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At least 1,189 records · Page 66

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DOE OSTI2025

Stress accommodation in nanoscale dolan bridges designed for superconducting qubits

Josephson junctions are the principal circuit element in numerous superconducting quantum information devices and can be readily integrated into large-scale electronics. However, device integration at the wafer scale necessarily depends on having a reliable, high-fidelity, and high-yield fabrication method for creating Josephson junctions. When creating Al/AlO x based superconducting qubits, the standard Josephson junction fabrication method relies on a sub-micron suspended resist bridge, known as a Dolan bridge, which tends to be particularly fragile and can often times fracture during the resist development process, ultimately resulting in device failure. In this work, we demonstrate a unique Josephson junction lithography mask design that incorporates stress-relief channels. Our simulation results show that the addition of stress-relief channels reduces the lateral stress in the Dolan bridge by more than 70% for all the bridge geometries investigated. In practice, our novel mask design significantly increased the survivability of the bridge during device processing, resulting in 100% yield for over 100 Josephson junctions fabricated.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

DOE OSTI2023

Automatic Time Step Control to Resolve Hydromechanically Driven Fault Reactivation, Spontaneous Nucleation, and Seismic Arrest

Abstract A physical understanding of the progression from flow‐driven (quasi‐static) poromechanical deformation to dynamic fault rupture is critical to the resilient operations of several engineering systems. These processes are bridged by a progression from fault reactivation to the spontaneous nucleation of unstable sliding. Toward addressing this challenge, novel automatic time step size control methods are developed to enable accurate and efficient simulation of these dynamics and transitions from the first principles. The controllers combine local models for discretization error and Coulomb failure conditions to automatically adjust the time step size across several orders of magnitude. The methods do not require additional empirical or theoretical input and can resolve the pre‐rupture, interseismic, and seismic periods to the allowed accuracy. The computational results reveal that the proposed methods automatically capture the onset of reactivation and nucleation for homogeneous and heterogeneous fields. Hydrodynamic and structural heterogeneity lead to disparate critical nucleation sizes compared to those predicted by theory. The results highlight its potential in predicting induced seismicity in realistic subsurface engineering systems and at practical scales.

Environmental Sciences & Ecology↗

NASA NTRS1973

Life prediction of turbine components: On-going studies at the NASA Lewis Research Center

An overview is presented of the many studies at NASA-Lewis that form the turbine component life prediction program. This program has three phases: (1) development of life prediction methods for major failure modes through materials studies, (2) evaluation and improvement of these methods through a variety of burner rig studies on simulated components in research engines and advanced rigs. These three phases form a cooperative, interdisciplinary program. A bibliography of Lewis publications on fatigue, oxidation and coatings, and turbine engine alloys is included.

Spera, D. A.↗

NASA NTRS1988

Analysis of the Space Shuttle Orbiter skin panels under simulated hydrodynamic loads

The Space Shuttle orbiter skin panels were analyzed under pressure loads simulating hydrodynamic loads to determine their capability to sustain a potential ditching and to determine pressures that typically would produce failures. Two Dynamic Crash Analysis of Structures (DYCAST) finite element models were used. One model was used to represent skin panels (bays) in the center body, while a second model was used to analyze a fuselage bay in the wing region of the orbiter. From an assessment of the DYCAST nonlinear computer results, it is concluded that the probability is extremely high that most, if not all, of the lower skin panels would rupture under ditching conditions. Extremely high pressure loads which are produced under hydrodynamic planning conditions far exceed the very low predicted failure pressures for the skin panels. Consequently, a ditching of the orbiter is not considered to have a high probability of success and should not be considered a means of emergency landing unless no other option exists.

Carden, Huey D.↗

NASA NTRS1988

Advances in turbulent transport modeling based on direct simulations of turbulence

Recent work using numerical simulations to study the modeling of scalar transport is outlined. A model developed by reference to simulations for homogeneous shear flow is presented. This model predicts cross-gradient transports that can give rise to the illusion of counter-gradient transport. The model is found to work remarkably well when compared to simulations for channel flow, but fails to predict important features of the scalar fluxes in mixing layers. Reasons for this failure are discussed and suggestions are made for future work.

