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NASA NTRS1975

Optimization of structures undergoing harmonic or stochastic excitation

The optimal design was investigated of simple structures subjected to dynamic loads, with constraints on the structures' responses. Optimal designs were examined for one dimensional structures excited by harmonically oscillating loads, similar structures excited by white noise, and a wing in the presence of continuous atmospheric turbulence. The first has constraints on the maximum allowable stress while the last two place bounds on the probability of failure of the structure. Approximations were made to replace the time parameter with a frequency parameter. For the first problem, this involved the steady state response, and in the remaining cases, power spectral techniques were employed to find the root mean square values of the responses. Optimal solutions were found by using computer algorithms which combined finite elements methods with optimization techniques based on mathematical programming. It was found that the inertial loads for these dynamic problems result in optimal structures that are radically different from those obtained for structures loaded statically by forces of comparable magnitude.

Johnson, E. H.↗

NASA NTRS1979

Mathematical model for preventive maintenance scheduling

A model is formulated to describe the effect of the time interval chosen for preventive maintenance upon the frequency of failure and frequency of total maintenance. Trade-offs between these two frequencies are determined by computation of an optimal interval in the case where the failure distribution is known. For unknown distributions, an adaptive statistical technique is developed that converges to an optimal preventive maintenance interval. A numerical illustration is given.

Lorden, G.↗

NASA NTRS1980

Proposed method for determining the thickness of glass in solar collector panels

An analytical method was developed for determining the minimum thickness for simply supported, rectangular glass plates subjected to uniform normal pressure environmental loads such as wind, earthquake, snow, and deadweight. The method consists of comparing an analytical prediction of the stress in the glass panel to a glass breakage stress determined from fracture mechanics considerations. Based on extensive analysis using the nonlinear finite element structural analysis program ARGUS, design curves for the structural analysis of simply supported rectangular plates were developed. These curves yield the center deflection, center stress and corner stress as a function of a dimensionless parameter describing the load intensity. A method of estimating the glass breakage stress as a function of a specified failure rate, degree of glass temper, design life, load duration time, and panel size is also presented.

Moore, D. M.↗

NASA NTRS1981

A comparison of screening techniques for ceramic capacitors

The techniques involved are ultrasonic scanning, neutron radiography, scanning laser acoustic microscopy, and voltage conditioning. The test capacitor, for this first phase, is a 0.47 uF, 50V capacitor style CKR06. Eighteen of 768 devices failed in voltage conditioning with elapsed times from 15 minutes to 1239 hours. Eleven of the failures were detected by ultrasonic scanning. Four failures were found by neutron radiography. Fourteen failures showed up in the acoustic microscopy test. Three failures in voltage conditioning were not detected by any of the techniques. Failures were confirmed by destructive physical analysis. There is no direct relationship between the size of the defect and electrical failure.

Kiernan, G. F.↗

NASA NTRS1984

Modeling material failure with a vectorized routine

The computational aspects of modelling material failure in structural wood members are presented with particular reference to vector processing aspects. Wood members are considered to be highly orthotropic, inhomogeneous, and discontinuous due to the complex microstructure of wood material and the presence of natural growth characteristics such as knots, cracks and cross grain in wood members. The simulation of strength behavior of wood members is accomplished through the use of a special purpose finite element/fracture mechanics routine, program STARW (Strength Analysis Routine for Wood). Program STARW employs quadratic finite elements combined with singular crack tip elements in a finite element mesh. Vector processing techniques are employed in mesh generation, stiffness matrix formation, simultaneous equation solution, and material failure calculations. The paper addresses these techniques along with the time and effort requirements needed to convert existing finite element code to a vectorized version. Comparisons in execution time between vectorized and nonvectorized routines are provided.

Cramer, S. M.↗

NASA NTRS1985

Reliability and engineering of thin-film photovoltaic modules

Objectives were to: examine thin-film cell attributes that influence module performance and reliability, explore the lessons and applicability of crystalline-silicon module technology to thin-film modules, review the current status of thin-film module technologies, and identify problem areas and needed research. A major need is to separate the effects and resons for reversible degradatin from nonreversible degradation. Amorphous-silicon (a-Si) reliability investigations are focusing on exploratory research investigations, accelerated Arrhenius-type testing of a-Si cells, real-time outdoor exposure testing of a-Si cells, cell failure analysis, and failure mechanism research. Studies included the reduction in strength of glass by high temperature depositions on glass and laser scribing, encapsulation materials development needs, and the testing of modules. The new materials and processes in thin-film modules will require a delinquent reliability effort, including: establishment of mechanism-specific reliability goals; quantification of mechanism parameter dependencies; prediction of expected long-term degradation; identification of cost-effective solutions; and testing and failure analysis of trial solutions.

