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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 1,405 records · Page 78

All sources NASA NTRS DOE OSTI

NASA NTRS2006

Nitrile/Buna N Material Failure Assessment for an O-Ring used on the Gaseous Hydrogen Flow Control Valve (FCV) of the Space Shuttle Main Engine

After the rollout of Space Shuttle Discovery in April 2005 in preparation for return-to-flight, there was a failure of the Orbiter (OV-103) helium signature leak test in the gaseous hydrogen (GH2) system. Leakage was attributed to the Flow Control Valve (FCV) in Main Engine 3. The FCV determined to be the source of the leak for OV-103 is designated as LV-58. The nitrile/Buna N rubber O-ring seal was removed from LV-58, and failure analysis indicated radial cracks providing leak paths in one quadrant. Cracks were eventually found in 6 of 9 FCV O-rings among the three Shuttle Orbiters, though none were as severe as those for LV-58, OV-103. Testing by EM10 at MSFC on all 9 FCV O- rings included: laser dimensional, Shore A hardness and properties from a dynamic mechanical analyzer (DMA) and an Instron tensile machine. The following test data was obtained on the cracked quadrant of the LV-58, OV-103 O-ring: (1) the estimated compression set was only 9.5%, compared to none for the rest of the O-ring; (2) Shore A hardness for the O.D. was higher by almost 4 durometer points than for the rest of the O-ring; and (3) DMA data showed that the storage/elastic modulus E was almost 25% lower than for the rest of the O-ring. Of the 8 FCV O-rings tested on an Instron, 4 yielded tensile strengths that were below the MIL spec requirement of 1350 psi-a likely influence of rubber cracking. Comparisons were made between values of modulus determined by DNA (elastic) and Instron (Young s). Each nitrile/Buna N O-ring used in the FCV conforms to the MIL-P-25732C specification. A number of such O-rings taken from shelf storage at MSFC and Kennedy Space Center (KSC) were used to generate a reference curve of DMA glass transition temperature (Tg) vs. shelf storage time ranging from 8 to 26 years. A similar reference curve of TGA onset temperature (of rubber weight loss) vs. shelf storage time was also generated. The DMA and TGA data for the used FCV O-rings were compared to the reference curves. Correlations were also made between the DMA modulus (at 22 C) and Shore A hardness for all 9 of the FCV O-rings used among the three Shuttle Orbiters. The radial cracking in the FCV O-rings was determined to be due to ozone attack, as nitrile/Buna N rubber is susceptible to such attack. Nitrile/Buna N material under MIL-P25732C should be used in a hydraulic fluid environment to help protect it from cracking. However, the FCV O-rings were used in an air only environment. The FCV design has as much as a 9-mil gap that allows the O.D. of the O-ring to be directly exposed to ozone, pressurized air and some elevated temperatures, accelerating the weathering process that leads to O-ring cracking. Space Shuttle flights will likely not continue past 2010. Therefore, Shuttle management decided to continue using the nitrile/Buna N material for the FCVs, but have each O-ring replaced after 3 years to minimize any chances for crack initiation.

Wingard, Doug↗

NASA NTRS2007

Flight Test Results from the NF-15B Intelligent Flight Control System (IFCS) Project with Adaptation to a Simulated Stabilator Failure

Adaptive flight control systems have the potential to be more resilient to extreme changes in airplane behavior. Extreme changes could be a result of a system failure or of damage to the airplane. A direct adaptive neural-network-based flight control system was developed for the National Aeronautics and Space Administration NF-15B Intelligent Flight Control System airplane and subjected to an inflight simulation of a failed (frozen) (unmovable) stabilator. Formation flight handling qualities evaluations were performed with and without neural network adaptation. The results of these flight tests are presented. Comparison with simulation predictions and analysis of the performance of the adaptation system are discussed. The performance of the adaptation system is assessed in terms of its ability to decouple the roll and pitch response and reestablish good onboard model tracking. Flight evaluation with the simulated stabilator failure and adaptation engaged showed that there was generally improvement in the pitch response; however, a tendency for roll pilot-induced oscillation was experienced. A detailed discussion of the cause of the mixed results is presented.

