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NASA NTRS2004

Investigation of Gear and Bearing Fatigue Damage Using Debris Particle Distributions

A diagnostic tool was developed for detecting fatigue damage to spur gears, spiral bevel gears, and rolling element bearings. This diagnostic tool was developed and evaluated experimentally by collecting oil debris data from fatigue tests performed in the NASA Glenn Spur Gear Fatigue Rig, Spiral Bevel Gear Test Facility, and the 500hp Helicopter Transmission Test Stand. During each test, data from an online, in-line, inductance type oil debris sensor was monitored and recorded for the occurrence of pitting damage. Results indicate oil debris alone cannot discriminate between bearing and gear fatigue damage.

Dempsey, Paula J.↗

NASA NTRS2004

Prediction of STS-107 Hypervelocity Flow Fields about the Shuttle Orbiter with Various Wing Leading Edge Damage

Computations were performed for damaged configurations of the Shuttle Orbiter in support of the STS-107 Columbia accident investigation. Two configurations with missing wing leading-edge reinforced carbon-carbon (RCC) panels were evaluated at conditions just prior to the peak heating trajectory point. The initial configuration modeled the Orbiter with an approximate missing RCC panel 6 to determine whether this damage could result in anomalous temperatures measured during the STS-107 reentry. This missing RCC panel 6 computation was found to produce heating augmentation factors of 5 times the nominal heating rates on the side fuselage with lesser heat increases on the front of the OMS pod. This is consistent with the thermocouple and resistance temperature detector sensors from the STS-107 re-entry which observed off nominal high early in the re-entry trajectory. A second damaged configuration modeled the Orbiter with missing RCC panel 9 and included ingestion of the flow into the outboard RCC channel. This computation lowered the level (only 2 times nominal) and moved the location of the heating augmentation on the leeside fuselage relative to the missing RCC panel 6 configuration. The lesser heating augmentation for missing RCC panel 9 was confined near the wing fuselage juncture. Near nominal heating was predicted on the remainder of the side fuselage with some lower than nominal heating on the front surface of the OMS pod. These results for missing RCC panel 9 are consistent with data from the STS-107 re-entry where the heating augmentation was observed to move off the side fuselage and OMS pod sensors at later times in the trajectory. As this solution requires supersonic mass ingestion into the RCC channel, it is probably not an appropriate model prior to penetration of the flow through the spar into the wing structure. It may, however, be representative of the conditions at later times and could account for the movement of the heating signature on the side fuselage.

Pulsonetti, Maria V.↗

NASA NTRS2001

Radiation-induced DNA damage and chromatin structure

DNA lesions induced by ionizing radiation in cells are clustered and not randomly distributed. For low linear energy transfer (LET) radiation this clustering occurs mainly on the small scales of DNA molecules and nucleosomes. For example, experimental evidence suggests that both strands of DNA on the nucleosomal surface can be damaged in single events and that this damage occurs with a 10-bp modulation because of protection by histones. For high LET radiation, clustering also occurs on a larger scale and depends on chromatin organization. A particularly significant clustering occurs when an ionizing particle traverses the 30 nm chromatin fiber with generation of heavily damaged DNA regions with an average size of about 2 kbp. On an even larger scale, high LET radiation can produce several DNA double-strand breaks in closer proximity than expected from randomness. It is suggested that this increases the probability of misrejoining of DNA ends and generation of lethal chromosome aberrations.

Review↗

NASA NTRS1995

Review of spaceflight and hindlimb suspension unloading induced sarcomere damage and repair

Hindlimb suspension unloading (HSU) and spaceflight microgravity induce atrophy of the slow adductor longus muscle fibers which, following reloading, exhibit eccentric contraction (EC)-like lesions (abnormal widening of sarcomeres with A band disruption and excessively wavy, extracted Z lines). These lesions are similar morphologically to those produced in normal muscles after strenuous eccentric exercise. It appears that atrophic muscles exhibit increased susceptibility to eccentric damage because lesions are produced during nonstressful voluntary movements upon return to weightbearing. The EC-like lesions are absent in the unweighted conditions, but appear in HSU rats 15-60 minutes after reloading and in space-flown rates about 4 hrs after landing. By 12 hours, many EC-like lesioned sarcomeres are fully covered by longitudinal patches of Z line-like material which increases in density by 48 hours, producing the so-called "Z line streaming" morphology. In this case, Z line streaming is indicative of rapid repair of damaged sarcomeres rather than the onset of sarcomere breakdown. Immunoelectron microscopy is necessary to determine the composition of this dense material. By 9 days of reloading at 1 gravity, sarcomeres have regained normal structure, except for very rare persistence of faint Z patches. The morphological data indicate that Z patches serve at least two functions: 1) to permit contractile force to be transmitted across the damaged sarcomeres and 2) to provide a scaffold upon which sarcomeres are reconstructed in an active functional muscle.

