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At least 1,153 records · Page 64

A Comparison of Single-Cycle Versus Multiple-Cycle Proof Testing Strategies

Single-cycle and multiple-cycle proof testing (SCPT and MCPT) strategies for reusable aerospace propulsion system components are critically evaluated and compared from a rigorous elastic-plastic fracture mechanics perspective. Earlier MCPT studies are briefly reviewed. New J-integral estimation methods for semi-elliptical surface cracks and cracks at notches are derived and validated. Engineering methods are developed to characterize crack growth rates during elastic-plastic fatigue crack growth (FCG) and the tear-fatigue interaction near instability. Surface crack growth experiments are conducted with Inconel 718 to characterize tearing resistance, FCG under small-scale yielding and elastic-plastic conditions, and crack growth during simulated MCPT. Fractography and acoustic emission studies provide additional insight. The relative merits of SCPT and MCPT are directly compared using a probabilistic analysis linked with an elastic-plastic crack growth computer code. The conditional probability of failure in service is computed for a population of components that have survived a previous proof test, based on an assumed distribution of initial crack depths. Parameter studies investigate the influence of proof factor, tearing resistance, crack shape, initial crack depth distribution, and notches on the MCPT vs. SCPT comparison. The parameter studies provide a rational basis to formulate conclusions about the relative advantages and disadvantages of SCPT and MCPT. Practical engineering guidelines are proposed to help select the optimum proof test protocol in a given application.

McClung, R. C.↗

A Comparison of Single-Cycle Versus Multiple-Cycle Proof Testing Strategies

Single-cycle and multiple-cycle proof testing (SCPT and MCPT) strategies for reusable aerospace propulsion system components are critically evaluated and compared from a rigorous elastic-plastic fracture mechanics perspective. Earlier MCPT studies are briefly reviewed. New J-integral estimation methods for semielliptical surface cracks and cracks at notches are derived and validated. Engineering methods are developed to characterize crack growth rates during elastic-plastic fatigue crack growth (FCG) and the tear-fatigue interaction near instability. Surface crack growth experiments are conducted with Inconel 718 to characterize tearing resistance, FCG under small-scale yielding and elastic-plastic conditions, and crack growth during simulated MCPT. Fractography and acoustic emission studies provide additional insight. The relative merits of SCPT and MCPT are directly compared using a probabilistic analysis linked with an elastic-plastic crack growth computer code. The conditional probability of failure in service is computed for a population of components that have survived a previous proof test, based on an assumed distribution of initial crack depths. Parameter studies investigate the influence of proof factor, tearing resistance, crack shape, initial crack depth distribution, and notches on the MCPT versus SCPT comparison. The parameter studies provide a rational basis to formulate conclusions about the relative advantages and disadvantages of SCPT and MCPT. Practical engineering guidelines are proposed to help select the optimum proof test protocol in a given application.

McClung, R. C.↗

Terahertz NDE of Stressed Composite Overwrapped Pressure Vessels - Initial Testing

Terahertz radiation nondestructive evaluation was applied to a set of Kevlar composite overwrapped pressure vessel bottles that had undergone a series of thermal and pressure tests to simulate stress rupture effects. The bottles in these nondestructive evaluation tests were bottles that had not ruptured but had survived various times at the elevated load and temperature levels. Some of the bottles showed evidence of minor composite failures. The terahertz radiation did detect visible surface flaws, but did not detect any internal chemical or material degradation of the thin overwraps.

Madaras, Eric I.↗

Robust Fault Detection and Isolation for Stochastic Systems

This paper outlines the formulation of a robust fault detection and isolation scheme that can precisely detect and isolate simultaneous actuator and sensor faults for uncertain linear stochastic systems. The given robust fault detection scheme based on the discontinuous robust observer approach would be able to distinguish between model uncertainties and actuator failures and therefore eliminate the problem of false alarms. Since the proposed approach involves precise reconstruction of sensor faults, it can also be used for sensor fault identification and the reconstruction of true outputs from faulty sensor outputs. Simulation results presented here validate the effectiveness of the robust fault detection and isolation system.

