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NASA NTRS2020

Model Checking as a Service: Towards Pragmatic Hidden Formal Methods

Executable models can be used to support all engineering activities in Model-Based Systems Engineering. Testing and simulation of such models can provide early feedback about design choices. How-ever, in today’s complex systems failures could arise due to subtle errors that are hard to find without checking all possible execution paths. Formal methods, and especially model checking can uncover such subtle errors, yet their usage in practice is limited due to the specialized expertise and high computing power required. There-fore we created an automated, cloud-based environment that can verify complex reachability properties on SysML State Machines using hidden model checkers. The approach and the prototype is illustrated using an example from the aerospace domain.

Karban, Robert↗

DOE OSTI2022

Grid Utility Asset Vulnerability Assessment (GUAVA) Software Tool

Increasing demand and changes in generation portfolios is pushing power grid to operate towards the limit. However, due to lack of analytical tools for understanding various scales of impact on grid, it is becoming more vulnerable to wide scale power outages and blackouts. A vulnerable grid operating at its limit can be easily disrupted by asset failures caused by devastating hurricanes which has been known to damage transmission and distribution lines along its track. In this direction, researchers have focused on determining these assets by conducting Monte Carlo simulations of hurricanes with uncertainties and collected a large set of simulation data. To determine the infrastructure updates necessary for mitigating wide scale impact of hurricanes on the grid, we propose a software tool named “Grid Utility Asset Vulnerability Analysis” (GUAVA) framework. GUAVA presents a novel data-driven probabilistic analytical approach to (1) post-process hurricane failure scenarios, (2) identify/rank assets that are most vulnerable and critical to failing and are associated with highest impact/risk, and (3) to inform system upgrade decisions & prioritization. Based on the observed results and employed data-driven methodology, it is expected GUAVA can be adapted to provide power system planners with a recommendation engine for making informed decisions to improve resilience of grid.

Mahapatra, Kaveri↗

NASA NTRS2002

Analysis of Composite Skin-Stiffener Debond Specimens Using Volume Elements and a Shell/3D Modeling Technique

The debonding of a skin/stringer specimen subjected to tension was studied using three-dimensional volume element modeling and computational fracture mechanics. Mixed mode strain energy release rates were calculated from finite element results using the virtual crack closure technique. The simulations revealed an increase in total energy release rate in the immediate vicinity of the free edges of the specimen. Correlation of the computed mixed-mode strain energy release rates along the delamination front contour with a two-dimensional mixed-mode interlaminar fracture criterion suggested that in spite of peak total energy release rates at the free edge the delamination would not advance at the edges first. The qualitative prediction of the shape of the delamination front was confirmed by X-ray photographs of a specimen taken during testing. The good correlation between prediction based on analysis and experiment demonstrated the efficiency of a mixed-mode failure analysis for the investigation of skin/stiffener separation due to delamination in the adherents. The application of a shell/3D modeling technique for the simulation of skin/stringer debond in a specimen subjected to three-point bending is also demonstrated. The global structure was modeled with shell elements. A local three-dimensional model, extending to about three specimen thicknesses on either side of the delamination front was used to capture the details of the damaged section. Computed total strain energy release rates and mixed-mode ratios obtained from shell/3D simulations were in good agreement with results obtained from full solid models. The good correlations of the results demonstrated the effectiveness of the shell/3D modeling technique for the investigation of skin/stiffener separation due to delamination in the adherents.

Krueger, Ronald↗

NASA NTRS2005

Space Suit Electrocardiographic Electrode Selection: Are commercial electrodes better than the old Apollo technology?