Bosworth, John T.↗

NASA NTRS2007

Flight Test Results from the NF-15B Intelligent Flight Control System (IFCS) Project with Adaptation to a Simulated Stabilator Failure

Bosworth, John T.↗

NASA NTRS2003

Method and system for detecting a failure or performance degradation in a dynamic system such as a flight vehicle

A method and system for detecting a failure or performance degradation in a dynamic system having sensors for measuring state variables and providing corresponding output signals in response to one or more system input signals are provided. The method includes calculating estimated gains of a filter and selecting an appropriate linear model for processing the output signals based on the input signals. The step of calculating utilizes one or more models of the dynamic system to obtain estimated signals. The method further includes calculating output error residuals based on the output signals and the estimated signals. The method also includes detecting one or more hypothesized failures or performance degradations of a component or subsystem of the dynamic system based on the error residuals. The step of calculating the estimated values is performed optimally with respect to one or more of: noise, uncertainty of parameters of the models and un-modeled dynamics of the dynamic system which may be a flight vehicle or financial market or modeled financial system.

Miller, Robert H.↗

NASA NTRS2008

Aircraft Loss-of-Control Accident Prevention: Switching Control of the GTM Aircraft with Elevator Jam Failures

Switching control, servomechanism, and H2 control theory are used to provide a practical and easy-to-implement solution for the actuator jam problem. A jammed actuator not only causes a reduction of control authority, but also creates a persistent disturbance with uncertain amplitude. The longitudinal dynamics model of the NASA GTM UAV is employed to demonstrate that a single fixed reconfigured controller design based on the proposed approach is capable of accommodating an elevator jam failure with arbitrary jam position as long as the thrust control has enough control authority. This paper is a first step towards solving a more comprehensive in-flight loss-of-control accident prevention problem that involves multiple actuator failures, structure damages, unanticipated faults, and nonlinear upset regime recovery, etc.

Chang, Bor-Chin↗

NASA NTRS2009

Lunar Module Electrical Power System Design Considerations and Failure Modes

This slide presentation reviews the design and redesign considerations of the Apollo lunar module electrical power system. Included in the work are graphics showing the lunar module power system. It describes the in-flight failures, and the lessons learned from these failures.

Interbartolo, Michael↗

NASA NTRS2009

CSM RCS Design Considerations and Failure Modes

Objectives include: a) Define major Command and Service Module (CSM) design considerations; b) List Command Module (CM) RCS failures and lessons learned; and c) List Service Module (SM) RCS failures and lessons learned.

Interbartolo, Michael↗

NASA NTRS2009

When Failure Means Success: Accepting Risk in Aerospace Development

Over the last three decades, NASA has been diligent in qualifying systems for human space flight. As the Agency transitions from operating the Space Shuttle, its employees must learn to accept higher risk levels to generate the data needed to certify its next human space flight system. The Marshall Center s Engineering workforce is developing the Ares I crew launch vehicle and designing the Ares V cargo launch vehicle for safety, reliability, and cost-effective operations. This presentation will provide a risk retrospective, using first-hand examples from the Delta Clipper-Experimental Advanced (DC-XA) and the X-33 single-stage-to-orbit flight demonstrators, while looking ahead to the upcoming Ares I-X uncrewed test flight. The DC-XA was successfully flown twice in 26 hours, setting a new turnaround-time record. Later, one of its 3 landing gears did not deploy, it tipped over, and was destroyed. During structural testing, the X-33 s advanced composite tanks were unable to withstand the forces to which it was subjected and the project was later cancelled. These are examples of successful failures, as the data generated are captured in databases used by vehicle designers today. More recently, the Ares I-X flight readiness review process was streamlined in keeping with the mission's objectives, since human lives are not at stake, which reflects the beginning of a cultural change. Failures are acceptable during testing, as they provide the lessons that actually lead to mission success. These and other examples will stimulate the discussion of when to accept risk in aerospace projects.

Dumbacher, Daniel L.↗

NASA NTRS2009

An Indirect Adaptive Control Scheme in the Presence of Actuator and Sensor Failures

The problem of controlling a system in the presence of unknown actuator and sensor faults is addressed. The system is assumed to have groups of actuators, and groups of sensors, with each group consisting of multiple redundant similar actuators or sensors. The types of actuator faults considered consist of unknown actuators stuck in unknown positions, as well as reduced actuator effectiveness. The sensor faults considered include unknown biases and outages. The approach employed for fault detection and estimation consists of a bank of Kalman filters based on multiple models, and subsequent control reconfiguration to mitigate the effect of biases caused by failed components as well as to obtain stability and satisfactory performance using the remaining actuators and sensors. Conditions for fault identifiability are presented, and the adaptive scheme is applied to an aircraft flight control example in the presence of actuator failures. Simulation results demonstrate that the method can rapidly and accurately detect faults and estimate the fault values, thus enabling safe operation and acceptable performance in spite of failures.