NASA Discipline Number 00-00↗

NASA NTRS1996

DNA damage and repair in oncogenic transformation by heavy ion radiation

Energetic heavy ions are present in galactic cosmic rays and solar particle events. One of the most important late effects in risk assessment is carcinogenesis. We have studied the carcinogenic effects of heavy ions at the cellular and molecular levels and have obtained quantitative data on dose-response curves and on the repair of oncogenic lesions for heavy particles with various charges and energies. Studies with repair inhibitors and restriction endonucleases indicated that for oncogenic transformation DNA is the primary target. Results from heavy ion experiments showed that the cross section increased with LET and reached a maximum value of about 0.02 micrometer2 at about 500 keV/micrometer. This limited size of cross section suggests that only a fraction of cellular genomic DNA is important in radiogenic transformation. Free radical scavengers, such as DMSO, do not give any effect on induction of oncogenic transformation by 600 MeV/u iron particles, suggesting most oncogenic damage induced by high-LET heavy ions is through direct action. Repair studies with stationary phase cells showed that the amount of reparable oncogenic lesions decreased with an increase of LET and that heavy ions with LET greater than 200 keV/micrometer produced only irreparable oncogenic damage. An enhancement effect for oncogenic transformation was observed in cells irradiated by low-dose-rate argon ions (400 MeV/u; 120 keV/micrometer). Chromosomal aberrations, such as translocation and deletion, but not sister chromatid exchange, are essential for heavy-ion-induced oncogenic transformation. The basic mechanism(s) of misrepair of DNA damage, which form oncogenic lesions, is unknown.

NASA Discipline Number 45-10↗

NASA NTRS2001

Cell killing and chromatid damage in primary human bronchial epithelial cells irradiated with accelerated 56Fe ions

We examined cell killing and chromatid damage in primary human bronchial epithelial cells irradiated with high-energy 56Fe ions. Cells were irradiated with graded doses of 56Fe ions (1 GeV/nucleon) accelerated with the Alternating Gradient Synchrotron at Brookhaven National Laboratory. The survival curves for cells plated 1 h after irradiation (immediate plating) showed little or no shoulder. However, the survival curves for cells plated 24 h after irradiation (delayed plating) had a small initial shoulder. The RBE for 56Fe ions compared to 137Cs gamma rays was 1.99 for immediate plating and 2.73 for delayed plating at the D10. The repair ratio (delayed plating/immediate plating) was 1.67 for 137Cs gamma rays and 1.22 for 56Fe ions. The dose-response curves for initially measured and residual chromatid fragments detected by the Calyculin A-mediated premature chromosome condensation technique showed a linear response. The results indicated that the induction frequency for initially measured fragments was the same for 137Cs gamma rays and 56Fe ions. On the other hand, approximately 85% of the fragments induced by 137Cs gamma rays had rejoined after 24 h of postirradiation incubation; the corresponding amount for 56Fe ions was 37%. Furthermore, the frequency of chromatid exchanges induced by gamma rays measured 24 h after irradiation was higher than that induced by 56Fe ions. No difference in the amount of chromatid damage induced by the two types of radiations was detected when assayed 1 h after irradiation. The results suggest that high-energy 56Fe ions induce a higher frequency of complex, unrepairable damage at both the cellular and chromosomal levels than 137Cs gamma rays in the target cells for radiation-induced lung cancers.

NASA Discipline Radiation Health↗

NASA NTRS2004

Monte Carlo Techniques for Calculations of Charge Deposition and Displacement Damage from Protons in Visible and Infrared Sensor Arrays

This slide presentation examines motivation for Monte Carlo methods, charge deposition in sensor arrays, displacement damage calculations, and future work. The discussion of charge deposition sensor arrays includes Si active pixel sensor APS arrays and LWIR HgCdTe FPAs. The discussion of displacement damage calculations includes nonionizing energy loss (NIEL), HgCdTe NIEL calculation results including variance, and implications for damage in HgCdTe detector arrays.

Marshall, Paul↗

NASA NTRS2004

An Interface Damage Model for the Simulation of Delamination Under Variable-Mode Ratio in Composite Materials

A thermodynamically consistent damage model for the simulation of progressive delamination under variable mode ratio is presented. The model is formulated in the context of the Damage Mechanics (DM). The constitutive equations that result from the variation of the free energy with damage are used to model the initiation and propagation of delamination. A new delamination initiation criterion is developed to assure that the formulation can account for changes in the loading mode in a thermodynamically consistent way. Interfacial penetration of two adjacent layers after complete decohesion is prevented by the formulation of the free energy. The model is implemented into the commercial finite element code ABAQUS by means of a user-written decohesion element. Finally, the numerical predictions given by the model are compared with experimental results.