The NASA Manned Space Program uses an electrocardiograph (ECG) system to monitor astronauts during extravehicular activity (EVA). This ECG system, called the Operational Bioinstrumentation System (OBS), was developed during the Apollo era. Throughout the Shuttle program these electrodes experienced failures during several EVAs performed from the Space Shuttle and International Space Station (ISS) airlocks. An attempt during Shuttle Flight STS-109 to replace the old electrodes with new commercial off-the-shelf (COTS) disposable electrodes proved unsuccessful. One assumption for failure of the STS-109 COTS electrodes was the expansion of trapped gases under the foam electrode pad, causing the electrode to be displaced from the skin. Given that our current electrodes provide insufficient reliability, a number of COTS ECG electrodes were tested at the NASA Altitude Manned Chamber Test Facility. Methods: OBS disposable electrodes were tested on human test subjects in an altitude chamber simulating an Extravehicular Mobility Unit (EMU) operating pressure of 4.3 psia with the following goals: (1) to confirm the root cause of the flight certified, disposable electrode failure during flight STS-109. (2) to identify an adequate COTS replacement electrode and determine if further modifications to the electrodes are required. (3) to evaluate the adhesion of each disposable electrode without preparation of the skin with isopropyl alcohol. Results: There were several electrodes that failed the pressure testing at 4.3psia, including the electrodes used during flight STS-109. Two electrodes functioned well throughout all testing and were selected for further testing in an EMU at altitude. A vent hole placed in all electrodes was also tested as a possible solution to prevent gas expansion from causing electrode failures. Conclusions: Two failure modes were identified: (1) foam-based porous electrodes entrapped air bubbles under the pad (2) poor adhesion caused some electrodes to fail

Redmond, M.↗

NASA NTRS1998

An Analysis of Failure Handling in Chameleon, A Framework for Supporting Cost-Effective Fault Tolerant Services

The desire for low-cost reliable computing is increasing. Most current fault tolerant computing solutions are not very flexible, i.e., they cannot adapt to reliability requirements of newly emerging applications in business, commerce, and manufacturing. It is important that users have a flexible, reliable platform to support both critical and noncritical applications. Chameleon, under development at the Center for Reliable and High-Performance Computing at the University of Illinois, is a software framework. for supporting cost-effective adaptable networked fault tolerant service. This thesis details a simulation of fault injection, detection, and recovery in Chameleon. The simulation was written in C++ using the DEPEND simulation library. The results obtained from the simulation included the amount of overhead incurred by the fault detection and recovery mechanisms supported by Chameleon. In addition, information about fault scenarios from which Chameleon cannot recover was gained. The results of the simulation showed that both critical and noncritical applications can be executed in the Chameleon environment with a fairly small amount of overhead. No single point of failure from which Chameleon could not recover was found. Chameleon was also found to be capable of recovering from several multiple failure scenarios.

Haakensen, Erik Edward↗

NASA NTRS2002

Linear Parameter Varying Control Synthesis for Actuator Failure, Based on Estimated Parameter

The design of a linear parameter varying (LPV) controller for an aircraft at actuator failure cases is presented. The controller synthesis for actuator failure cases is formulated into linear matrix inequality (LMI) optimizations based on an estimated failure parameter with pre-defined estimation error bounds. The inherent conservatism of an LPV control synthesis methodology is reduced using a scaling factor on the uncertainty block which represents estimated parameter uncertainties. The fault parameter is estimated using the two-stage Kalman filter. The simulation results of the designed LPV controller for a HiMXT (Highly Maneuverable Aircraft Technology) vehicle with the on-line estimator show that the desired performance and robustness objectives are achieved for actuator failure cases.

Shin, Jong-Yeob↗

NASA NTRS2001

Importance of the Annual Cycles of SST and Solar Irradiance for Circulation and Rainfall: A Climate Model Simulation Study

