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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 1,207 records · Page 67

All sources NASA NTRS DOE OSTI

NASA NTRS1993

Analysis of bolt-loaded elliptical holes in laminated composite joints

The feasibility of changing the bolt shape from circular to elliptical in order to increase the joint strength was investigated. An analytical method using a cosine series to represent the bearing stress was derived, and a boundary collocation method was used to determine the unknown coefficients of this cosine series. Stresses at the hole edge predicted by the analytical method agreed very well with finite element solutions. Failure analyses of joints in two different laminates were performed, and each laminate exhibited a different joint failure mode. Results demonstrate that the joint strength of both laminates can be improved substantially by changing the bolt shape to elliptical. The joint that failed in a bearing mode showed a greater strength increase compared to the joint that failed in a shearing mode.

Wang, J. T.↗

DOE OSTI2014

Enhanced Component Performance Study. Emergency Diesel Generators 1998–2013

This report presents an enhanced performance evaluation of emergency diesel generators (EDGs) at U.S. commercial nuclear power plants. This report evaluates component performance over time using Institute of Nuclear Power Operations (INPO) Consolidated Events Database (ICES) data from 1998 through 2013 and maintenance unavailability (UA) performance data using Mitigating Systems Performance Index (MSPI) Basis Document data from 2002 through 2013. The objective is to present an analysis of factors that could influence the system and component trends in addition to annual performance trends of failure rates and probabilities. The factors analyzed for the EDG component are the differences in failures between all demands and actual unplanned engineered safety feature (ESF) demands, differences among manufacturers, and differences among EDG ratings. Statistical analyses of these differences are performed and results showing whether pooling is acceptable across these factors. In addition, engineering analyses were performed with respect to time period and failure mode. The factors analyzed are: sub-component, failure cause, detection method, recovery, manufacturer, and EDG rating.

20 FOSSIL-FUELED POWER PLANTS↗

NASA NTRS1992

Life support systems for Mars transit

The structural elements of life-support systems are reviewed in order to assess the suitability of specific features for use during a Mars mission. Life-support requirements are estimated by means of an approximate input/output analysis, and the advantages are listed relating to the use of recycling and regeneration techniques. The technological options for regeneration are presented in categories such as CO2 reduction, organics removal, polishing, food production, and organics oxidation. These data form the basis of proposed mission requirements and constraints as well as the definition of what constitutes an adequate reserve. Regenerative physical/chemical life-support systems are championed based exclusively on the mass savings inherent in the technology. The resiliency and 'soft' failure modes of bioregenerative life-support systems are identified as areas of investigation.

Macelroy, R. D.↗

NASA NTRSDate not supplied

Knowledge Discovery for Early Failure Assessment of Complex Engineered Systems Using Natural Language Processing

Emerging complex engineered systems may have unexpected safety issues due to novel operational environments, increasing autonomy, human-machine interaction, and other factors. To prevent failures in operation or testing that necessitate costly redesign, it is desirable to predict likely failure modes early in the design process. Text-based information about past engineering failures presents one possible solution by facilitating the retrieval of information that can inform new designs. However, identifying documents containing relevant information and extracting required information can be prohibitively time-consuming when implemented at scale. In this research, an automated natural language processing-based framework is proposed to discover relevant knowledge from documents containing failure-related design information. Documents containing usable information are filtered using sentiment analysis based on a custom lexicon specialized for engineering design and by filtering out documents containing only irrelevant topics. Next, from the identified usable documents, information relating to engineering failures, contributing factors that can be controlled at design time (“risk factors”), and recommended preventative actions are extracted. Semantic similarity is then used to group similar pieces of extracted information for improved generalizability. The proposed framework is applied to NASA’s Lessons Learned Information System (LLIS). The framework can be used to identify documents containing usable failure-related design information from other databases, extract relevant information from these documents, and generalize the acquired knowledge such that it can be applied to novel systems.

