SEARCH · Engineering Papers

Results for “Failure Rate”

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 721 records · Page 40

All sources NASA NTRS DOE OSTI

NASA NTRS1982

Design of analytical failure detection using secondary observers

The problem of designing analytical failure-detection systems (FDS) for sensors and actuators, using observers, is addressed. The use of observers in FDS is related to the examination of the n-dimensional observer error vector which carries the necessary information on possible failures. The problem is that in practical systems, in which only some of the components of the state vector are measured, one has access only to the m-dimensional observer-output error vector, with m or = to n. In order to cope with these cases, a secondary observer is synthesized to reconstruct the entire observer-error vector from the observer output error vector. This approach leads toward the design of highly sensitive and reliable FDS, with the possibility of obtaining a unique fingerprint for every possible failure. In order to keep the observer's (or Kalman filter) false-alarm rate under a certain specified value, it is necessary to have an acceptable matching between the observer (or Kalman filter) models and the system parameters. A previously developed adaptive observer algorithm is used to maintain the desired system-observer model matching, despite initial mismatching or system parameter variations. Conditions for convergence for the adaptive process are obtained, leading to a simple adaptive law (algorithm) with the possibility of an a priori choice of fixed adaptive gains. Simulation results show good tracking performance with small observer output errors, while accurate and fast parameter identification, in both deterministic and stochastic cases, is obtained.

Sisar, M.↗

NASA NTRS1994

Refurbishment of a 39 foot thermal vacuum chamber

The 39' thermal vacuum chamber at Space Systems/Loral has been used to test numerous spacecraft including those of the GOES, Intelsat, Insat, Superbird, N-Star, NATO and other programs. Ten years ago, the aluminum LN2 shroud experienced serious fatigue failures in the field welded jumper tubing, effectively shutting down the chamber for vacuum testing. The problem was repaired at the time, but new failures began to reappear a few months ago and are now occurring at a rate that suggests that the shroud may again become inoperable. Consequently, Space Systems/Loral is spending in excess of $6 million to replace the shroud and the existing LN2 equipment with a new, state of the art cryogenic system. In May, 1994, a contract was awarded to remove the existing shroud and LN2 pumping system and replace it with a gravity fed shroud and distribution system. Included in the contract are eight skid mounted gaseous nitrogen pumping systems capable of controlling shroud zone temperatures between +150 C and -180 C. The project is scheduled to be completed in April 1995.

Edwards, Arthur A.↗

NASA NTRS1995

Correlations of Different Surface Tests: Tire Behavior Math Model for the High Speed Civil Transport (HSCT) and Michelin Tire Properties Tests for Boeing 777

In the surfaces correlation study, several different volumetric and drainage measurement techniques for classifying surface texture were evaluated as part of a major study to develop and improve methods for predicting tire friction performance on all types of pavement. The objective of the evaluation was to seek relationships between the different techniques, and to relate those results to surface frictional characteristics. We needed to know how each of the tests could be related to each other. Another of my assigned projects was to make a tire behavior math model for the High Speed Civil Transport (HSCT) using the same methods used for the space shuttle a few years ago. A provided third order equation with two variables was used. This model will also be used for studies with the Boeing 777. Only a few changes will be necessary to adapt it for this other aircraft, which is the newest offered by Boeing. In my final project I was involved with testing the tires for this new aircraft using the Aircraft Landing Dynamics Facility (ALDF) test carriage within the carriage house at LaRC. A 50 inch diameter radial tire manufactured by Michelin Aircraft Tire Corporation had to be tested to double overload of 114,000 pounds. The rated load of each tire is 57,000 pounds, but Boeing required tests assuming failure of a companion tire that could have cost Michelin approximately $12 million to build a facility to provide the required test capability. Here at LaRC, only minimum modifications to the facility were required to perform this specific test.

Roman, Ivan↗

NASA NTRS1999

Oxygen Diffusion and Reaction Kinetics in Continuous Fiber Ceramic Matrix Composites

Previous stressed oxidation tests of C/SiC composites at elevated temperatures (350 C to 1500 C) and sustained stresses (69 MPa and 172 MPa) have led to the development of a finite difference cracked matrix model. The times to failure in the samples suggest oxidation occurred in two kinetic regimes defined by the rate controlling mechanisms (i.e. diffusion controlled and reaction controlled kinetics). Microstructural analysis revealed preferential oxidation along as-fabricated, matrix microcracks and also suggested two regimes of oxidation kinetics dependent on the oxidation temperature. Based on experimental results, observation, and theory, a finite difference model was developed. The model simulates the diffusion of oxygen into a matrix crack bridged by carbon fibers. The model facilitates the study of the relative importance of temperature, the reaction rate constant, and the diffusion coefficient on the overall oxidation kinetics.