Royal, E. L.↗

NASA NTRS1985

Photothermal degradation studies

Key reaction intermediates of photooxidation identified and characterized by laser flash Electron Spin Resonance (ESR) spectroscopy were discussed. Effects of temperature and ultraviolet intensity were studied in order to develop meaningful accelerated testing procedures for encapsulant evaluation. In a program to study the failure of Tedlar/ethylene vinyl acetate (EVA)/stainless steel modules, failure modes similar to those observed outdoors in real-time conditions were simulated in accelerated testing. An experimental technique was developed to quantitatively assess the extent of degradation.

Liang, R. H.↗

NASA NTRS1989

Product assurance technology for procuring reliable, radiation-hard, custom LSI/VLSI electronics

Advanced measurement methods using microelectronic test chips are described. These chips are intended to be used in acquiring the data needed to qualify Application Specific Integrated Circuits (ASIC's) for space use. Efforts were focused on developing the technology for obtaining custom IC's from CMOS/bulk silicon foundries. A series of test chips were developed: a parametric test strip, a fault chip, a set of reliability chips, and the CRRES (Combined Release and Radiation Effects Satellite) chip, a test circuit for monitoring space radiation effects. The technical accomplishments of the effort include: (1) development of a fault chip that contains a set of test structures used to evaluate the density of various process-induced defects; (2) development of new test structures and testing techniques for measuring gate-oxide capacitance, gate-overlap capacitance, and propagation delay; (3) development of a set of reliability chips that are used to evaluate failure mechanisms in CMOS/bulk: interconnect and contact electromigration and time-dependent dielectric breakdown; (4) development of MOSFET parameter extraction procedures for evaluating subthreshold characteristics; (5) evaluation of test chips and test strips on the second CRRES wafer run; (6) two dedicated fabrication runs for the CRRES chip flight parts; and (7) publication of two papers: one on the split-cross bridge resistor and another on asymmetrical SRAM (static random access memory) cells for single-event upset analysis.

Buehler, M. G.↗

NASA NTRS1993

Predicting Failure Behaviors Of Thermoset Polymers

Useful predictions made from measurements on test-tube quantities. Mathematical model for viscoelastic failure behavior of epoxy or other thermoset polymer reduces considerably time and expense necessary to evaluate new polymer. One quickly obtains first-order estimates of viscoelastic properties, and decides more easily whether material rejected or good candidate for more thorough evaluation. Only properties required by model are equilibrium pressure vs. volume vs. temperature (PVT) response and linear viscoelastic shear and bulk moduli.

Bowles, Kenneth J.↗

NASA NTRS1992

Using software metrics and software reliability models to attain acceptable quality software for flight and ground support software for avionic systems

This paper is concerned with methods of measuring and developing quality software. Reliable flight and ground support software is a highly important factor in the successful operation of the space shuttle program. Reliability is probably the most important of the characteristics inherent in the concept of 'software quality'. It is the probability of failure free operation of a computer program for a specified time and environment.

Lawrence, Stella↗

NASA NTRS1995

In-flight demonstration of a Real-Time Flush Airdata Sensing (RT-FADS) system

A prototype real-time flush airdata sensing (RT-FADS) system has been developed and flight tested at the NASA Dryden Flight Research Center. This system uses a matrix of pressure orifices on the vehicle nose to estimate airdata parameters in real time using nonlinear regression. The algorithm is robust to sensor failures and noise in the measured pressures. The RT-FADS system has been calibrated using inertial trajectory measurements that were bootstrapped for atmospheric conditions using meteorological data. Mach numbers as high as 1.6 and angles of attack greater than 45 deg have been tested. The system performance has been evaluated by comparing the RT-FADS to the ship system airdata computer measurements to give a quantitative evaluation relative to an accepted measurement standard. Nominal agreements of approximately 0.003 in Mach number and 0.20 deg in angle of attack and angle of sideslip have been achieved.

Whitmore, Stephen A.↗

NASA NTRS1994

NASA/CARES dual-use ceramic technology spinoff applications

NASA has developed software that enables American industry to establish the reliability and life of ceramic structures in a wide variety of 21st Century applications. Designing ceramic components to survive at higher temperatures than the capability of most metals and in severe loading environments involves the disciplines of statistics and fracture mechanics. Successful application of advanced ceramics material properties and the use of a probabilistic brittle material design methodology. The NASA program, known as CARES (Ceramics Analysis and Reliability Evaluation of Structures), is a comprehensive general purpose design tool that predicts the probability of failure of a ceramic component as a function of its time in service. The latest version of this software, CARESALIFE, is coupled to several commercially available finite element analysis programs (ANSYS, MSC/NASTRAN, ABAQUS, COSMOS/N4, MARC), resulting in an advanced integrated design tool which is adapted to the computing environment of the user. The NASA-developed CARES software has been successfully used by industrial, government, and academic organizations to design and optimize ceramic components for many demanding applications. Industrial sectors impacted by this program include aerospace, automotive, electronic, medical, and energy applications. Dual-use applications include engine components, graphite and ceramic high temperature valves, TV picture tubes, ceramic bearings, electronic chips, glass building panels, infrared windows, radiant heater tubes, heat exchangers, and artificial hips, knee caps, and teeth.