Reynolds, W. C.↗

NASA NTRS1989

CONFIG - Adapting qualitative modeling and discrete event simulation for design of fault management systems

CONFIG is a modeling and simulation tool prototype for analyzing the normal and faulty qualitative behaviors of engineered systems. Qualitative modeling and discrete-event simulation have been adapted and integrated, to support early development, during system design, of software and procedures for management of failures, especially in diagnostic expert systems. Qualitative component models are defined in terms of normal and faulty modes and processes, which are defined by invocation statements and effect statements with time delays. System models are constructed graphically by using instances of components and relations from object-oriented hierarchical model libraries. Extension and reuse of CONFIG models and analysis capabilities in hybrid rule- and model-based expert fault-management support systems are discussed.

Malin, Jane T.↗

NASA NTRS1992

Summary: Experimental validation of real-time fault-tolerant systems

Testing and validation of real-time systems is always difficult to perform since neither the error generation process nor the fault propagation problem is easy to comprehend. There is no better substitute to results based on actual measurements and experimentation. Such results are essential for developing a rational basis for evaluation and validation of real-time systems. However, with physical experimentation, controllability and observability are limited to external instrumentation that can be hooked-up to the system under test. And this process is quite a difficult, if not impossible, task for a complex system. Also, to set up such experiments for measurements, physical hardware must exist. On the other hand, a simulation approach allows flexibility that is unequaled by any other existing method for system evaluation. A simulation methodology for system evaluation was successfully developed and implemented and the environment was demonstrated using existing real-time avionic systems. The research was oriented toward evaluating the impact of permanent and transient faults in aircraft control computers. Results were obtained for the Bendix BDX 930 system and Hamilton Standard EEC131 jet engine controller. The studies showed that simulated fault injection is valuable, in the design stage, to evaluate the susceptibility of computing sytems to different types of failures.

Iyer, R. K.↗

NASA NTRS2001

Hyper-X Stage Separation: Simulation Development and Results

This paper provides an overview of stage separation simulation development and results for NASA's Hyper-X program; a focused hypersonic technology effort designed to move hypersonic, airbreathing vehicle technology from the laboratory environment to the flight environment. This paper presents an account of the development of the current 14 degree of freedom stage separation simulation tool (SepSim) and results from use of the tool in a Monte Carlo analysis to evaluate the risk of failure for the separation event. Results from use of the tool show that there is only a very small risk of failure in the separation event.

Reubush, David E.↗

NASA NTRS2003

NEXT Ion Optics Simulation via ffx

Simulations of the erosion processes for two proposed sets of ion thruster grids for the NEXT project are presented. Structural failure and electron backstreaming due to accelerator grid erosion are discussed as two possible failure mechanisms of these grid sets. The TAG grid set was seen to outperform the NSTAR grid set both in terms of margin against electron backstreaming and accelerator grid mass loss for a variety of operating points. An investigation into the possibility of reducing the accelerator grid voltage magnitude for the TAG grid set showed improved propellant throughput capability.

Soulas, George↗

NASA NTRS1990

Design/Analysis of the JWST ISIM Bonded Joints for Survivability at Cryogenic Temperatures

A major design and analysis challenge for the JWST ISIM structure is thermal survivability of metal/composite bonded joints below the cryogenic temperature of 30K (-405 F). Current bonded joint concepts include internal invar plug fittings, external saddle titanium/invar fittings and composite gusset/clip joints all bonded to M55J/954-6 and T300/954-6 hybrid composite tubes (75mm square). Analytical experience and design work done on metal/composite bonded joints at temperatures below that of liquid nitrogen are limited and important analysis tools, material properties, and failure criteria for composites at cryogenic temperatures are sparse in the literature. Increasing this challenge is the difficulty in testing for these required tools and properties at cryogenic temperatures. To gain confidence in analyzing and designing the ISIM joints, a comprehensive joint development test program has been planned and is currently running. The test program is designed to produce required analytical tools and develop a composite failure criterion for bonded joint strengths at cryogenic temperatures. Finite element analysis is used to design simple test coupons that simulate anticipated stress states in the flight joints; subsequently the test results are used to correlate the analysis technique for the final design of the bonded joints. In this work, we present an overview of the analysis and test methodology, current results, and working joint designs based on developed techniques and properties.