Halbig, Michael C.↗

NASA NTRS2003

Oxidation of Carbon Fibers in Water Vapor Studied

T-300 carbon fibers (BP Amoco Chemicals, Greenville, SC) are a common reinforcement for silicon carbide composite materials, and carbon-fiber-reinforced silicon carbide composites (C/SiC) are proposed for use in space propulsion applications. It has been shown that the time to failure for C/SiC in stressed oxidation tests is directly correlated with the fiber oxidation rate (ref. 1). To date, most of the testing of these fibers and composites has been conducted in oxygen or air environments; however, many components for space propulsion, such as turbopumps, combustors, and thrusters, are expected to operate in hydrogen and water vapor (H2/H2O) environments with very low oxygen contents. The oxidation rate of carbon fibers in conditions representative of space propulsion environments is, therefore, critical for predicting component lifetimes for real applications. This report describes experimental results that demonstrate that, under some conditions, lower oxidation rates of carbon fibers are observed in water vapor and H2/H2O environments than are found in oxygen or air. At the NASA Glenn Research Center, the weight loss of the fibers was studied as a function of water pressure, temperature, and gas velocity. The rate of carbon fiber oxidation was determined, and the reaction mechanism was identified.

Opila, Elizabeth J.↗

NASA NTRS1996

Risk as a Resource - A New Paradigm

NASA must change dramatically because of the current United States federal budget climate. The American people and their elected officials have mandated a smaller, more efficient and effective government. For the past decade, NASA's budget had grown at or slightly above the rate of inflation. In that era, taking all steps to avoid the risk of failure was the rule. Spacecraft development was characterized by extensive analyses, numerous reviews, and multiple conservative tests. This methodology was consistent with the long available schedules for developing hardware and software for very large, billion dollar spacecraft. Those days are over. The time when every identifiable step was taken to avoid risk is being replaced by a new paradigm which manages risk in much the same way as other resources (schedule, performance, or dollars) are managed. While success is paramount to survival, it can no longer be bought with a large growing NASA budget.

Risk Resource↗

NASA NTRS2008

Status of the NEXT Ion Thruster Long-Duration Test After 10,100 hr and 207 kg Demonstrated

The NASA s Evolutionary Xenon Thruster (NEXT) program is developing the next-generation ion propulsion system with significant enhancements beyond the state-of-the-art in ion propulsion to provide future NASA science missions with enhanced mission capabilities at a low total development cost. As part of a comprehensive thruster service life assessment utilizing both testing and analyses, a Long-Duration Test (LDT) was initiated to validate and qualify the NEXT propellant throughput capability to a qualification-level of 450 kg, 1.5 times the mission-derived throughput requirement of 300 kg. This wear test is being conducted with a modified, flight-representative NEXT engineering model ion thruster, designated EM3. As of June 21, 2007, the thruster has accumulated 10,100 hr of operation at the thruster full-input-power of 6.9 kW with 3.52 A beam current and 1800 V beam power supply voltage. The thruster has processed 207 kg of xenon and demonstrated a total impulse of 8.5 106 N-s; the highest total impulse ever demonstrated by an ion thruster in the history of space propulsion. Thruster performance tests are conducted periodically over the entire NEXT throttle table with input power ranging 0.5 to 6.9 kW. Overall ion thruster performance parameters including thrust, input power, specific impulse, and thruster efficiency have been nominal with little variation to date. Lifetime-limiting component erosion rates have been consistent with the NEXT service life assessment, which predicts the earliest failure sometime after 750 kg of xenon propellant throughput; well beyond the mission-derived lifetime requirement. The NEXT wear test data confirm that the erosion of the discharge keeper orifice, enlarging of nominal-current-density accelerator grid aperture cusps, and the decrease in cold grid-gap observed during the NSTAR Extended Life Test have been mitigated. This paper presents the status of the NEXT LDT to date.

