encountered in different mission phases. We discuss how to combine traditional reliability analyses with Monte Carlo simulation methods and physics-based engineering models to produce loss-of- mission and loss-of-crew risk estimates supporting risk-based decision-making and requirement verification. This approach facilitates risk-informed design by providing more realistic representation of system failures and interactions; identifying key risk-driving sensitivities, dependencies, and assumptions; and tracking multiple figures of merit within a single, responsive assessment framework that can readily incorporate evolving design information throughout system development.

Risk assessment↗
NASA NTRSDate not supplied

Assessing Impact of Joint Actuator Failure on Lunar Rover Mobility

Wheeled rovers are critical to exploration of the lunar surface, and loss of mobility actuators can have mission-ending consequences. NASA’s upcoming Volatiles Investigating Polar Exploration Rover (VIPER) has a four-wheeled active suspension, which gives it flexible extreme terrain mobility at the cost of an increased number of mobility actuators and potentially a higher mobility cost due to actuator loss than might occur on a similar six-wheeled rover. Impact varies greatly by both the affected joint and its failure state, and that in some cases modification of driving strategy may be able to partially mitigate mobility impact.

rover↗
NASA NTRS2024

Extended Investigation into Fault-Tolerant Integrated Motor Drive for a Quadrotor Urban Air Mobility (UAM) Aircraft

Electric propulsor machines and their associated power electronics have been identified in past studies as low-reliability components in emerging Urban Air Mobility (UAM) Vertical Takeoff and Landing (VTOL) vehicles that raise their predicted catastrophic failure rates. This research effort extends previously presented work investigating the use of fault-tolerant (FT) motor drives in quadrotor aircraft as a promising approach to significantly increase their mean-time-to-failure (MTTF). In particular, fault-tolerant modular motor drives (FT-MMDs) are identified as strong candidates for closing the electric propulsor reliability gap. These FT-MMDs divide a machine drive into multiple redundant modules, each consisting of three phase stator windings and power electronics units, enabling continued machine operation after a module failure. Achieving the highest possible isolation between modules (physical, magnetic, thermal, electrical) is critically important in FT-MMDs to prevent the propagation of any failure between modules. Key additional requirements for achieving the highest possible reliability characteristics with FT-MMDs are high repair rates and aggressive suppression of all single-point failures.

quadrotor↗
NASA NTRS1990

Thermal/structural analysis of the shaft-disk region of a fan drive system

In January 1989, a mishap occurred in the National Transonic Facility wind tunnel at NASA-Langley. It is believed that the failure of an insulation retainer holding foam insulation around the exterior of the fan drive shaft resulted in the subsequent damage to other components in the tunnel. The effect was determined of removing the external thermal insulation on the shaft would have on the stresses on the shaft, disk and bolts holding the two together. To accomplish this, a detailed thermal/structural finite element analysis of the shaft-disk interface was performed. The maximum stresses on the three components were determined for several configurations and conditions with and without the external thermal insulation, and then these results were compared to the original analyses to access the effect of removing the external thermal insulation on the proposed future operation of the shaft/disk structures of the fan drive system. Although the stresses were higher without the external insulation, the stresses did meet all stress criteria. In addition, all stresses were within the infinite life regime of the Modified Goodman diagram. Therefore, it was determined that the structural integrity of the shaft-disk region is not compromised if the external insulation is removed.

Gregory, Peyton B.↗
NASA NTRS1990

Analysis of the National Transonic Facility mishap

The nonlinear dynamic finite element code DYnamic Crash Analysis of STructures (DYCAST) was used to model an accident scenario that occurred at the National Transonic Facility (NTF) wind tunnel. A post mishap investigation revealed that a total of five upstream bulkhead fairing plates were missing, three in one location and two in another. These plates were drawn into the wind tunnel's composite fan blades causing extensive damage. A DYCAST model was developed to determine if one-half of a small thermal shield flange clamp, weighing approximately 2.7 lbs., could have spun off the NTF drive shaft and impacted the bulkhead fairing plates with sufficient energy to cause failure of the attachment bolts. The clamp was presumed to have spun off at a tangent from the NTF drive shaft at a velocity of 1624 in/sec (drive shaft rotating at 580 rpm). The DYCAST analytical model predicts that impact of the 2.7 lbs projectile failed all of the bolts in two of the fairing plates allowing them to escape from the bulkhead ring with a low velocity of a few in/sec.

Fasanella, Edwin L.↗
NASA NTRS1979

Diagnostics of wear in aeronautical systems

Maintenance costs associated with the transmissions and drive train greatly increase the maintenance burden and failure risk. Detection measurements fall under two general categories of vibration and particle detectors. The latter are more amenable to tracking wear. Wear debris analysis can supply a great deal of information such as: particle concentration, rate of change in concentration, composition, particle size and shape, principal metals, etc. It is not economically feasible to monitor all variables. At least one role of the lubrication and wear specialist is to provide guidance in selecting the most appropriate variables to monitor.