Annual cycle of climate and precipitation is related to annual cycle of sunshine and sea-surface temperatures. Understanding its behavior is important for the welfare of humans worldwide. For example, failure of Asian monsoons can cause widespread famine and grave economic disaster in the subtropical regions. For centuries meteorologists have struggled to understand the importance of the summer sunshine and associated heating and the annual cycle of sea-surface temperatures (SSTs) on rainfall in the subtropics. Because the solar income is pretty steady from year to year, while SSTs depict large interannual variability as consequence of the variability of ocean dynamics, the influence of SSTs on the monsoons are better understood through observational and modeling studies whereas the relationship of annual rainfall to sunshine remains elusive. However, using NASA's state of the art climate model(s) that can generate realistic climate in a computer simulation, one can answer such questions. We asked the question: if there was no annual cycle of the sunshine (and its associated land-heating) or the SST and its associated influence on global circulation, what will happen to the annual cycle of monsoon rains? By comparing the simulation of a 4-year integration of a baseline Control case with two parallel anomaly experiments: 1) with annual mean solar and 2) with annual mean sea-surface temperatures, we were able to draw the following conclusions: (1) Tropical convergence zone and rainfall which moves with the Sun into the northern and southern hemispheres, specifically over the Indian, African, South American and Australian regions, is strongly modulated by the annual cycles of SSTs as well as solar forcings. The influence of the annual cycle of solar heating over land, however, is much stronger than the corresponding SST influence for almost all regions, particularly the subtropics; (2) The seasonal circulation patterns over the vast land-masses of the Northern Hemisphere at mid and high latitudes also get strongly influenced by the annual cycles of solar heating. The SST influence is largely limited to the oceanic regions of these latitudes; (3) The annual mode of precipitation over Amazonia has an equatorial regime revealing a maxima in the month of March associated with SST, and another maxima in the month of January associated with the solar annual cycles, respectively. The baseline simulation, which has both annual cycles, depicts both annual modes and its rainfall is virtually equal to the sum of those two modes; (4) Rainfall over Sahelian-Africa is significantly reduced (increased) in simulations lacking (invoking) solar irradiation with (without) the annual cycle. In fact, the dominant influence of solar irradiation emerges in almost all monsoonal-land regions: India, Southeast Asia, as well as Australia. The only exception is the Continental United States, where solar annual cycle shows only a relatively minor influence on the annual mode of rainfall.

Sud, Yogesh C.↗

NASA NTRS2018

Impact of Advanced Synoptics and Simplified Checklists During Aircraft Systems Failures

Abstract—Natural human capacities are becoming increasingly mismatched to the enormous data volumes, processing capabilities, and decision speeds demanded in today’s aviation environment. Increasingly Autonomous Systems (IAS) are uniquely suited to solve this problem. NASA is conducting research and development of IAS - hardware and software systems, utilizing machine learning algorithms, seamlessly integrated with humans whereby task performance of the combined system is significantly greater than the individual components. IAS offer the potential for significantly improved levels of performance and safety that are superior to either human or automation alone. A human-in-the-loop test was conducted in NASA Langley’s Integration Flight Deck B-737-800 simulator to evaluate advanced synoptic pages with simplified interactive electronic checklists as an IAS for routine air carrier flight operations and in response to aircraft system failures. Twelve U.S. airline crews flew various normal and non-normal procedures and their actions and performance were recorded in response to failures. These data are fundamental to and critical for the design and development of future increasingly autonomous systems that can better support the human in the cockpit. Synoptic pages and electronic checklists significantly improved pilot responses to non-normal scenarios, but implementation of these aids and other intelligent assistants have barriers to implementation (e.g., certification cost) that must overcome.

Etherington, Timothy J.↗

NASA NTRS1991

Failure prediction of thin beryllium sheets used in spacecraft structures

The primary objective of this study is to develop a method for prediction of failure of thin beryllium sheets that undergo complex states of stress. Major components of the research include experimental evaluation of strength parameters for cross-rolled beryllium sheet, application of the Tsai-Wu failure criterion to plate bending problems, development of a high order failure criterion, application of the new criterion to a variety of structures, and incorporation of both failure criteria into a finite element code. A Tsai-Wu failure model for SR-200 sheet material is developed from available tensile data, experiments carried out by NASA on two circular plates, and compression and off-axis experiments performed in this study. The failure surface obtained from the resulting criterion forms an ellipsoid. By supplementing experimental data used in the the two-dimensional criterion and modifying previously suggested failure criteria, a multi-dimensional failure surface is proposed for thin beryllium structures. The new criterion for orthotropic material is represented by a failure surface in six-dimensional stress space. In order to determine coefficients of the governing equation, a number of uniaxial, biaxial, and triaxial experiments are required. Details of these experiments and a complementary ultrasonic investigation are described in detail. Finally, validity of the criterion and newly determined mechanical properties is established through experiments on structures composed of SR200 sheet material. These experiments include a plate-plug arrangement under a complex state of stress and a series of plates with an out-of-plane central point load. Both criteria have been incorporated into a general purpose finite element analysis code. Numerical simulation incrementally applied loads to a structural component that is being designed and checks each nodal point in the model for exceedance of a failure criterion. If stresses at all locations do not exceed the failure criterion, the load is increased and the process is repeated. Failure results for the plate-plug and clamped plate tests are accurate to within 2 percent.