Herman, Daniel A.↗

NASA NTRS2009

NEXT Long-Duration Test After 11,570 h and 237 kg of Xenon Processed

The NASA s Evolutionary Xenon Thruster (NEXT) program is developing the next-generation ion propulsion system with significant enhancements beyond the state-of-the-art in ion propulsion to provide future NASA science missions with enhanced mission capabilities at a low total development cost. As part of a comprehensive thruster service life assessment utilizing both testing and analyses, a Long-Duration Test (LDT) was initiated to validate and qualify the NEXT propellant throughput capability to a qualification-level of 450 kg, 1.5 times the mission-derived throughput requirement of 300 kg. This wear test is being conducted with a modified, flight-representative NEXT engineering model ion thruster, designated EM3. As of September 1, 2007, the thruster has accumulated 11,570 h of operation primarily at the thruster full-input-power of 6.9 kW with 3.52 A beam current and 1800 V beam power supply voltage. The thruster has processed 237 kg of xenon surpassing the NSTAR propellant throughput demonstrated during the extended life testing of the Deep Space 1 (DS1) flight spare. The NEXT LDT has demonstrated a total impulse of 9.78 10(exp 6) N(dot)s; the highest total impulse ever demonstrated by an ion thruster. Thruster performance tests are conducted periodically over the entire NEXT throttle table with input power ranging 0.5 to 6.9 kW. Thruster performance parameters including thrust, input power, specific impulse, and thruster efficiency have been nominal with little variation to date. Lifetime-limiting component erosion rates have been consistent with the NEXT service life assessment, which predicts the earliest failure sometime after 750 kg of xenon propellant throughput; well beyond the mission-derived lifetime requirement. The NEXT wear test data confirm that the erosion of the discharge keeper orifice, enlarging of nominal-current-density accelerator grid aperture cusps at full-power, and the decrease in cold grid-gap observed during NSTAR wear testing have been mitigated in the NEXT design. NEXT grid-gap data indicate a hot grid-gap at full-power that is 60 percent of the nominal cold grid-gap. This paper presents the status of the NEXT LDT to date with emphasis on comparison to the NSTAR extended life test results.

Soulas, George C.↗

NASA NTRS2010

Estimating the Reliability of a Soyuz Spacecraft Mission

Once the US Space Shuttle retires in 2010, the Russian Soyuz Launcher and Soyuz Spacecraft will comprise the only means for crew transportation to and from the International Space Station (ISS). The U.S. Government and NASA have contracted for crew transportation services to the ISS with Russia. The resulting implications for the US space program including issues such as astronaut safety must be carefully considered. Are the astronauts and cosmonauts safer on the Soyuz than the Space Shuttle system? Is the Soyuz launch system more robust than the Space Shuttle? Is it safer to continue to fly the 30 year old Shuttle fleet for crew transportation and cargo resupply than the Soyuz? Should we extend the life of the Shuttle Program? How does the development of the Orion/Ares crew transportation system affect these decisions? The Soyuz launcher has been in operation for over 40 years. There have been only two loss of life incidents and two loss of mission incidents. Given that the most recent incident took place in 1983, how do we determine current reliability of the system? Do failures of unmanned Soyuz rockets impact the reliability of the currently operational man-rated launcher? Does the Soyuz exhibit characteristics that demonstrate reliability growth and how would that be reflected in future estimates of success? NASA s next manned rocket and spacecraft development project is currently underway. Though the projects ultimate goal is to return to the Moon and then to Mars, the launch vehicle and spacecraft s first mission will be for crew transportation to and from the ISS. The reliability targets are currently several times higher than the Shuttle and possibly even the Soyuz. Can these targets be compared to the reliability of the Soyuz to determine whether they are realistic and achievable? To help answer these questions this paper will explore how to estimate the reliability of the Soyuz Launcher/Spacecraft system, compare it to the Space Shuttle, and its potential impacts for the future of manned spaceflight. Specifically it will look at estimating the Loss of Mission (LOM) probability using historical data, reliability growth, and Probabilistic Risk Assessment techniques