Sequoia R. Andrade↗

DOE OSTI2015

Mitigation of Micropitting in Wind Turbine Main Shaft Bearings

In recent years, increasing evidence of failures has been reported from spherical roller main bearings used in three-point mounting (TPM) drivetrains of wind turbines. One of the leading causes has been micropitting, a failure mode that is possibly overlooked by design, selection and life-prediction tools. It remains to be seen if retrofitting problematic spherical roller bearings (SRBs) with improved bearing design solutions can improve their durability. Questions to ask might be: ‘Are the operating conditions of the main bearing well understood?’ and ‘Are the failures caused by deficient design practice or other unidentified external sources within the system?’ These questions fundamentally challenge the underlying design basis and encourage the need for a system analysis approach that is currently being undertaken by researchers from the National Renewable Energy Laboratory (NREL). Specifically, this article discusses a few potential design alternatives and system-level reassessment to circumvent micropitting in main bearings used in TPM drivetrains.

17 WIND ENERGY↗

DOE OSTI2023

Failure analysis of nuclear transient-tested UN tristructural isotropic fuel particles in a 3D printed SiC matrix

Fully ceramic microencapsulated fuel elements containing UN tristructural isotropic (TRISO) fuel particles within a 3D printed SiC matrix were subjected to transient testing with varying energy depositions. Detailed post-irradiation examinations were performed, including leaching in hot HNO3 and post-leaching X-ray computed tomography, to quantify the percentage of failed TRISO particles and crack propagation within the particles and surrounding fuel matrix. In parallel, detailed finite element analyses were performed for comparison with experimental findings and to better evaluate transient failure modes. The lowest transient energy deposition—which still exceeded bounding values for high-temperature gas-cooled reactor applications—resulted in no detectable TRISO particle failures or matrix cracking, which was consistent with the simulations. Simulations of the higher-energy transients for which significant TRISO particle failure was expected were generally able to reproduce the transient temperatures and matrix cracking. Thus, the TRISO particle failures were explained based on the effects of local SiC matrix thickness and porosity. Results generally confirmed the high strength of the additively manufactured SiC matrix but also affirmed the need for a modified UN TRISO architecture to prevent SiC matrix cracks from propagating through TRISO layers. This unique failure mode has not historically been considered for TRISO fuels contained in weaker graphite matrices.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2018

The Phase Evolution and Degradation Modes of $ R\overline{3}$ m Li x Ni 1-y-z Co y Al z O 2 Electrodes Cycled Near Complete Delithiation

We report that the practical utilization of energy densities near the theoretical limit for $ R\overline{3}m$ layered oxide positive electrode materials is dependent on the stability of the electrochemical performance of these materials at or near full delithiation. In order to develop new chemistries and novel approaches towards the improvement of the electrochemical performance of these materials at such high states of charge, a robust understanding of the failure mechanisms limiting current materials is necessary. Thorough analysis of Li x Co 1-y Al y O 2 and Li x Ni 1-y Al y O 2 as well as Li x Ni 0.8 Co 0.2 O 2 and Li x Ni 0.8 Co 0.15 Al 0.05 O 2 (1 ≥ x ≥ 0 and 0.2 ≥ y ≥ 0) enabled the identification of key relationships between the transition metal chemistry of the electrode, its structural stability, and cycling characteristics at or near complete delithiation (4.75 V). Extensive characterization of these materials was achieved by a multitude of physical and electrochemical techniques to investigate the relative importance of surface vs. bulk phenomena. Here, the resulting insights derived from these analyses highlight the importance of the intrinsic structural and mechanical stability of the electrode when highly delithiated and establish guidelines for identifying positive electrode materials with improved high state of charge performance. Lastly, particularly important is the contrasting electrochemical impact of Al substitution into LiCoO 2 - and LiNiO 2 -based materials, which is shown to likely arise from the enhanced propensity for Al ions to migrate to the tetrahedral site in Co-rich compounds at high states of delithiation.