George, Jemin↗

The Effects of Hygrothermal Aging on the Impact Penetration Resistance of Triaxially Braided Composites

An experimental study was conducted to measure the effects of long term hygrothermal aging on the impact penetration resistance of triaxially braided polymer composites. Flat panels of three different materials were subjected to repeated cycles of high and low temperature and high and low humidity for two years. Samples of the panels were periodically tested under impact loading during the two year time period. The purpose of the study was to identify and quantify any degradation in impact penetration resistance of these composites under cyclic temperature and humidity conditions experienced by materials in the fan section of commercial gas turbine engines for a representative aircraft flight cycle. The materials tested consisted of Toray ® T700S carbon fibers in a 2D triaxial braid with three different resins, Cycom® PR520, a toughened resin, Hercules® 3502, an untoughened resin and EPON 862, intermediate between the two. The fiber preforms consisted of a quasi-isotropic 0/+60/-60 braid with 24K tows in the axial direction and 12K tows in the bias directions. The composite panels were manufactured using a resin transfer molding process producing panels with a thickness of 0.125 inches. The materials were tested in their as-processed condition and again after one year and two years of aging (1.6 years in the case of E862). The aging process involved subjecting the test panels to two cycles per day of high and low temperature and high and low humidity. A temperature range of -60degF to 250degF and a humidity range of 0 to 85% rh was used to simulate extreme conditions for composite components in the fan section of a commercial gas turbine engine. Additional testing was conducted on the as-processed PR520 composite under cryogenic conditions. After aging there was some change in the failure pattern, but there was no reduction in impact penetration threshold for any of the three systems, and in the case of the 3502 system, a significant increase in penetration threshold. There was also an increase in the penetration resistance of the PR520 system impacted under cryogenic conditions.

composite↗

Robust Platinum Resistor Thermometer (PRT) Sensors and Reliable Bonding for Space Missions

Platinum resistance thermometers (PRTs) provide accurate temperature measurements over a wide temperature range and are used extensively on space missions due to their simplicity and linearity. A standard on spacecraft, PRTs are used to provide precision temperature control and vehicle health assessment. This paper reviews the extensive reliability testing of platinum resistor thermometer sensors (PRTs) and bonding methods used on the Mars Science Laboratory (MSL) mission and for the upcoming Soil Moisture Active Passive (SMAP) mission. During the Mars Exploration Rover (MER) mission, several key, JPL-packaged PRTs failed on those rovers prior to and within 1-Sol of landing due to thermally induced stresses. Similar failures can be traced back to other JPL missions dating back thirty years. As a result, MSL sought out a PRT more forgiving to the packaging configurations used at JPL, and extensively tested the Honeywell HRTS-5760-B-U-0-12 sensor to successfully demonstrate suitable robustness to thermal cycling. Specifically, this PRT was cycled 2,000 times, simulating three Martian winters and summers. The PRTs were bonded to six substrate materials (Aluminum 7050, treated Magnesium AZ231-B, Stainless Steel 304, Albemet, Titanium 6AL4V, and G-10), using four different aerospace adhesives--two epoxies and two silicones--that conformed to MSL's low out-gassing requirements. An additional epoxy was tested in a shorter environmental cycling test, when the need for a different temperature range adhesive was necessary for mobility and actuator hardware late in the fabrication process. All of this testing, along with electrostatic discharge (ESD) and destructive part analyses, demonstrate that this PRT is highly robust, and not subject to the failure of PRTs on previous missions. While there were two PRTs that failed during fabrication, to date there have been no in-flight PRT failures on MSL, including those on the Curiosity rover. Since MSL, the sensor has gone through a change in construction such that the manufacturer significantly restricts the minimum temperature. However, significant subsequent testing was performed with this new version of the part to show that it indeed is still robust to at least Mars minimum temperatures of -135(sup o)C. The additional completed testing will be described. This work has resulted in a successful sensor package qualification and a reliable bonding method suitable for use over large temperature extremes.

dectector↗

Robust Platinum Resistor Thermometer (PRT) Sensors and Reliable Bonding for Space Missions