Roschke, Paul N.↗

NASA NTRS2002

Predicting System Accidents with Model Analysis During Hybrid Simulation

Standard discrete event simulation is commonly used to identify system bottlenecks and starving and blocking conditions in resources and services. The CONFIG hybrid discrete/continuous simulation tool can simulate such conditions in combination with inputs external to the simulation. This provides a means for evaluating the vulnerability to system accidents of a system's design, operating procedures, and control software. System accidents are brought about by complex unexpected interactions among multiple system failures , faulty or misleading sensor data, and inappropriate responses of human operators or software. The flows of resource and product materials play a central role in the hazardous situations that may arise in fluid transport and processing systems. We describe the capabilities of CONFIG for simulation-time linear circuit analysis of fluid flows in the context of model-based hazard analysis. We focus on how CONFIG simulates the static stresses in systems of flow. Unlike other flow-related properties, static stresses (or static potentials) cannot be represented by a set of state equations. The distribution of static stresses is dependent on the specific history of operations performed on a system. We discuss the use of this type of information in hazard analysis of system designs.

Malin, Jane T.↗

NASA NTRS1975

Corona-vacuum failure mechanism test facilities

A nondestructive corona-vacuum test facility for testing high-voltage power system components has been developed using commercially available hardware. The facility simulates operating temperature and vacuum while monitoring coronal discharges with residual gases. Corona threshold voltages obtained from statorette tests with various gas-solid dielectric systems and comparison with calculated data support the following conclusions: (1) air gives the highest corona threshold voltage and helium the lowest, with argon and helium-xenon mixtures intermediate; (2) corona threshold voltage increases with gas pressure; (3) corona threshold voltage for an armature winding can be accurately calculated by using Paschen curves for a uniform field; and (4) Paschen curves for argon can be used to calculate the corona threshold voltage in He-Xe mixtures, for which Paschen curves are unavailable.-

Lalli, V. R.↗

NASA NTRS1988

Computational simulation methods for composite fracture mechanics

Structural integrity, durability, and damage tolerance of advanced composites are assessed by studying damage initiation at various scales (micro, macro, and global) and accumulation and growth leading to global failure, quantitatively and qualitatively. In addition, various fracture toughness parameters associated with a typical damage and its growth must be determined. Computational structural analysis codes to aid the composite design engineer in performing these tasks were developed. CODSTRAN (COmposite Durability STRuctural ANalysis) is used to qualitatively and quantitatively assess the progressive damage occurring in composite structures due to mechanical and environmental loads. Next, methods are covered that are currently being developed and used at Lewis to predict interlaminar fracture toughness and related parameters of fiber composites given a prescribed damage. The general purpose finite element code MSC/NASTRAN was used to simulate the interlaminar fracture and the associated individual as well as mixed-mode strain energy release rates in fiber composites.

Murthy, Pappu L. N.↗

DOE OSTI2020

Polysulfide entrapment and retardation in gel electrolyte Li–S batteries: experiments and modeling