Bartoszyk, Andrew↗

NASA NTRS2009

An Overview of the State of the Art in Atomistic and Multiscale Simulation of Fracture

The emerging field of nanomechanics is providing a new focus in the study of the mechanics of materials, particularly in simulating fundamental atomic mechanisms involved in the initiation and evolution of damage. Simulating fundamental material processes using first principles in physics strongly motivates the formulation of computational multiscale methods to link macroscopic failure to the underlying atomic processes from which all material behavior originates. This report gives an overview of the state of the art in applying concurrent and sequential multiscale methods to analyze damage and failure mechanisms across length scales.

Saether, Erik↗

NASA NTRS2009

Probabilistic Estimation of Critical Flaw Sizes in the Primary Structure Welds of the Ares I-X Launch Vehicle

The primary structure of the Ares I-X Upper Stage Simulator (USS) launch vehicle is constructed of welded mild steel plates. There is some concern over the possibility of structural failure due to welding flaws. It was considered critical to quantify the impact of uncertainties in residual stress, material porosity, applied loads, and material and crack growth properties on the reliability of the welds during its pre-flight and flight. A criterion--an existing maximum size crack at the weld toe must be smaller than the maximum allowable flaw size--was established to estimate the reliability of the welds. A spectrum of maximum allowable flaw sizes was developed for different possible combinations of all of the above listed variables by performing probabilistic crack growth analyses using the ANSYS finite element analysis code in conjunction with the NASGRO crack growth code. Two alternative methods were used to account for residual stresses: (1) The mean residual stress was assumed to be 41 ksi and a limit was set on the net section flow stress during crack propagation. The critical flaw size was determined by parametrically increasing the initial flaw size and detecting if this limit was exceeded during four complete flight cycles, and (2) The mean residual stress was assumed to be 49.6 ksi (the parent material s yield strength) and the net section flow stress limit was ignored. The critical flaw size was determined by parametrically increasing the initial flaw size and detecting if catastrophic crack growth occurred during four complete flight cycles. Both surface-crack models and through-crack models were utilized to characterize cracks in the weld toe.

Pai, Shantaram S.↗

NASA NTRS2010

Automatically Finding the Control Variables for Complex System Behavior

Testing large-scale systems is expensive in terms of both time and money. Running simulations early in the process is a proven method of finding the design faults likely to lead to critical system failures, but determining the exact cause of those errors is still time-consuming and requires access to a limited number of domain experts. It is desirable to find an automated method that explores the large number of combinations and is able to isolate likely fault points. Treatment learning is a subset of minimal contrast-set learning that, rather than classifying data into distinct categories, focuses on finding the unique factors that lead to a particular classification. That is, they find the smallest change to the data that causes the largest change in the class distribution. These treatments, when imposed, are able to identify the factors most likely to cause a mission-critical failure. The goal of this research is to comparatively assess treatment learning against state-of-the-art numerical optimization techniques. To achieve this, this paper benchmarks the TAR3 and TAR4.1 treatment learners against optimization techniques across three complex systems, including two projects from the Robust Software Engineering (RSE) group within the National Aeronautics and Space Administration (NASA) Ames Research Center. The results clearly show that treatment learning is both faster and more accurate than traditional optimization methods.

Gay, Gregory↗

NASA NTRS2005

Comprehensive Micromechanics-Analysis Code - Version 4.0

Version 4.0 of the Micromechanics Analysis Code With Generalized Method of Cells (MAC/GMC) has been developed as an improved means of computational simulation of advanced composite materials. The previous version of MAC/GMC was described in "Comprehensive Micromechanics-Analysis Code" (LEW-16870), NASA Tech Briefs, Vol. 24, No. 6 (June 2000), page 38. To recapitulate: MAC/GMC is a computer program that predicts the elastic and inelastic thermomechanical responses of continuous and discontinuous composite materials with arbitrary internal microstructures and reinforcement shapes. The predictive capability of MAC/GMC rests on a model known as the generalized method of cells (GMC) - a continuum-based model of micromechanics that provides closed-form expressions for the macroscopic response of a composite material in terms of the properties, sizes, shapes, and responses of the individual constituents or phases that make up the material. Enhancements in version 4.0 include a capability for modeling thermomechanically and electromagnetically coupled ("smart") materials; a more-accurate (high-fidelity) version of the GMC; a capability to simulate discontinuous plies within a laminate; additional constitutive models of materials; expanded yield-surface-analysis capabilities; and expanded failure-analysis and life-prediction capabilities on both the microscopic and macroscopic scales.