Lutomski, Michael G.↗

NASA NTRS2011

Estimating the Loss of Crew and Loss of Mission for Crew Spacecraft

Once the US Space Shuttle retires in 2011, the Russian Soyuz Launcher and Soyuz Spacecraft will comprise the only means for crew transportation to and from the International Space Station (ISS). The U.S. Government and NASA have contracted for crew transportation services to the ISS with Russia. The resulting implications for the US space program including issues such as astronaut safety must be carefully considered. Are the astronauts and cosmonauts safer on the Soyuz than the Space Shuttle system? Is the Soyuz launch system more robust than the Space Shuttle? The Soyuz launcher has been in operation for over 40 years. There have been only two loss of life incidents and two loss of mission incidents. Given that the most recent incident took place in 1983, how do we determine current reliability of the system? Do failures of unmanned Soyuz rockets impact the reliability of the currently operational man-rated launcher? Does the Soyuz exhibit characteristics that demonstrate reliability growth and how would that be reflected in future estimates of success? NASA s next manned rocket and spacecraft development project will have to meet the Agency Threshold requirements set forth by NASA. The reliability targets are currently several times higher than the Shuttle and possibly even the Soyuz. Can these targets be compared to the reliability of the Soyuz to determine whether they are realistic and achievable? To help answer these questions this paper will explore how to estimate the reliability of the Soyuz Launcher/Spacecraft system, compare it to the Space Shuttle, and its potential impacts for the future of manned spaceflight. Specifically it will look at estimating the Loss of Crew (LOC) and Loss of Mission (LOM) probability using historical data, reliability growth, and Probabilistic Risk Assessment techniques used to generate these numbers.

Lutomski, Michael G.↗

NASA NTRS2023

SafeAeroBERT: Towards a Safety-Informed Aerospace-Specific Language Model

As aviation systems continue to operate with high traffic, large amounts of documents containing safety-relevant data continue to be generated via reporting systems such as the ASRS. Advanced natural language processing techniques, specifically pre-trained language models, have shown great success in domain-specific applications; however, the text in aviation safety reports is inundated with jargon and thus not fully utilized by general pre-trained models. In this research, we work towards developing a safety-informed aerospace-specific language model by pre-training a Bidirectional Encoder Representations from Transformer (BERT) model on reports from the Aviation Safety Reporting System and the National Transportation Safety Board. The resulting model, called SafeAeroBERT, is fine-tuned for the specific task of document classification, and can be further tuned for named-entity recognition, relation detection, information retrieval, and summarization. Results from the classification task are compared between SafeAeroBERT, the base BERT, and SciBERT models and show SafeAeroBERT outperforms the general BERT and SciBERT on classifying reports about human factors, aircraft, and procedure. SafeAeroBERT can be used on custom tasks, not limited to document classification, and is intended to aid an intelligent knowledge manager for safety report repositories.

Aviation↗

NASA NTRS1999

Strain Rate Dependent Deformation and Strength Modeling of a Polymer Matrix Composite Utilizing a Micromechanics Approach

Potential gas turbine applications will expose polymer matrix composites to very high strain rate loading conditions, requiring an ability to understand and predict the material behavior under extreme conditions. Specifically, analytical methods designed for these applications must have the capability of properly capturing the strain rate sensitivities and nonlinearities that are present in the material response. The Ramaswamy-Stouffer constitutive equations, originally developed to analyze the viscoplastic deformation of metals, have been modified to simulate the nonlinear deformation response of ductile, crystalline polymers. The constitutive model is characterized and correlated for two representative ductile polymers. Fiberite 977-2 and PEEK, and the computed results correlate well with experimental values. The polymer constitutive equations are implemented in a mechanics of materials based composite micromechanics model to predict the nonlinear, rate dependent deformation response of a composite ply. Uniform stress and uniform strain assumptions are applied to compute the effective stresses of a composite unit cell from the applied strains. The micromechanics equations are successfully verified for two polymer matrix composites. IM7/977-2 and AS4/PEEK. The ultimate strength of a composite ply is predicted with the Hashin failure criteria that were implemented in the composite micromechanics model. The failure stresses of the two composite material systems are accurately predicted for a variety of fiber orientations and strain rates. The composite deformation model is implemented in LS-DYNA, a commercially available transient dynamic explicit finite element code. The matrix constitutive equations are converted into an incremental form, and the model is implemented into LS-DYNA through the use of a user defined material subroutine. The deformation response of a bulk polymer and a polymer matrix composite are predicted by finite element analyses. The results compare reasonably well to experimental values, with some discrepancies. The discrepancies are at least partially caused by the method used to integrate the rate equations in the polymer constitutive model.