Turon, Albert↗

NASA NTRS2004

Transmission Bearing Damage Detection Using Decision Fusion Analysis

A diagnostic tool was developed for detecting fatigue damage to rolling element bearings in an OH-58 main rotor transmission. Two different monitoring technologies, oil debris analysis and vibration, were integrated using data fusion into a health monitoring system for detecting bearing surface fatigue pitting damage. This integrated system showed improved detection and decision-making capabilities as compared to using individual monitoring technologies. This diagnostic tool was evaluated by collecting vibration and oil debris data from tests performed in the NASA Glenn 500 hp Helicopter Transmission Test Stand. Data was collected during experiments performed in this test rig when two unanticipated bearing failures occurred. Results show that combining the vibration and oil debris measurement technologies improves the detection of pitting damage on spiral bevel gears duplex ball bearings and spiral bevel pinion triplex ball bearings in a main rotor transmission.

Dempsey, Paula J.↗

NASA NTRS2004

Mechanical Data for Use in Damage Tolerance Analyses

This report describes the results of a research program to determine the damage tolerance properties of metallic propeller materials. Three alloys were selected for investigation: 2025-T6 Aluminum, D6AC Steel and 4340 Steel. Mechanical response, fatigue (S-N) and fatigue crack growth rate data are presented for all of the alloys. The main conclusions that can be drawn from this study are as follows. The damage tolerant design of a propeller system will require a complete understanding of the fatigue crack growth threshold. There exists no experimental procedure to reliably develop the fatigue crack growth threshold data that is needed for damage tolerant design methods. Significant research will be required to fully understand the fatigue crack growth threshold. The development of alternative precracking methods, evaluating the effect of specimen configuration and attempting to identify micromechanical issues are simply the first steps to understanding the mechanics of the threshold.

Forth, Scott C.↗

NASA NTRS2003

The Carrier's Liability for Damage Caused by Delay in International Air Transport

Delay in the air transport occurs when passengers, baggage or cargo do not arrive at their destination at the time indicated in the contract of carriage. The causes of delay in the carriage of passengers are booking errors or double booking, delayed departure of aircraft, incorrect information regarding the time of departure, failure to land at the scheduled destination and changes in flight schedule or addition of extra landing stops. Delay in the carriage of baggage or cargo may have different causes: no reservation, lack of space, failure to load the baggage or cargo at the right place, or to deliver the covering documents at the right place. The Montreal Convention of 1999 Article 19 provides that 'The carrier is liable for damage occasioned by delay in the carriage by air of passengers, baggage or cargo. Nevertheless, the carder shall not be liable for damage occasioned by delay if it proves that it and its servants and agents took all measures that could reasonably be required to avoid the damage or that it was impossible for it or them to take such measures'. The Montreal Convention Article 22 provides liability limits of the carrier in case of delay for passengers and their baggage and for cargo. In the carriage of persons, the liability of the carrier for each passenger is limited to 4,150 SDR. In the carriage of baggage, the liability of the carrier is limited to 1,000 SDR for each passenger unless a special declaration as to the value of the baggage has been made. In the carriage of cargo, the liability of the carrier is limited to 17 SDR per kilogram unless a special declaration as to the value of the cargo has been made. The Montreal Convention Article 19 has shortcomings: it is silent on the duration of the liability for carriage,andit does not make any distinction between persons and good. It does not give any indication concerning the circumstances to be taken into account in cases of delay, and about the length of delay. In conclusion, it is desirable to define the period of carriage with accuracy, and to insert the word 'unreasonable' in Article 19.