Sun, Joy Z.↗

NASA NTRS2009

Development, Testing, and Failure Mechanisms of a Replicative Ice Phase Change Material Heat Exchanger

Phase change materials (PCM) may be useful for thermal control systems that involve cyclical heat loads or cyclical thermal environments such as Low Earth Orbit (LEO) and Low Lunar Orbit (LLO). Thermal energy can be stored in the PCM during peak heat loads or in adverse thermal environments. The stored thermal energy can then be released later during minimum heat loads or in more favorable thermal environments. One advantage that PCM s have over evaporators in this scenario is that they do not use a consumable. Wax PCM units have been baselined for the Orion thermal control system and also provide risk mitigation for the Altair Lander. However, the use of water as a PCM has the potential for significant mass reduction since the latent heat of formation of water is approximately 70% greater than that of wax. One of the potential drawbacks of using ice as a PCM is its potential to rupture its container as water expands upon freezing. In order to develop a space qualified ice PCM heat exchanger, failure mechanisms must first be understood. Therefore, a methodical experimental investigation has been undertaken to demonstrate and document specific failure mechanisms due to ice expansion in the PCM. An ice PCM heat exchanger that replicates the thermal energy storage capacity of an existing wax PCM unit was fabricated and tested. Additionally, methods for controlling void location in order to reduce the risk of damage due to ice expansion are investigated. This paper presents the results to date of this investigation.

Leimkuehler, Thomas O.↗

NASA NTRS2009

Multiscale Failure Analysis of Laminated Composite Panels Subjected to Blast Loading Using FEAMAC/Explicit

This preliminary report demonstrates the capabilities of the recently developed software implementation that links the Generalized Method of Cells to explicit finite element analysis by extending a previous development which tied the generalized method of cells to implicit finite elements. The multiscale framework, which uses explicit finite elements at the global-scale and the generalized method of cells at the microscale is detailed. This implementation is suitable for both dynamic mechanics problems and static problems exhibiting drastic and sudden changes in material properties, which often encounter convergence issues with commercial implicit solvers. Progressive failure analysis of stiffened and un-stiffened fiber-reinforced laminates subjected to normal blast pressure loads was performed and is used to demonstrate the capabilities of this framework. The focus of this report is to document the development of the software implementation; thus, no comparison between the results of the models and experimental data is drawn. However, the validity of the results are assessed qualitatively through the observation of failure paths, stress contours, and the distribution of system energies.

Pineda, Evan J.↗

NASA NTRS2009

Evaluating Failures and Near Misses in Human Spaceflight History for Lessons for Future Human Spaceflight

There have been a number of studies done in the past drawn on lessons learned with regard to human loss-of-life events. Generally, the systemic causes and proximate causes for fatal events have both been examined in considerable detail. However, an examination of near-fatal accidents and failures that narrowly missed being fatal could be equally useful, not only in detecting causes, both proximate and systemic, but also for determining what factors averted disaster, what design decisions and/or operator actions prevented catastrophe. Additionally, review of risk factors for upcoming or future programs will often look at trending statistics, generally focusing on failure/success statistics. Unfortunately, doing so can give a skewed or misleading view of past reliability or a reliability that cannot be presumed to apply to a new program. One reason for this might be that failure/success criteria aren't the same across programs, but also that apparent success can hide systemic faults that, under other circumstances, can be fatal to a program with different parameters. A program with a number of near misses can look more reliable than a consistently healthy program with a single out-of-family failure and provide very misleading data if it is not examined in detail. This is particularly true for a manned space program where failure/success includes more than making a particular orbit. Augmenting reliability evaluations with this near miss data can provide insight and expand on the limitations of a strictly pass/fail evaluation. Even more importantly, a thorough understanding of these near miss events can identify conditions that prevented fatalities. Those conditions may be key to a programs reliability, but, without insight to the repercussions if such conditions were not in place, their importance may not be readily clear. As programs mature and political and fiscal responsibilities come to the fore, often there is considerable incentive to eliminate unnecessary conservatism, design margin, redundancy, operational support, testing, training, or safety oversight. An evaluation that demonstrates how these features and capabilities averted disaster can ensure processes that saved lives or missions are not discarded without appropriate review and understanding. Close examination of accidents that almost were can also highlight differences in design from one program to another, either justifying reliability comparisons or negating them. It can also provide considerable insight into how those saving factors were developed and implemented so that similar methods can be used to ensure appropriate life-saving and mission saving factors can be developed, even for a dissimilar space program. The lessons are appropriate for seasoned manned space programs and agencies, but crucial for untried agencies and organizations that are interested in sending man into space. The large body of publicly available near miss and accident data available provide invaluable insight into programmatic, technical, and even political issues that can be addressed before they impact safety. In this paper, we examine a number of these near misses and accidents and steps a program, agency, or potential spacefaring company might take to improve their chances of success and avoid mission or safety disasters using this data.