Gelling the electrolyte in lithium–sulfur (Li–S) batteries provides advantages in terms of safety and mitigating polysulfide shuttling leading to reduced side reactions and dendrite growth on the anode side. In the current study, organic and ceramic crosslinkers have been used to improve the entrapment of polysulfides and prevent them from shuttling to the anode side. However, the performance of gel electrolytes is still far from being on par with liquid electrolytes in terms of raw capacity. The discharge curves exhibit an extended first plateau for gel electrolyte batteries compared to liquid electrolytes, showing that polysulfides are better trapped in the gel system. Yet, in the conversion of soluble polysulfides into insoluble polysulfides, the second plateau was delayed. Qualitative and quantitative analysis of the polysulfide diffusion in the liquid electrolyte and gel electrolyte systems were also conducted to predict the relative diffusivity ratio between the liquid electrolyte and gel electrolyte for simulation. To probe what happens at the end of the discharge, where the mass transport in the gel electrolyte appears to be slow, a modified discharge procedure was used where the cell is first paused after discharge and then discharged a second time before recharging normally. Coin cell tests for two gel electrolytes in addition to liquid electrolyte show up to 7% capacity recovery after the pause, which indicates that the diffusion of species during the pause is responsible for the failure recovery. Additionally, the recovery is higher for gel electrolytes compared to liquid, for higher C-rates, and for longer pause times. To better understand this behavior, a Li–S numerical model with mass transport limited reactions was used to examine the polysulfide diffusion coefficients expected in different electrolyte systems. The model is able to reproduce the trends seen in experiments and yields a higher recovery for smaller Li 2 S 4 diffusion coefficients, suggesting that insufficient Li 2 S 4 mass transport is responsible for failure at the end of discharge. By identifying the effect that gel electrolytes have on the state of the battery during discharge using both experimental and simulation methods, this work is a step towards leveraging the advantages of gel electrolytes and mitigating their weaknesses.

25 ENERGY STORAGE↗

DOE OSTI2023

TRISO Burnup-Dependent Failure Analysis of a HTGR Design-Basis Accident Using BISON

Here, this work assesses the failure behavior of the silicon carbide (SiC) layer in TRIstructural ISOtropic (TRISO) fuel particles with BISON during both steady-state and transient conditions for the MHTGR-350 design by General Atomics. A one-dimensional BISON model for a uranium oxycarbide–bearing TRISO is developed to simulate a power level of 50 mW/particles up to 12.4% fissions per initial metal atom (FIMA). Stress predictions for the materials of interest are presented as a function of burnup, along with the SiC failure probability computed using Weibull statistics under the assumption of realistic SiC quality.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

NASA NTRS2000

Wormhole Formation in RSRM Nozzle Joint Backfill

The RSRM nozzle uses a barrier of RTV rubber upstream of the nozzle O-ring seals. Post flight inspection of the RSRM nozzle continues to reveal occurrence of "wormholes" into the RTV backfill. The term "wormholes", sometimes called "gas paths", indicates a gas flow path not caused by pre-existing voids, but by a little-understood internal failure mode of the material during motor operation. Fundamental understanding of the mechanics of the RSRM nozzle joints during motor operation, nonlinear viscoelastic characterization of the RTV backfill material, identification of the conditions that predispose the RTV to form wormholes, and screening of candidate replacement materials is being pursued by a joint effort between Thiokol Propulsion, NASA, and the Army Propulsion & Structures Directorate at Redstone Arsenal. The performance of the RTV backfill in the joint is controlled by the joint environment. Joint movement, which applies a tension and shear load on the material, coupled with the introduction of high pressure gas in combination create an environment that exceeds the capability of the material to withstand the wormhole effect. Little data exists to evaluate why the material fails under the modeled joint conditions, so an effort to characterize and evaluate the material under these conditions was undertaken. Viscoelastic property data from characterization testing will anchor structural analysis models. Data over a range of temperatures, environmental pressures, and strain rates was used to develop a nonlinear viscoelastic model to predict material performance, develop criteria for replacement materials, and quantify material properties influencing wormhole growth. Three joint simulation analogs were developed to analyze and validate joint thermal barrier (backfill) material performance. Two exploratory tests focus on detection of wormhole failure under specific motor operating conditions. A "validation" test system provides data to "validate" computer models and predictions. Finally, two candidate replacement materials are being screened and "validated" using the developed test systems.