Lee, Kang Bin↗

NASA NTRS2005

Single Particle Damage Events in Candidate Star Camera Sensors

Si charge coupled devices (CCDs) are currently the preeminent detector in star cameras as well as in the near ultraviolet (uv) to visible wavelength region for astronomical observations in space and in earth-observing space missions. Unfortunately, the performance of CCDs is permanently degraded by total ionizing dose (TID) and displacement damage effects. TID produces threshold voltage shifts on the CCD gates and displacement damage reduces the charge transfer efficiency (CTE), increases the dark current, produces dark current nonuniformities and creates random telegraph noise in individual pixels. In addition to these long term effects, cosmic ray and trapped proton transients also interfere with device operation on orbit. In the present paper, we investigate the dark current behavior of CCDs - in particular the formation and annealing of hot pixels. Such pixels degrade the ability of a CCD to perform science and also can present problems to the performance of star camera functions (especially if their numbers are not correctly anticipated). To date, most dark current radiation studies have been performed by irradiating the CCDs at room temperature but this can result in a significantly optimistic picture of the hot pixel count. We know from the Hubble Space Telescope (HST) that high dark current pixels (so-called hot pixels or hot spikes) accumulate as a function of time on orbit. For example, the HST Advanced Camera for Surveys/Wide Field Camera instrument performs monthly anneals despite the loss of observational time, in order to partially anneal the hot pixels. Note that the fact that significant reduction in hot pixel populations occurs for room temperature anneals is not presently understood since none of the commonly expected defects in Si (e.g. divacancy, E center, and A-center) anneal at such a low temperature. A HST Wide Field Camera 3 (WFC3) CCD manufactured by E2V was irradiated while operating at -83C and the dark current studied as a function of temperature while the CCD was warmed to a sequence of temperatures up to a maximum of +30C. The device was then cooled back down to -83 and re-measured. Hot pixel populations were tracked during the warm-up and cool-down. Hot pixel annealing began below 40C and the anneal process was largely completed before the detector reached +3OC. There was no apparent sharp temperature dependence in the annealing. Although a large fraction of the hot pixels fell below the threshold to be counted as a hot pixel, they nevertheless remained warmer than the remaining population. The details of the mechanism for the formation and annealing of hot pixels is not presently understood, but it appears likely that hot pixels are associated with displacement damage occurring in high electric field regions.

Marshall, Paul↗

NASA NTRS2005

Thermographic Characterization of Impact Damage in SiC/SiC Composite Materials

SiC/SiC composite materials targeted as turbine components for next-generation aero-engines are being investigated at NASA Glenn Research Center. In order to examine damage mechanisms in these materials, SiC/SiC coupons were impacted with 1.59 mm diameter steel spheres at increasing velocities from 115 m/s to 400 m/s. Pulsed thermography, a nondestructive evaluation technique that monitors the thermal response of a sample over time, was utilized to characterize the impact damage. A thermal standard of similar material was fabricated to aid in the interpretation of the thermographic data and to provide information regarding thermography system detection capabilities in 2.4 mm thick SiC/SiC composite materials. Flat bottom holes at various depths with aspect ratios greater than 2.5 were detectable in the thermal images. In addition, the edges of holes at depths of 1.93 mm into the sample were not as resolvable as flat bottom holes closer to the surface. Finally, cooling behavior was characterized in SiC/SiC materials and used to determine impact damage depth within an 8.5% error of a known depth.

Fox, Dennis S.↗

NASA NTRS1998

Continuum Damage Mechanics Used to Predict the Creep Life of Monolithic Ceramics

Significant improvements in propulsion and power generation for the next century will require revolutionary advances in high-temperature materials and structural design. Advanced ceramics are candidate materials for these elevated temperature applications. High-temperature and long-duration applications of monolithic ceramics can place their failure mode in the creep rupture regime. An analytical methodology in the form of the integrated design program-Ceramics Analysis and Reliability Evaluation of Structures/Creep (CARES/Creep) has been developed by the NASA Lewis Research Center to predict the life of ceramic structural components subjected to creep rupture conditions. This program utilizes commercially available finite element packages and takes into account the transient state of stress and creep strain distributions (stress relaxation as well as the asymmetric response to tension and compression). The creep life of a component is discretized into short time steps, during which the stress distribution is assumed constant. Then, the damage is calculated for each time step on the basis of a modified Monkman-Grant (MMG) creep rupture criterion. The cumulative damage is subsequently calculated as time elapses in a manner similar to Miner's rule for cyclic fatigue loading. Failure is assumed to occur when the normalized cumulative damage at any point in the component reaches unity. The corresponding time is the creep rupture life for that component.