Barr, Stephanie↗

NASA NTRS2009

Failure Analysis of Sapphire Refractive Secondary Concentrators

Failure analysis was performed on two sapphire, refractive secondary concentrators (RSC) that failed during elevated temperature testing. Both concentrators failed from machining/handling damage on the lens face. The first concentrator, which failed during testing to 1300 C, exhibited a large r-plane twin extending from the lens through much of the cone. The second concentrator, which was an attempt to reduce temperature gradients and failed during testing to 649 C, exhibited a few small twins on the lens face. The twins were not located at the origin, but represent another mode of failure that needs to be considered in the design of sapphire components. In order to estimate the fracture stress from fractographic evidence, branching constants were measured on sapphire strength specimens. The fractographic analysis indicated radial tensile stresses of 44 to 65 MPa on the lens faces near the origins. Finite element analysis indicated similar stresses for the first RSC, but lower stresses for the second RSC. Better machining and handling might have prevented the fractures, however, temperature gradients and resultant thermal stresses need to be reduced to prevent twinning.

Salem, Jonathan A.↗

NASA NTRS2010

Development, Testing, and Failure Mechanisms of a Replicative Ice Phase Change Material Heat Exchanger

Phase change materials (PCM) may be useful for thermal control systems that involve cyclical heat loads or cyclical thermal environments such as Low Earth Orbit (LEO) and Low Lunar Orbit (LLO). Thermal energy can be stored in the PCM during peak heat loads or in adverse thermal environments. The stored thermal energy can then be released later during minimum heat loads or in more favorable thermal environments. One advantage that PCM's have over evaporators in this scenario is that they do not use a consumable. Wax PCM units have been baselined for the Orion thermal control system and also provide risk mitigation for the Altair Lander. However, the use of water as a PCM has the potential for significant mass reduction since the latent heat of formation of water is approximately 70% greater than that of wax. One of the potential drawbacks of using ice as a PCM is its potential to rupture its container as water expands upon freezing. In order to develop a space qualified ice PCM heat exchanger, failure mechanisms must first be understood. Therefore, a methodical experimental investigation has been undertaken to demonstrate and document specific failure mechanisms due to ice expansion in the PCM. An ice PCM heat exchanger that replicates the thermal energy storage capacity of an existing wax PCM unit was fabricated and tested. Additionally, methods for controlling void location in order to reduce the risk of damage due to ice expansion are investigated. This paper presents the results to date of this investigation. Nomenclature

Leimkuehler, Thomas O.↗

NASA NTRS2010

Analysis of the STS-126 Flow Control Valve Structural-Acoustic Coupling Failure

During the Space Transportation System mission STS-126, one of the main engine's flow control valves incurred an unexpected failure. A section of the valve broke off during liftoff. It is theorized that an acoustic mode of the flowing fuel, coupled with a structural mode of the valve, causing a high cycle fatigue failure. This report documents the analysis efforts conducted in an attempt to verify this theory. Hand calculations, computational fluid dynamics, and finite element methods are all implemented and analyses are performed using steady-state methods in addition to transient analysis methods. The conclusion of the analyses is that there is a critical acoustic mode that aligns with a structural mode of the valve

Jones, Trevor M.↗

NASA NTRS2009

A New Monte Carlo Filtering Method for the Diagnosis of Mission-Critical Failures

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 settings most likely to cause a mission-critical failure. This research benchmarks two treatment learning methods against standard 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. It is shown that these treatment learners are both faster than traditional methods and show demonstrably better results.

Gay, Gregory↗

NASA NTRS2010

Flight Test Results from the NF-15B Intelligent Flight Control System (IFCS) Project with Adaptation to a Simulated Stabilator Failure

Bosworth, John T.↗

NASA NTRS2001

Hybrid Modeling for Scenario-Based Evaluation of Failure Effects in Advanced Hardware-Software Designs

This paper describes an incremental scenario-based simulation approach to evaluation of intelligent software for control and management of hardware systems. A hybrid continuous/discrete event simulation of the hardware dynamically interacts with the intelligent software in operations scenarios. Embedded anomalous conditions and failures in simulated hardware can lead to emergent software behavior and identification of missing or faulty software or hardware requirements. An approach is described for extending simulation-based automated incremental failure modes and effects analysis, to support concurrent evaluation of intelligent software and the hardware controlled by the software

Malin, Jane T.↗