25 ENERGY STORAGE↗

DOE OSTI2025

In-device Battery Failure Analysis

Lithium-ion batteries are indispensable power sources for a wide range of modern electronic devices. However, battery lifespan remains a critical limitation, directly affecting the sustainability and user experience. Conventional battery failure analysis in controlled lab settings may not capture the complex interactions and environmental factors encountered in real-world, in-device operating conditions. Here, this study analyzes the failure of commercial wireless earbud batteries as a model system within their intended usage context. Through multiscale and multimodal characterizations, the degradations from the material level to the device level are correlated, elucidating a failure pattern that is closely tied to the specific device configuration and operating conditions. The findings indicate that the ultimate failure mode is determined by the interplay of battery materials, cell structural design, and the in-device microenvironment, such as temperature gradients and their fluctuations. This holistic, in-device perspective on environmental influences provides critical insights for battery integration design, enhancing the reliability of modern electronics.

36 MATERIALS SCIENCE↗

NASA NTRSDate not supplied

Lessons Learned from the Arecibo Observatory Auxiliary M4N Socket Analysis and Implications for Future Observatory Designs

The Arecibo Observatory collapsed after a progressive structural failure stemming from the failure of a single socket joint cable termination. A failure investigation was conducted to identify the cause of the first failed cable termination socket. Due to the nature of the suspended observatory receiver, the dominant source of loading in the suspension cables was due to deadload, with secondary contributions coming from environmental effects and observatory operation. The high ratio of deadload vs. live load applied to the cable over many years resulted in a creep failure mode of the cast zinc within the socket which further induced stress into the highly stress wires at the entrance of the socket. The design of the socket joint did not explicitly consider socket constituent stress margins and time-dependent damage mechanisms such as creep. Lessons learned from this investigation led to recommendations for revising civil engineering cable standards, and recommendations for manufacturers and designers. The design of cables employing socket terminations should consider the cumulative damage effects from creep and cyclic loading identify their corresponding worst-case inspectable defects or establish a sufficiently high factor of safety so that the design is sufficiently robust to defects and time-dependent failure modes. The design should specify end-of-life capability and set service life inspection intervals with pass/fail inspection criteria. Finally, trial studies on design iterations were conducted to increase the reliability of cables with socket joints.

Pavel Babuska↗

NASA NTRS2002

Effect of Environment on Stress-Rupture Behavior of a Carbon Fiber-Reinforced Silicon Carbide (C/SiC) Ceramic Matrix Composite

Stress-rupture tests were conducted in air, vacuum, and steam-containing environments to identify the failure modes and degradation mechanisms of a carbon fiber-reinforced silicon carbide (C/SiC) composite at two temperatures, 600 and 1200 C. Stress-rupture lives in air and steam containing environments (50 - 80% steam with argon) are similar for a composite stress of 69 MPa at 1200 C. Lives of specimens tested in a 20% steam/argon environment were about twice as long. For tests conducted at 600 C, composite life in 20% steam/argon was 20 times longer than life in air. Thermogravimetric analysis of the carbon fibers was conducted under similar conditions to the stress-rupture tests. The oxidation rate of the fibers in the various environments correlated with the composite stress-rupture lives. Examination of the failed specimens indicated that oxidation of the carbon fibers was the primary damage mode for specimens tested in air and steam environments at both temperatures.

Verrilli, Michael J.↗

NASA NTRS2004

Characterization of the Edge Crack Torsion (ECT) Test for Mode III Fracture Toughness Measurement of Laminated Composites

The edge crack torsion (ECT) test is designed to initiate mode III delamination growth in composite laminates. An ECT specimen is a rectangular laminate, containing an edge delamination at the laminate mid-plane. Torsion load is applied to the specimens, resulting in relative transverse shear sliding of the delaminated faces. The test data reduction schemes are intended to yield initiation values of critical mode III strain energy release rate, G(sub IIIc), that are constant with delamination length. The test has undergone several design changes during its development. The objective of this paper was to determine the suitability of the current ECT test design as a mode III fracture test. To this end, ECT tests were conducted on specimens manufactured from IM7/8552 and specimens made from S2/8552 tape laminates. Several specimens, each with different delamination lengths are tested. Detailed, three-dimensional finite element analyses of the specimens were performed. The analysis results were used to calculate the distribution of mode I, mode II, and mode III strain energy release rate along the delamination front. The results indicated that mode III-dominated delamination growth would be initiated from the specimen center. However, in specimens of both material types, the measured values of G(sub IIIc) exhibited significant dependence on delamination length. Furthermore, there was a large amount of scatter in the data. Load-displacement response of the specimens exhibited significant deviation from linearity before specimen failure. X-radiographs of a sample of specimens revealed that damage was initiated in the specimens prior to failure. Further inspection of the failure surfaces is required to identify the damage and determine that mode III delamination is initiated in the specimens.