Powers, Lynn M.↗

NASA NTRS2001

Damage Assessment of Creep Tested and Thermally Aged Metallic Alloys Using Acousto-Ultrasonics

In recent years emphasis has been placed on the early detection of material changes experienced in turbine powerplant components. During the scheduled overhaul of a turbine, the current techniques of examination of various hot section components aim to find flaws such as cracks, wear, and erosion, as well as excessive deformations. Thus far, these localized damage modes have been detected with satisfactory results. However, the techniques used to find these flaws provide no information on life until the flaws are actually detected. Major improvements in damage assessment, safety, as well as more accurate life prediction could be achieved if nondestructive evaluation (NDE) techniques could be utilized to sense material changes that occur prior to the localized defects mentioned. Because of elevated temperatures and excessive stresses, turbine components may experience creep behavior. As a result, it is desirable to monitor and access the current condition of such components. Research at the NASA Glenn Research Center involves developing and utilizing an NDE technique that discloses distributed material changes that occur prior to the localized damage detected by the current methods of inspection. In a recent study, creep processes in a nickel-base alloy were the life-limiting condition of interest, and the NDE technique was acousto-ultrasonics (AU). AU is an NDE technique that utilizes two ultrasonic transducers to interrogate the condition of a test specimen. The sending transducer introduces an ultrasonic pulse at a point on the surface of the specimen while a receiving transducer detects the signal after it has passed through the material. The goal of the method is to correlate certain parameters of the detected waveform to characteristics of the material between the two transducers. Here, the waveform parameter of interest is the attenuation due to internal damping for which information is being garnered from the frequency domain. The parameters utilized to indirectly quantify the attenuation are the ultrasonic decay rate as well as various moments of the frequency power spectrum. A new, user-friendly, graphical interface AU system was developed at NASA Glenn. This system is an all-inclusive, multifunction system that controls the sending and receiving ultrasonic transducers as well as all posttest signal analysis. The system's postprocessing software calculates the multiple parameters used to study the material of interest.

Gyekenyesi, Andrew L.↗

NASA NTRS2005

Optical Sensing using Fiber Bragg Gratings for Monitoring Structural Damage in Composite Over-Wrapped Vessels

Composite Over-Wrap Vessels are widely used in the aerospace community. They are made of thin-walled bottles that are over wrapped with high strength fibers embedded in a matrix material. There is a strong drive to reduce the weight of space borne vehicles and thus pushes designers to adopt COPVs that are over wrapped with graphite fibers embedded in its epoxy matrix. Unfortunately, this same fiber-matrix configuration is more susceptible to impact damage than others and to make matters worse; there is a regime where impacts that damage the over wrap leave no visible scar on the COPV surface. In this paper FBG sensors are presented as a means of monitoring and detecting these types of damage. The FBG sensors are surface mounted to the COPVs and optically interrogated to explore the structural properties of these composite pressure vessels. These gratings optically inscribed into the core of a single mode fiber are used as a tool to monitor the stress strain relation in the composite matrix. The response of these fiber-optic sensors is investigated by pressurizing the cylinder up to its burst pressure of around 4500 psi. A Fiber Optic Demodulation System built by Blue Road Research, is used for interrogation of the Bragg gratings.

Grant, Joseph↗

NASA NTRS2005

Inspection of the Math Model Tools for On-Orbit Assessment of Impact Damage Report

In Spring of 2005, the NASA Engineering Safety Center (NESC) was engaged by the Space Shuttle Program (SSP) to peer review the suite of analytical tools being developed to support the determination of impact and damage tolerance of the Orbiter Thermal Protection Systems (TPS). The NESC formed an independent review team with the core disciplines of materials, flight sciences, structures, mechanical analysis and thermal analysis. The Math Model Tools reviewed included damage prediction and stress analysis, aeroheating analysis, and thermal analysis tools. Some tools are physics-based and other tools are empirically-derived. Each tool was created for a specific use and timeframe, including certification, real-time pre-launch assessments, and real-time on-orbit assessments. The tools are used together in an integrated strategy for assessing the ramifications of impact damage to tile and RCC. The NESC teams conducted a peer review of the engineering data package for each Math Model Tool. This report contains the summary of the team observations and recommendations from these reviews.

Harris, Charles E.↗

NASA NTRS2005

Computational Simulation of Damage Propagation in Three-Dimensional Woven Composites

Three dimensional (3D) woven composites have demonstrated multi-directional properties and improved transverse strength, impact resistance, and shear characteristics. The objective of this research is to develop a new model for predicting the elastic constants, hygrothermal effects, thermomechanical response, and stress limits of 3D woven composites; and to develop a computational tool to facilitate the evaluation of 3D woven composite structures with regard to damage tolerance and durability. Fiber orientations of weave and braid patterns are defined with reference to composite structural coordinates. Orthotropic ply properties and stress limits computed via micromechanics are transformed to composite structural coordinates and integrated to obtain the 3D properties. The various stages of degradation, from damage initiation to collapse of structures, in the 3D woven structures are simulated for the first time. Three dimensional woven composite specimens with various woven patterns under different loading conditions, such as tension, compression, bending, and shear are simulated in the validation process of this research. Damage initiation, growth, accumulation, and propagation to fracture are included in these simulations.

Huang, Dade↗