Stevens, J.↗

DOE OSTI2022

Pellet cladding mechanical interaction as a potential failure mechanism during a control rod drop accident in a boiling water reactor

Boiling water reactors (BWRs) represent approximately one-third of the operating fleet in the United States, contributing significantly towards the global effort in reducing carbon emissions. Even though most of the operating fleet has been in operation for quite some time, continued advancements in new nuclear fuel (such as accident tolerant fuel) or operating regimes (such as power up-rates and higher burnup operation) necessitates similar advancements in modeling and simulation capabilities. Bison, a component of the Virtual Environment for Reactor Applications (VERA), is a high-fidelity fuel performance code able to explore the fuel performance of a wide variety of fuel types in one-, two-, and three-dimensions. Until recently, the code had not been used for analyses of BWRs. Modeling capabilities have been added for Gd-bearing UO{sub 2} and pure zirconium liners. New models have been added based upon the U.S. Nuclear Regulatory Commission (NRC) guide-lines for hydrogen pickup in Zircaloy-2 claddings and pellet-clad mechanical interaction (PCMI) failure during a reactivity insertion accident (RIA), known as a rod drop accident (CRDA) in BWRs. Implementing and/or improving Bison modeling capabilities extended its analytical reach to areas beyond its original intended purpose. This paper demonstrates one of these capabilities as a proof of concept. Recently developed models enable Bison to provide an alternate approach for cladding integrity determination in CRDA evaluations, which currently use bounding conservative estimates. As part of this demonstration, NRC guidance on hydrogen-pickup and PCMI failure models were utilized in this research. Even though more research is needed in establishing right inputs and process in this area, this paper demonstrates Bison's ability to determine cladding integrity in a CRDA evaluation. This first of a kind demonstration is a proof of concept in this area, which could potentially be extended to a number of other areas where a more accurate cladding integrity determination would be needed. (authors)

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

NASA NTRS2017

Degradation and ESR Failures in MnO2 Chip Tantalum Capacitors

Equivalent series resistance (ESR) of chip tantalum capacitors determines the rate of energy delivery and power dissipation thus affecting temperature and reliability of the parts. Employment of advanced capacitors with reduced ESR decreases power losses and improves efficiency in power systems. Stability of ESR is essential for correct operations of power units and might cause malfunctioning and failures when ESR becomes too high or too low. Several cases with ESR values in CWR29 capacitors exceeding the specified limit that were observed recently raised concerns regarding environmental factors affecting ESR and the adequacy of the existing screening and qualification testing. In this work, results of stress testing of various types of military and commercial capacitors obtained over years by GSFC test lab and NEPP projects that involved ESR measurements are described. Environmental stress tests include testing in humidity and vacuum chambers, temperature cycling, long-term storage at high temperatures, and various soldering simulation tests. Note that in many cases parts failed due to excessive leakage currents or reduced breakdown voltages. However, only ESR-related degradation and failures are discussed. Mechanisms of moisture effect are discussed and recommendations to improve screening and qualification system are suggested.

Equivalent Series Resistance (ESR)↗

NASA NTRS2017

Extraction-Separation Performance and Dynamic Modeling of Orion Test Vehicles with Adams Simulation: 3rd Edition

NASA's Orion Capsule Parachute Assembly System (CPAS) Project is now in the qualification phase of testing, and the Adams simulation has continued to evolve to model the complex dynamics experienced during the test article extraction and separation phases of flight. The ability to initiate tests near the upper altitude limit of the Orion parachute deployment envelope requires extractions from the aircraft at 35,000 ft-MSL. Engineering development phase testing of the Parachute Test Vehicle (PTV) carried by the Carriage Platform Separation System (CPSS) at altitude resulted in test support equipment hardware failures due to increased energy caused by higher true airspeeds. As a result, hardware modifications became a necessity requiring ground static testing of the textile components to be conducted and a new ground dynamic test of the extraction system to be devised. Force-displacement curves from static tests were incorporated into the Adams simulations, allowing prediction of loads, velocities and margins encountered during both flight and ground dynamic tests. The Adams simulation was then further refined by fine tuning the damping terms to match the peak loads recorded in the ground dynamic tests. The failure observed in flight testing was successfully replicated in ground testing and true safety margins of the textile components were revealed. A multi-loop energy modulator was then incorporated into the system level Adams simulation model and the effect on improving test margins be properly evaluated leading to high confidence ground verification testing of the final design solution.

Varela, Jose G.↗