Ratcliffe, James G.↗

NASA NTRS1976

Failure mechanics of fiber composite notched charpy specimens

A finite element stress analysis was performed to determine the stress variation in the vicinity of the notch and far field of fiber composites Charpy specimens (ASTM Standard). NASTRAN was used for the finite element analysis assuming linear behavior and equivalent static load. The unidirectional composites investigated ranged from Thornel 75 Epoxy to S-Glass/Epoxy with the fiber direction parallel to the long dimension of the specimen. The results indicate a biaxial stress state exists in (1) the notch vicinity which is dominated by transverse tensile and interlaminar shear and (2) near the load application point which is dominated by transverse compression and interlaminar shear. The results also lead to the postulation of hypotheses for the predominant failure modes, the fracture initiation, and the fracture process. Finally, the results indicate that the notched Charpy test specimen is not suitable for assessing the impact resistance of nonmetallic fiber composites directly.

Chamis, C. C.↗

NASA NTRS1982

The role of peel stresses in cyclic debonding

When an adhesively bonded joint is undergoing cyclic loading, one of the possible damage modes that occurs is called cyclic debonding - progressive separation of the adherends by failure of the adhesive bond under cyclic loading. In most practical structures, both peel and shear stresses exist in the adhesive bonding during cyclic loading. The results of an experimental and analytical study to determine the role of peel stresses on cyclic debonding in a mixed mode specimen are presented. Experimentally, this was done by controlling the forces that create the peel stresses by applying a clamping force to oppose the peel stresses. Cracked lap shear joints were chosen for this study. A finite element analysis was developed to assess the effect of the clamping force on the strain energy release rates due to shear and peel stresses. The results imply that the peel stress is the principal stress causing cyclic debonding.

Everett, R. A., Jr.↗

NASA NTRS1983

Analysis, testing, and evaluation of faulted and unfaulted Wye, Delta, and open Delta connected electromechanical actuators

Mathematical models capable of simulating the transient, steady state, and faulted performance characteristics of various brushless dc machine-PSA (power switching assembly) configurations were developed. These systems are intended for possible future use as primemovers in EMAs (electromechanical actuators) for flight control applications. These machine-PSA configurations include wye, delta, and open-delta connected systems. The research performed under this contract was initially broken down into the following six tasks: development of mathematical models for various machine-PSA configurations; experimental validation of the model for failure modes; experimental validation of the mathematical model for shorted turn-failure modes; tradeoff study; and documentation of results and methodology.

Nehl, T. W.↗

NASA NTRS1988

Delamination durability of composite materials for rotorcraft

Delamination is the most commonly observed failure mode in composite rotorcraft dynamic components. Although delamination may not cause immediate failure of the composite part, it often precipitates component repair or replacement, which inhibits fleet readiness, and results in increased life cycle costs. A fracture mechanics approach for analyzing, characterizing, and designing against delamination will be outlined. Examples of delamination problems will be illustrated where the strain energy release rate associated with delamination growth was found to be a useful generic parameter, independent of thickness, layup, and delamination source, for characterizing delamination failure. Several analysis techniques for calculating strain energy release rates for delamination from a variety of sources will be outlined. Current efforts to develop ASTM standard test methods for measuring interlaminar fracture toughness and developing delamination failure criteria will be reviewed. A technique for quantifying delamination durability due to cyclic loading will be presented. The use of this technique for predicting fatigue life of composite laminates and developing a fatigue design philosophy for composite structural components will be reviewed.