Goldberg, Robert K.↗

NASA NTRS1979

Phase change in liquid face seals. II - Isothermal and adiabatic bounds with real fluids

Analytical studies of phase change effects in parallel and tapered liquid face seals are presented. An isothermal and adiabatic model of low Reynolds number flow are considered by numerical integration of the descriptive equations for a real fluid, and its thermodynamic properties are calculated for each step, using a computer program for the steam tables or fluid thermodynamic properties. It was shown that for low leakage rate the isothermal model is more accurate and for high leakage rates the adiabatic model is more accurate; that both models yield the same conclusions regarding stability; and that the transient of collapse is described by the adiabatic model which predicts a catastrophic collapse and then either failure or explosive return to a larger film thickness value. Finally, it is shown that converging seals may become unstable and the mass leakage rate is reduced significantly below the all liquid value when boiling occurs.

Hughes, W. F.↗

NASA NTRS1986

Piloted simulation study of the effects of an automated trim system on flight characteristics of a light twin-engine airplane with one engine inoperative

A simulation study was conducted to investigate the piloting problems associated with failure of an engine on a generic light twin-engine airplane. A primary piloting problem for a light twin-engine airplane after an engine failure is maintaining precise control of the airplane in the presence of large steady control forces. To address this problem, a simulated automatic trim system which drives the trim tabs as an open-loop function of propeller slipstream measurements was developed. The simulated automatic trim system was found to greatly increase the controllability in asymmetric powered flight without having to resort to complex control laws or an irreversible control system. However, the trim-tab control rates needed to produce the dramatic increase in controllability may require special design consideration for automatic trim system failures. Limited measurements obtained in full-scale flight tests confirmed the fundamental validity of the proposed control law.

Stewart, E. C.↗

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 NTRS1978

Helium glow detector experiment, MA-088

Of the two 584 A channels in the helium glow detector, channel #1 appeared to provide data with erratic count rates and undue susceptibility to dayglow and solar contamination possibly because of filter fatigue or failure. Channel #3 data appear normal and of high quality. For this reason only data from this last channel was analyzed and used for detailed comparison with theory. Reduction and fitting techniques are described, as well as applications of the data in the study of nighttime and daytime Hel 584 A emission. A hot model of the interstellar medium is presented. Topics covered in the appendix include: observations of interstellar helium with a gas absorption cell: implications for the structure of the local interstellar medium; EUV dayglow observations with a helium gas absorption cell; and EUV scattering from local interstellar helium at nonzero temperatures: implications for the derivations of interstellar medium parameters.

Bowyer, C. S.↗

NASA NTRS1980

Testing of reciprocating seals for application in a Stirling cycle engine

Six single stage reciprocating seal configurations to the requirements of the Stirling cycle engine were evaluated. The seals tested were: the Boeing Footseal, NASA Chevron polyimide seal, Bell seal, Quad seal, Tetraseal, and Dynabak seal. None of these seal configurations met the leakage goals of .002 cc/sec at helium gas pressure of 1.22 x 10 to the 7th power PA, rod speed of 7.19 m/sec peak, and seal environmental temperature of 408 K for 1500 hours. Most seals failed due to high temperatures. Catastrophic failures were observed for a minimum number of test runs characterized by extremely high leakage rates and large temperature rises. The Bell seal attained 63 hours of run time at significantly lowered test conditions.

Curulla, J. F.↗

NASA NTRS1980

Effect of thermal cycling on ZrO2-Y2O3 thermal barrier coatings

The paper studies the comparative life of plasma-sprayed ZrO2-Y2O3 thermal barrier coatings on NiCrAlY bond coats on Rene 41 in short (4 min) and long (57 min) thermal cycles at 1040 C in a 0.3-Mach flame. Attention is given to determining the effect of short- and long-duration cycles on ZrO2-Y2O3 coatings, the cause of any cycle frequency effects, and methods to improve tolerance to thermal stress. Short cycles greatly reduced the life of the ceramic coating in terms of time at temperatures as compared to longer cycles, the failed coating indicating compressive failure. The experiments and stress calculations show that repeatedly subjecting a ceramic coating to high rates of initial heating has a more destructive influence on the coating than sustained operation at temperature. The effect of such thermal compressive stresses might be minimized through coating deposition and thickness control and by turbine cycle measurement to keep starting heating rates below critical values.

Mcdonald, G.↗