Platinum resistance thermometers (PRTs) provide accurate temperature measurements over a wide temperature range and are used extensively on space missions due to their simplicity and linearity. A standard on spacecraft, PRTs are used to provide precision temperature control and vehicle health assessment. This paper reviews the extensive reliability testing of platinum resistor thermometer sensors (PRTs) and bonding methods used on the Mars Science Laboratory (MSL) mission and for the upcoming Soil Moisture Active Passive (SMAP) mission. During the Mars Exploration Rover (MER) mission, several key, JPL-packaged PRTs failed on those rovers prior to and within 1-Sol of landing due to thermally induced stresses. Similar failures can be traced back to other JPL missions dating back thirty years. As a result, MSL sought out a PRT more forgiving to the packaging configurations used at JPL, and extensively tested the Honeywell HRTS-5760-B-U-0-12 sensor to successfully demonstrate suitable robustness to thermal cycling. Specifically, this PRT was cycled 2,000 times, simulating three Martian winters and summers. The PRTs were bonded to six substrate materials (Aluminum 7050, treated Magnesium AZ231-B, Stainless Steel 304, Albemet, Titanium 6AL4V, and G-10), using four different aerospace adhesives--two epoxies and two silicones--that conformed to MSL's low out-gassing requirements. An additional epoxy was tested in a shorter environmental cycling test, when the need for a different temperature range adhesive was necessary for mobility and actuator hardware late in the fabrication process. All of this testing, along with electrostatic discharge (ESD) and destructive part analyses, demonstrate that this PRT is highly robust, and not subject to the failure of PRTs on previous missions. While there were two PRTs that failed during fabrication, to date there have been no in-flight PRT failures on MSL, including those on the Curiosity rover. Since MSL, the sensor has gone through a change in construction such that the manufacturer significantly restricts the minimum temperature. However, significant subsequent testing was performed with this new version of the part to show that it indeed is still robust to at least Mars minimum temperatures of -135 degrees Centigrade. The additional completed testing will be described. This work has resulted in a successful sensor package qualification and a reliable bonding method suitable for use over large temperature extremes

Platinum Resistor Thermometer (PRT)↗

Progressive Damage Failure Analysis of Post-Buckled Composite Single-Stringer Panel with Teflon Inserts

The high strength-to-weight and stiffness-to-weight ratio materials, such as laminated composites, are advantageous for modern aircraft. Laminated composites with initial flaws are susceptible to delamination under buckling loads. PDA tools help enhance the industry’s understanding of the mechanisms for damage initiation and growth in composite structures while assisting in the design, analysis, and sustainment methods of these composite structures. The global-local modeling approach for the single-stringer post-buckled panel was evaluated through this effort, using Teflon inserts to simulate the defect of damage during manufacturing. This understanding is essential for designing the post-buckled structure, reducing weight while predicting damage initiation location, and addressing a potential design review for future aircraft repairs. In this work, the initial damage was captured with Teflon inserts as the starting configuration; and any reference to the damage initiation refers to any damage beyond the “initial unbonded region.” The effort aims to develop, evaluate, and enhance methods to predict damage initiation and progression and the failure of post-buckled hat-stiffened panels using multiple Abaqus FEA Virtual Crack Closure Technique (VCCT) definitions. Validation of the PDA using the VCCT material model was performed on a large single-stringer panel subjected to compressive loading. The compressive loading of the panel caused the skin to buckle before any damage began to occur locally. In addition, comparisons are made for critical aspects of the damage morphology, such as a growth pattern that included delamination from the skin-stiffener interface to the skin and ply interfaces. When compared against the experimental data produced through the NASA Advanced Composites Project (ACP), the present model captured damage migration from one surface to another, and model validations were within 4% of the experimental data.

PDA↗

Lightning tests of the orbiter pyrotechnic escape system

An experimental test program was undertaken to demonstrate that the Space Shuttle Orbiter Vehicle pyrotechnics actuated Crew Escape System was not subject to failure resulting from a lightning strike in the vicinity of the cockpit. A test sample representing a full-scale portion of the Orbiter Outer Panel was preheated to 325 F and struck with three different current waveforms to simulate the various effects of lightning: (1) 2 micro sec risetime, to 180 kA pulse to evaluate fast current rise shock effects; (2) a 205 kA, 100 micro sec wide pulse to evaluate full energy shock effects; and (3) a 490 ampere, 370 msec continuing current to evaluate the thermal effects of a lightning strike. These tests show that the Orbiter outer panel pyrotechnics are adequately protected against damage resulting from a lightning strike.