Wedeven, L. D.↗
NASA NTRS1981

RAMP - A fault tolerant distributed microcomputer structure for aircraft navigation and control

Design methodologies for realizing future high authority autoflight control systems are being investigated, taking into account also the study of distributed microcomputer architectures. Attention is given to the redundant asynchronous microprocessor (RAMP) structure. RAMP comprises a connected network of microcomputers which has as input command and sensor information, and which generates servo information to drive actuators, and thrust linkages. Tolerance to hardware failures is achieved by static redundancy. Results of a failed microcomputer are simply rejected. This is done in lieu of dynamic redundancy wherein the distributed computer system performs real time fault detection and reconfiguration of the system. Attention is given to the RAMP network structure and operation, flight control with parallel asynchronous computers, and intermittent fault tolerance.

Dunn, W. R.↗
NASA NTRS2003

Bond Sensitivity to Silicone Contamination

Currently during fabrication of the Space Shuttle booster rocket motors, the use of silicone and silicone-containing products is prohibited in most applications. Many shop aids and other materials containing silicone have the potential, if they make contact with a bond surface, to transfer some of the silicone to the substrates being bonded. Such transfer could result in a reduction of the bond strength or even failure of the subsequent bonds. This concern is driving the need to understand the effect of silicones and the concentration needed to affect a given bond-line strength. Additionally, as silicone detection methods used for materials acceptance improve what may have gone unnoticed earlier is now being detected. Thus, realistic silicone limits for process materials (below which bond performance is satisfactory) are needed rather than having an absolute no silicone permitted policy.

Caldwell, G. A.↗
NASA NTRS2012

Oxidation and the Effects of High Temperature Exposures on Notched Fatigue Life of an Advanced Powder Metallurgy Disk Superalloy

Oxidation and the effects of high temperature exposures on notched fatigue life were considered for a powder metallurgy processed supersolvus heat-treated ME3 disk superalloy. The isothermal static oxidation response at 704 C, 760 C, and 815 C was consistent with other chromia forming nickel-based superalloys: a TiO2-Cr2O3 external oxide formed with a branched Al2O3 internal subscale that extended into a recrystallized - dissolution layer. These surface changes can potentially impact disk durability, making layer growth rates important. Growth of the external scales and dissolution layers followed a cubic rate law, while Al2O3 subscales followed a parabolic rate law. Cr- rich M23C6 carbides at the grain boundaries dissolved to help sustain Cr2O3 growth to depths about 12 times thicker than the scale. The effect of prior exposures was examined through notched low cycle fatigue tests performed to failure in air at 704 C. Prior exposures led to pronounced debits of up to 99 % in fatigue life, where fatigue life decreased inversely with exposure time. Exposures that produced roughly equivalent 1 m thick external scales at the various isotherms showed statistically equivalent fatigue lives, establishing that surface damage drives fatigue debit, not exposure temperature. Fractographic evaluation indicated the failure mode for the pre-exposed specimens involved surface crack initiations that shifted with exposure from predominately single intergranular initiations with transgranular propagation to multi-initiations from the cracked external oxide with intergranular propagation. Weakened grain boundaries at the surface resulting from the M23C6 carbide dissolution are partially responsible for the intergranular cracking. Removing the scale and subscale while leaving a layer where M23C6 carbides were dissolved did not lead to a significant fatigue life improvement, however, also removing the M23C6 carbide dissolution layer led to nearly full recovery of life, with a transgranular initiation typical to that observed in unexposed specimens.

Sudbrack, Chantal K.↗
NASA NTRSDate not supplied

Design Study of a Coupled Inner-Stator Magnetically Geared Motor for Electric Aircraft Applications

Electric aircraft require high performance and high reliability electric motor drivetrains. A geared electric motor drivetrain will outperform a direct drive motor drivetrain in most applications. Traditional mechanical gearing, however, has mechanical contact-based wear and failure modes that result in added maintenance costs and require an oil lubrication system. Magnetically geared motor drives are a potential technology for electric aircraft applications capable of enabling the benefits of a geared drive without the maintenance, reliability, and lubrication system cost of mechanical gears. In this paper, a topology of magnetically geared motor, an inner stator magnetically geared motor, is explored to estimate its achievable performance for electric aircraft applications. Optimization results on the topology show that it can achieve greater than 15 Nm/kg and 96% efficiency at 100 kW of power.

Thomas Tallerico↗
NASA NTRSDate not supplied

Design Study of a Coupled Inner-Stator Magnetically Geared Motor for Electric Aircraft Applications

Abstract- Electric aircraft require high performance and high reliability electric motor drivetrains. A geared electric motor drivetrain will outperform a direct drive motor drivetrain in most applications. Traditional mechanical gearing, however, has mechanical contact-based wear and failure modes that result in added maintenance costs and require an oil lubrication system. Magnetically geared motor drives are a potential technology for electric aircraft applications capable of enabling the benefits of a geared drive without the maintenance, reliability, and lubrication system cost of mechanical gears. In this paper, a topology of magnetically geared motor, an inner-stator magnetically geared motor, is explored to estimate its achievable performance for electric aircraft applications. Optimization results on the topology show that it can achieve greater than 15 Nm/kg specific torque and 96% efficiency at 100 kW of power.

Thomas Tallerico↗