Powers, Lynn M.↗

NASA NTRS1997

Enhanced CARES Software Enables Improved Ceramic Life Prediction

The NASA Lewis Research Center has developed award-winning software that enables American industry to establish the reliability and life of brittle material (e.g., ceramic, intermetallic, graphite) structures in a wide variety of 21st century applications. The CARES (Ceramics Analysis and Reliability Evaluation of Structures) series of software is successfully used by numerous engineers in industrial, academic, and government organizations as an essential element of the structural design and material selection processes. The latest version of this software, CARES/Life, provides a general- purpose design tool that predicts the probability of failure of a ceramic component as a function of its time in service. CARES/Life was recently enhanced by adding new modules designed to improve functionality and user-friendliness. In addition, a beta version of the newly-developed CARES/Creep program (for determining the creep life of monolithic ceramic components) has just been released to selected organizations.

Janosik, Lesley A.↗

NASA NTRS1999

Nondestructive Detection of Cracks in Ceramics Using Vicinal Illumination

Cracks and other defects in ceramic materials can be difficult or impossible to examine and photograph due to the extreme lack of contrast. A method for inspecting translucent ceramics using scattered light, also known as vicinal illumination, will be described. This method has been known in the ceramics industry for quite some time, but is not well known in the testing and failure analysis community. Electronics applications include substrates, packages, multilayer capacitors, and thin film resistors. Ceramic materials are used in electronic applications as microcircuit packages and substrates which carry signals and power between microcircuits. Fine cracks in ceramic materials can result in mechanical failures, electrical failures, and loss of hermeticity. Often, fine cracks are difficult or impossible to detect using standard nondestructive inspection techniques such as visual inspection, ultrasonic inspection, or vapor crack detection. Dye penetrant inspection is usually effective, but contaminates the part, which is unacceptable for space flight hardware. One effective nondestructive inspection method of detecting cracks involves examining the way in which light scatters through the ceramic material when viewed with a standard bright field reflected light microscope. This method, termed vicinal illumination, has been used for detecting cracks during failure analyses of several part types, and screening of space flight hardware. The technique has proven effective on several different types of ceramic materials as well. A related method for use with dark field equipment has also been used to successfully locate otherwise invisible cracks.

Hull, Scott M.↗

NASA NTRS2001

Hall Thruster Plume Measurements On-Board the Russian Express Satellites

The operation of North-South and East-West station-keeping Hall thruster propulsion systems on-board two Russian Express-A geosynchronous communication satellites were investigated through a collaborative effort with the manufacturer of the spacecraft. Over 435 firings of 16 different thrusters with a cumulative run time of over 550 hr were reported with no thruster failures. Momentum transfer due to plume impingement was evaluated based on reductions in the effective thrust of the SPT-100 thrusters and induced disturbance torques determined based on attitude control system data and range data. Hall thruster plasma plume effects on the transmission of C-band and Ku-band communication signals were shown to be negligible. On-orbit ion current density measurements were made and subsequently compared to predictions and ground test data. Ion energy, total pressure, and electric field strength measurements were also measured on-orbit. The effect of Hall thruster operation on solar array performance over several months was investigated. A subset of these data is presented.

Manzella, David↗

NASA NTRS2002

Plant Growth During the Greenhouse II Experiment on the MIR Orbital Station

We carried out three experiments with Super Dwarf wheat in the Bulgarian/Russian growth chamber Svet (0.1 sq m growing area) on the Space Station Mir. This paper mostly describes the first of these NASA-supported trials, began on Aug. 13, 1995. Plants were sampled five times and harvested on Nov. 9 after 90 days. Equipment failures led to low irradiance (three, then four of six lamp sets failed), instances of high temperatures (ca. 37 C), and sometimes excessive-substrate moisture. Although plants grew for the 90 days, no wheat heads were produced. Considering the low light levels, plants were surprisingly green, but of course biomass production was low. Plants were highly disoriented (low light, mirror walls?). Fixed and dried samples and the root module were returned on the US Shuttle Atlantis on Nov. 20, 1995. Samples of the substrate, a nutrient-charged zeolite called Balkanine, were taken from the root module, carefully examined for roots, weighed, dried, and reweighed. The Svet control unit and the light bank were shipped to Moscow. An experiment validation test (EVT) of plant growth and experiment procedures, carried out in Moscow, was highly successful. Equipment built in Utah to measure CO2, H2O vapor, irradiance, air and leaf (IR) temperature, O2, pressure, and substrate moisture worked well in the EVT and in space. After this manuscript was first prepared, plants were grown in Mir with a new light bank and controller for 123 days in late 1996 and 39 days in 1996/1997. Plants grew exceptionally well with higher biomass production than in any previous space experiment, but the ca. 280 wheat heads that were produced in 1996 contained no seeds. Ethylene in the cabin atmosphere was responsible.