Arnold, S. M.↗

NASA NTRS2013

Comparative Study of Vibration Condition Indicators for Detecting Cracks in Spur Gears

This paper reports the results of an empirical study on the tooth breakage failure mode in spur gears. Of four dominant gear failure modes (breakage, wear, pitting, and scoring), tooth breakage is the most precipitous and often leads to catastrophic failures. The cracks were initiated using a fatigue tester and a custom-designed single-tooth bending fixture to simulate over-load conditions, instead of traditional notching using wire electrical discharge machining (EDM). The cracks were then propagated on a dynamometer. The ground truth of damage level during crack propagation was monitored with crack-propagation sensors. Ten crack propagations have been performed to compare the existing condition indicators (CIs) with respect to their: ability to detect a crack, ability to assess the damage, and sensitivity to sensor placement. Of more than thirty computed CIs, this paper compares five commonly used: raw RMS, FM0, NA4, raw kurtosis, and NP4. The performance of combined CIs was also investigated, using linear, logistic, and boosted regression trees based feature fusion.

Nanadic, Nenad↗

NASA NTRS2014

Land Surface Microwave Emissivity Dynamics: Observations, Analysis and Modeling

Land surface microwave emissivity affects remote sensing of both the atmosphere and the land surface. The dynamical behavior of microwave emissivity over a very diverse sample of land surface types is studied. With seven years of satellite measurements from AMSR-E, we identified various dynamical regimes of the land surface emission. In addition, we used two radiative transfer models (RTMs), the Community Radiative Transfer Model (CRTM) and the Community Microwave Emission Modeling Platform (CMEM), to simulate land surface emissivity dynamics. With both CRTM and CMEM coupled to NASA's Land Information System, global-scale land surface microwave emissivities were simulated for five years, and evaluated against AMSR-E observations. It is found that both models have successes and failures over various types of land surfaces. Among them, the desert shows the most consistent underestimates (by approx. 70-80%), due to limitations of the physical models used, and requires a revision in both systems. Other snow-free surface types exhibit various degrees of success and it is expected that parameter tuning can improve their performances.

Modeling↗

NASA NTRSDate not supplied

Finite Element Modeling of Plastic Deformation During Spin Forming of Aluminum 6061-O

Spin and flow forming are metal deformation techniques in which a disk or tube of material is radially thinned and axially lengthened over a rotating mandrel. A finite-element continuum model (FEM) based on commercial software (DEFORM®) was developed to determine the stress/strain distribution and damage accumulation in a flow-formed, near-net-shape part. Computational validation and experimental verification of the model was leveraged to assess the effectiveness of computer simulations. Quantitative comparisons between experimental and computational results show promise for applying a FEM to the flow forming process. Experimental failure locations correlated well with computed damage gradients, and there was good agreement between the measured and predicted roller forces during forming.

Elizabeth Urig↗

NASA NTRSDate not supplied

Off-Nominal Event Analysis in Autonomous Flights Based on Explainable Artificial Intelligence

A key objective in the Urban Air Mobility program at NASA is to intelligently perform an autonomous flight in a complex urban environment under all weather conditions with guaranteed levels of safety. To accomplish this, the mission manager (central decision-making module) of the vehicle needs to make informed decisions between various Courses of Action (CoA) based on its' interpretation of the inputs it receives. If an off-nominal event is detected either based on the amalgamation of sensor data or the use of machine learning models, the mission manager may greatly benefit from identification of the input features that most likely contributed to that specific event. Such an understanding is usually not possible to obtain from the classical machine learning models (deep learning) due to the inherent black box like structure. However, this understanding is achieved using eXplainable Artificial Intelligence (XAI) models that provide a human interpretable rationale for the predictions made. This work presents a game theory inspired XAI model for the off-nominal assessment of autonomous flights. The proposed approach based on Shapley values is model agnostic, provides local as well as global explanation and satisfies the four axioms (efficiency, symmetry, dummy, additivity) to achieve fair contribution. The versatility of the approach is first demonstrated on a simulated dataset in which the significance of each input to flight phase prediction is clearly identified. Subsequently, data from simulated flight trajectories are fed into the model which reveal the input features that most likely contributed to a rotor failure event thereby empowering the mission manager to take the appropriate CoA.

autonomy↗