Cohen, R.↗

Impact-initiated damage thresholds in composites

An experimental investigation was conducted to study the effect of low velocity projectile impact on the sandwich-type structural components. The materials used in the fabrication of the impact surface were graphite-, Kevlar-, and boron-fibers with appropriate epoxy matrices. The testing of the specimens was performed at moderately low- and high-temperatures as well as at room temperature to assess the impact-initiated strength degradation of the laminates. Eleven laminates with different stacking sequences, orientations, and thicknesses were tested. The low energy projectile impact is considered to simulate the damage caused by runway debris, dropping of the hand tools during servicing, etc., on the secondary aircraft structures fabricated with the composite materials. The results show the preload and the impact energy combinations necessary to cause catastrophic failures in the laminates tested. A set of faired curves indicating the failure thresholds is shown separately for the tension- and compression-loaded laminates. The specific-strengths and -moduli for the various laminates tested are also given.

Sharma, A. V.↗

SIMS chemical analysis of extended impacts on the leading and trailing edges of LDEF experiment AO187-2

Numerous 'extended impacts' found in both leading and trailing edge capture cells were successfully analyzed for the chemical composition of projectile residues by secondary ion mass spectrometry (SIMS). Most data were obtained from the trailing edge cells where 45 of 58 impacts were classified as 'probably natural' and the remainder as 'possibly man-made debris.' This is in striking contrast to leading edge cells where 9 of 11 impacts so far measured are definitely classified as orbital debris. Although all the leading edge cells had lost their plastic entrance foils during flight, the rate of foil failure was similar to that of the trailing edge cells, 10 percent of which were recovered intact. Ultraviolet embrittlement is suspected as the major cause of failure on both leading and trailing edges. The major impediment to the accurate determination of projectile chemistry is the fractionation of volatile and refractory elements in the hypervelocity impact and redeposition processes. This effect had been noted in a simulation experiment but is more pronounced in the LDEF capture cells, probably due to the higher average velocities of the space impacts. Surface contamination of the pure Ge surfaces with a substance rich in Si, but also containing Mg and Al, provides an additional problem for the accurate determination of impactor chemistry. The effect is variable, being much larger on surfaces that were exposed to space than in those cells that remained intact. Future work will concentrate on the analyses of more leading edge impacts and the development of new SIMS techniques for the measurement of elemental abundances in extended impacts.

Amari, S.↗

Transient Finite Element Analyses Developed to Model Fan Containment Impact Events

Research is underway to establish an increased level of confidence in existing numerical techniques for predicting transient behavior when the fan of a jet engine is released and impacts the fan containment system. To evaluate the predictive accuracy that can currently be obtained, researchers at the NASA Lewis Research Center used the DYNA 3D computer code to simulate large-scale subcomponent impact tests that were conducted at the University of Dayton Research Institute (UDRI) Impact Physics Lab. In these tests, 20- by 40-in. flat metal panels, contoured to the shape of a typical fan case, were impacted by the root section of a fan blade. The panels were oriented at an angle to the path of the projectile that would simulate the conditions in an actual blade-out event. The metal panels were modeled in DYNA 3D using a kinematic hardening model with the strain rate dependence of the yield stress governed by the Cowper-Simons rule. Failure was governed by the effective plastic strain criterion. The model of the fan blade and case just after impact is shown. By varying the maximum effective plastic strain, we obtained good qualitative agreement between the model and the experiments. Both the velocity required to penetrate the case and the deflection during impact compared well. This indicates that the failure criterion and constitutive model may be appropriate, but for DYNA 3D to be useful as a predictive tool, methods to determine accurate model parameters must be established. Simple methods for measuring model parameters are currently being developed. In addition, alternative constitutive models and failure criteria are being investigated.

Pereira, J. Michael↗

Applying Model-based Diagnosis to a Rapid Propellant Loading System

The overall objective of the US Air Force Research Laboratory (AFRL) Rapid Propellant Loading (RPL) Program is to develop a launch vehicle, payload and ground support equipment that can support a rapid propellant load and launch within one hour. NASA Kennedy Space Center (KSC) has been funded by AFRL to develop hardware and software to demonstrate this capability. The key features of the software would be the ability to recognize and adapt to failures in the physical hardware components, advise operators of equipment faults and workarounds, and put the system in a safe configuration if unable to fly. In December 2008 NASA KSC and NASA Ames Research Center (ARC) demonstrated model based simulation and diagnosis capabilities for a scaled-down configuration of the RPL hardware. In this paper we present a description of the model-based technologies that were included as part of this demonstration and the results that were achieved. In continuation of this work we are currently testing the technologies on a simulation of the complete RPL system. Later in the year, when the RPL hardware is ready, we will be integrating these technologies with the real-time operation of the system to provide live state estimates. In future years we will be developing the capability to recover from faulty conditions via redundancy and reconfiguration.