Salisbury, F. B.↗

NASA NTRS2002

Reliability Analysis of Brittle Material Structures - Including MEMS(?) - With the CARES/Life Program

Brittle materials are being used, or considered, for a wide variety of high tech applications that operate in harsh environments, including static and rotating turbine parts. thermal protection systems, dental prosthetics, fuel cells, oxygen transport membranes, radomes, and MEMS. Designing components to sustain repeated load without fracturing while using the minimum amount of material requires the use of a probabilistic design methodology. The CARES/Life code provides a general-purpose analysis tool that predicts the probability of failure of a ceramic component as a function of its time in service. For this presentation an interview of the CARES/Life program will be provided. Emphasis will be placed on describing the latest enhancements to the code for reliability analysis with time varying loads and temperatures (fully transient reliability analysis). Also, early efforts in investigating the validity of using Weibull statistics, the basis of the CARES/Life program, to characterize the strength of MEMS structures will be described as as well as the version of CARES/Life for MEMS (CARES/MEMS) being prepared which incorporates single crystal and edge flaw reliability analysis capability. It is hoped this talk will open a dialog for potential collaboration in the area of MEMS testing and life prediction.

Nemeth, Noel N.↗

NASA NTRS2003

A New Objective Technique for Verifying Mesoscale Numerical Weather Prediction Models

This report presents a new objective technique to verify predictions of the sea-breeze phenomenon over east-central Florida by the Regional Atmospheric Modeling System (RAMS) mesoscale numerical weather prediction (NWP) model. The Contour Error Map (CEM) technique identifies sea-breeze transition times in objectively-analyzed grids of observed and forecast wind, verifies the forecast sea-breeze transition times against the observed times, and computes the mean post-sea breeze wind direction and speed to compare the observed and forecast winds behind the sea-breeze front. The CEM technique is superior to traditional objective verification techniques and previously-used subjective verification methodologies because: It is automated, requiring little manual intervention, It accounts for both spatial and temporal scales and variations, It accurately identifies and verifies the sea-breeze transition times, and It provides verification contour maps and simple statistical parameters for easy interpretation. The CEM uses a parallel lowpass boxcar filter and a high-order bandpass filter to identify the sea-breeze transition times in the observed and model grid points. Once the transition times are identified, CEM fits a Gaussian histogram function to the actual histogram of transition time differences between the model and observations. The fitted parameters of the Gaussian function subsequently explain the timing bias and variance of the timing differences across the valid comparison domain. Once the transition times are all identified at each grid point, the CEM computes the mean wind direction and speed during the remainder of the day for all times and grid points after the sea-breeze transition time. The CEM technique performed quite well when compared to independent meteorological assessments of the sea-breeze transition times and results from a previously published subjective evaluation. The algorithm correctly identified a forecast or observed sea-breeze occurrence or absence 93% of the time during the two- month evaluation period from July and August 2000. Nearly all failures in CEM were the result of complex precipitation features (observed or forecast) that contaminated the wind field, resulting in a false identification of a sea-breeze transition. A qualitative comparison between the CEM timing errors and the subjectively determined observed and forecast transition times indicate that the algorithm performed very well overall. Most discrepancies between the CEM results and the subjective analysis were again caused by observed or forecast areas of precipitation that led to complex wind patterns. The CEM also failed on a day when the observed sea- breeze transition affected only a very small portion of the verification domain. Based on the results of CEM, the RAMS tended to predict the onset and movement of the sea-breeze transition too early and/or quickly. The domain-wide timing biases provided by CEM indicated an early bias on 30 out of 37 days when both an observed and forecast sea breeze occurred over the same portions of the analysis domain. These results are consistent with previous subjective verifications of the RAMS sea breeze predictions. A comparison of the mean post-sea breeze winds indicate that RAMS has a positive wind-speed bias for .all days, which is also consistent with the early bias in the sea-breeze transition time since the higher wind speeds resulted in a faster inland penetration of the sea breeze compared to reality.

Case, Jonathan L.↗