Obrien, T. Kevin↗

NASA NTRS1990

Simulated fault injection - A methodology to evaluate fault tolerant microprocessor architectures

A simulation-based fault-injection method for validating fault-tolerant microprocessor architectures is described. The approach uses mixed-mode simulation (electrical/logic analysis), and injects transient errors in run-time to assess the resulting fault impact. As an example, a fault-tolerant architecture which models the digital aspects of a dual-channel real-time jet-engine controller is used. The level of effectiveness of the dual configuration with respect to single and multiple transients is measured. The results indicate 100 percent coverage of single transients. Approximately 12 percent of the multiple transients affect both channels; none result in controller failure since two additional levels of redundancy exist.

Choi, Gwan S.↗

NASA NTRS2019

Multiple Boundary Layer Instability Modes with Nonequilibrium and Wall Temperature Effects Using LASTRAC

Prediction and control of boundary layer transition from laminar to turbulent is important to many flow regimes and vehicle designs, including vehicles operating at hypersonic conditions where nonequilibrium effects may be encountered. Wall cooling is known to affect the instability characteristics of the boundary layer and subsequently the transition location. Design considerations, including material failure and fuel chemistry, require the use of actively cooled walls in hypersonic vehicles, further motivating the study of wall temperature effects on top of the considerations of reducing heat flux, drag, and uncertainty. In this work, we analyze the stability of a boundary layer with chemical and thermal nonequilibrium on a Mach 20, 6 wedge. We investigate the effects of wall temperature on multiple unstable modes individually and on the integrated growth of disturbances along the surface. We use the LAngley Stability and TRansition Analysis Code (LASTRAC) to evaluate boundary layer stability, using capabilities implemented by the authors. Included are results that address chemical nonequilibrium with both thermal equilibrium and nonequilibrium.

Kline, H. L.↗

DOE OSTI2021

Hydrogen Component Leak Rate Quantification for System Risk and Reliability Assessment through QRA and PHM Frameworks: Preprint

The National Renewable Energy Laboratory's (NREL) Hydrogen Safety Research and Development (HSR&D) program in collaboration with the University of Maryland's Systems Risk and Reliability Analysis Laboratory (SyRRA) are working to improve reliability and reduce risk in hydrogen systems. This approach strives to use quantitative data on component leaks and failures, together with Prognosis and Health Management (PHM), and Quantitative Risk Assessment (QRA) to identify at-risk components, reduce component failures and downtime, and predict when components require maintenance. Hydrogen component failures increase facility maintenance cost, facility downtime, and reduce public acceptance of hydrogen technologies, ultimately increasing facility size and cost because of potentially overly conservative requirements. Leaks are a predominant failure mode for hydrogen components. However, uncertainties in the amount of hydrogen emitted from leaking components and the frequency of those failure events limit the understanding of the risks that they present under real-world operational conditions. NREL has deployed a test fixture, the Leak Rate Quantification Apparatus (LRQA), to quantify the mass flow rate of leaking gases from medium and high-pressure components that have failed while in service. Quantitative hydrogen leak rate data from this system could ultimately be used to better inform risk assessment and Regulation Codes and Standards (RCS). Parallel activity explores the use of PHM and QRA techniques to assess and reduce risk, thereby improving safety and reliability of hydrogen systems. The results of QRAs could further provide a systematic and science-based foundation for the design and implementation of RCS, as in the latest versions of the NFPA 2 code for gaseous hydrogen stations. Alternatively, data-driven techniques of PHM could provide new damage diagnosis and health-state prognosis tools. This research will help end users, station owners and operators, and regulatory bodies move towards risk-informed preventative maintenance versus emergency corrective maintenance, reducing cost and improving reliability. Predictive modelling of failures could improve safety and affect RCS requirements such as setback distances at liquid refuelling sites. The combination of leak rate quantification research, PHM, and QRA can lead to better informed models enabling data-based decision to be made for hydrogen system safety improvements.

codes and standards↗