Goodrich, Charlie H.↗

Modeling of Failure for Analysis of Triaxial Braided Carbon Fiber Composites

In the development of advanced aircraft-engine fan cases and containment systems, composite materials are beginning to be used due to their low weight and high strength. The design of these structures must include the capability of withstanding impact loads from a released fan blade. Relatively complex triaxially braided fiber architectures have been found to yield the best performance for the fan cases. To properly work with and design these structures, robust analytical tools are required that can be used in the design process. A new analytical approach models triaxially braided carbon fiber composite materials within the environment of a transient dynamic finite-element code, specifically the commercially available transient dynamic finite-element code LS-DYNA. The geometry of the braided composites is approximated by a series of parallel laminated composites. The composite is modeled by using shell finite elements. The material property data are computed by examining test data from static tests on braided composites, where optical strain measurement techniques are used to examine the local strain variations within the material. These local strain data from the braided composite tests are used along with a judicious application of composite micromechanics- based methods to compute the stiffness properties of an equivalent unidirectional laminated composite required for the shell elements. The local strain data from the braided composite tests are also applied to back out strength and failure properties of the equivalent unidirectional composite. The properties utilized are geared towards the application of a continuum damage mechanics-based composite constitutive model available within LS-DYNA. The developed model can be applied to conduct impact simulations of structures composed of triaxially braided composites. The advantage of this technology is that it facilitates the analysis of the deformation and damage response of a triaxially braided polymer matrix composite within the environment of a transient dynamic finite-element code such as LS-DYNA in a manner which accounts for the local physical mechanisms but is still computationally efficient. This methodology is tightly coupled to experimental tests on the braided composite, which ensures that the material properties have physical significance. Aerospace or automotive companies interested in using triaxially braided composites in their structures, particularly for impact or crash applications, would find the technology useful. By the development of improved design tools, the amount of very expensive impact testing that will need to be performed can be significantly reduced.

Goldberg, Robert K.↗

Spinoff 2013

Topics covered include: Innovative Software Tools Measure Behavioral Alertness; Miniaturized, Portable Sensors Monitor Metabolic Health; Patient Simulators Train Emergency Caregivers; Solar Refrigerators Store Life-Saving Vaccines; Monitors Enable Medication Management in Patients' Homes; Handheld Diagnostic Device Delivers Quick Medical Readings; Experiments Result in Safer, Spin-Resistant Aircraft; Interfaces Visualize Data for Airline Safety, Efficiency; Data Mining Tools Make Flights Safer, More Efficient; NASA Standards Inform Comfortable Car Seats; Heat Shield Paves the Way for Commercial Space; Air Systems Provide Life Support to Miners; Coatings Preserve Metal, Stone, Tile, and Concrete; Robots Spur Software That Lends a Hand; Cloud-Based Data Sharing Connects Emergency Managers; Catalytic Converters Maintain Air Quality in Mines; NASA-Enhanced Water Bottles Filter Water on the Go; Brainwave Monitoring Software Improves Distracted Minds; Thermal Materials Protect Priceless, Personal Keepsakes; Home Air Purifiers Eradicate Harmful Pathogens; Thermal Materials Drive Professional Apparel Line; Radiant Barriers Save Energy in Buildings; Open Source Initiative Powers Real-Time Data Streams; Shuttle Engine Designs Revolutionize Solar Power; Procedure-Authoring Tool Improves Safety on Oil Rigs; Satellite Data Aid Monitoring of Nation's Forests; Mars Technologies Spawn Durable Wind Turbines; Programs Visualize Earth and Space for Interactive Education; Processor Units Reduce Satellite Construction Costs; Software Accelerates Computing Time for Complex Math; Simulation Tools Prevent Signal Interference on Spacecraft; Software Simplifies the Sharing of Numerical Models; Virtual Machine Language Controls Remote Devices; Micro-Accelerometers Monitor Equipment Health; Reactors Save Energy, Costs for Hydrogen Production; Cameras Monitor Spacecraft Integrity to Prevent Failures; Testing Devices Garner Data on Insulation Performance; Smart Sensors Gather Information for Machine Diagnostics; Oxygen Sensors Monitor Bioreactors and Ensure Health and Safety; Vision Algorithms Catch Defects in Screen Displays; and Deformable Mirrors Capture Exoplanet Data, Reflect Lasers.

Source record↗

Developing an Integration Infrastructure for Distributed Engine Control Technologies

Turbine engine control technology is poised to make the first revolutionary leap forward since the advent of full authority digital engine control in the mid-1980s. This change aims squarely at overcoming the physical constraints that have historically limited control system hardware on aero-engines to a federated architecture. Distributed control architecture allows complex analog interfaces existing between system elements and the control unit to be replaced by standardized digital interfaces. Embedded processing, enabled by high temperature electronics, provides for digitization of signals at the source and network communications resulting in a modular system at the hardware level. While this scheme simplifies the physical integration of the system, its complexity appears in other ways. In fact, integration now becomes a shared responsibility among suppliers and system integrators. While these are the most obvious changes, there are additional concerns about performance, reliability, and failure modes due to distributed architecture that warrant detailed study. This paper describes the development of a new facility intended to address the many challenges of the underlying technologies of distributed control. The facility is capable of performing both simulation and hardware studies ranging from component to system level complexity. Its modular and hierarchical structure allows the user to focus their interaction on specific areas of interest.

distributed control↗

Accounting for the Speed-Accuracy Trade-Off in Quantifying Human-In-The-Loop Error Probabilities

Human-in-the-loop (HITL) simulations cannot collect enough data from human operators to validate estimates of error probabilities for task components. Error rates for tasks have been estimated by using laboratory data for error rates depending on variables such as the cognitive complexity of the task. The limited channel capacity of human operators compels error rates to be strongly related to the time available for the task, the speed-accuracy trade-off. HITL simulations can provide valuable data on the time available for the operator's tasks. We propose that the response times be used in conjunction with measured speed-accuracy curves to estimate the operator error rates contributing to mission failure. Such analyses should be especially important in the estimation of error rates in off-nominal situations.

probability↗

Stochastic Simulation of Mudcrack Damage Formation in an Environmental Barrier Coating

The FEAMAC/CARES program, which integrates finite element analysis (FEA) with the MAC/GMC (Micromechanics Analysis Code with Generalized Method of Cells) and the CARES/Life (Ceramics Analysis and Reliability Evaluation of Structures / Life Prediction) programs, was used to simulate the formation of mudcracks during the cooling of a multilayered environmental barrier coating (EBC) deposited on a silicon carbide substrate. FEAMAC/CARES combines the MAC/GMC multiscale micromechanics analysis capability (primarily developed for composite materials) with the CARES/Life probabilistic multiaxial failure criteria (developed for brittle ceramic materials) and Abaqus (Dassault Systèmes) FEA. In this report, elastic modulus reduction of randomly damaged finite elements was used to represent discrete cracking events. The use of many small-sized low-aspect-ratio elements enabled the formation of crack boundaries, leading to development of mudcrack-patterned damage. Finite element models of a disk-shaped three-dimensional specimen and a twodimensional model of a through-the-thickness cross section subjected to progressive cooling from 1,300 °C to an ambient temperature of 23 °C were made. Mudcrack damage in the coating resulted from the buildup of residual tensile stresses between the individual material constituents because of thermal expansion mismatches between coating layers and the substrate. A two-parameter Weibull distribution characterized the coating layer stochastic strength response and allowed the effect of the Weibull modulus on the formation of damage and crack segmentation lengths to be studied. The spontaneous initiation of cracking and crack coalescence resulted in progressively smaller mudcrack cells as cooling progressed, consistent with a fractal-behaved fracture pattern. Other failure modes such as delamination, and possibly spallation, could also be reproduced. The physical basis assumed and the heuristic approach employed, which involves a simple stochastic cellular automaton methodology to approximate the crack growth process, are described. The results ultimately show that a selforganizing mudcrack formation can derive from a Weibull distribution that is used to describe the stochastic strength response of the bulk brittle ceramic material layers of an EBC.

Nemeth, Noel N.↗