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NASA NTRS2011

Failure Modes in Capacitors When Tested Under a Time-Varying Stress

Power-on failure has been the prevalent failure mechanism for solid tantalum capacitors in decoupling applications. A surge step stress test (SSST) has been previously applied to identify the critical stress level of a capacitor batch to give some predictability to the power-on failure mechanism [1]. But SSST can also be viewed as an electrically destructive test under a time-varying stress (voltage). It consists of rapidly charging the capacitor with incremental voltage increases, through a low resistance in series, until the capacitor under test is electrically shorted. When the reliability of capacitors is evaluated, a highly accelerated life test (HALT) is usually adopted since it is a time-efficient method of determining the failure mechanism; however, a destructive test under a time-varying stress such as SSST is even more time efficient. It usually takes days or weeks to complete a HALT test, but it only takes minutes for a time-varying stress test to produce failures. The advantage of incorporating a specific time-varying stress profile into a statistical model is significant in providing an alternative life test method for quickly revealing the failure mechanism in capacitors. In this paper, a time-varying stress that mimics a typical SSST has been incorporated into the Weibull model to characterize the failure mechanism in different types of capacitors. The SSST circuit and transient conditions for correctly surge testing capacitors are discussed. Finally, the SSST was applied for testing Ta capacitors, polymer aluminum capacitors (PA capacitors), and multi-layer ceramic (MLC) capacitors with both precious metal electrodes (PME) and base metal electrodes (BME). The test results are found to be directly associated with the dielectric layer breakdown in Ta and PA capacitors and are independent of the capacitor values, the way the capacitors were built, and the capacitors manufacturers. The test results also show that MLC capacitors exhibit surge breakdown voltages much higher than the rated voltage and that the breakdown field is inversely proportional to the dielectric layer thickness. The SSST data can also be used to comparatively evaluate the voltage robustness of capacitors for decoupling applications.

Liu, David (Donhang)↗

NASA NTRS1978

Conceptual design study of a Harrier V/STOL research aircraft

MCAIR recently completed a conceptual design study to define modification approaches to, and derive planning prices for the conversion of a two place Harrier to a V/STOL control, display and guidance research aircraft. Control concepts such as rate damping, attitude stabilization, velocity command, and cockpit controllers are to be demonstrated. Display formats will also be investigated, and landing, navigation and guidance systems flight tested. The rear cockpit is modified such that it can be quickly adapted to faithfully simulate the controls, displays and handling qualities of a Type A or Type B V/STOL. The safety pilot always has take command capability. The modifications studied fall into two categories: basic modifications and optional modifications. Technical descriptions of the basic modifications and of the optional modifications are presented. The modification plan and schedule as well as the test plan and schedule are presented. The failure mode and effects analysis, aircraft performance, aircraft weight, and aircraft support are discussed.

Bode, W. E.↗

NASA NTRS1979

Structural analysis of cylindrical thrust chambers, volume 1

Life predictions of regeneratively cooled rocket thrust chambers are normally derived from classical material fatigue principles. The failures observed in experimental thrust chambers do not appear to be due entirely to material fatigue. The chamber coolant walls in the failed areas exhibit progressive bulging and thinning during cyclic firings until the wall stress finally exceeds the material rupture stress and failure occurs. A preliminary analysis of an oxygen free high conductivity (OFHC) copper cylindrical thrust chamber demonstrated that the inclusion of cumulative cyclic plastic effects enables the observed coolant wall thinout to be predicted. The thinout curve constructed from the referent analysis of 10 firing cycles was extrapolated from the tenth cycle to the 200th cycle. The preliminary OFHC copper chamber 10-cycle analysis was extended so that the extrapolated thinout curve could be established by performing cyclic analysis of deformed configurations at 100 and 200 cycles. Thus the original range of extrapolation was reduced and the thinout curve was adjusted by using calculated thinout rates at 100 and 100 cycles. An analysis of the same underformed chamber model constructed of half-hard Amzirc to study the effect of material properties on the thinout curve is included.

Armstrong, W. H.↗

NASA NTRS1980

Effect of positive pulse charge waveforms on cycle life of nickel-zinc cells

Five amp-hour nickel-zinc cells were life cycled to evaluate four different charge methods. Three of the four waveforms investigated were 120 Hz full wave rectified sinusoidal (FWRS), 120 Hz silicon controlled rectified (SCR), and 1 kHz square wave (SW). The fourth, a constant current method, was used as a baseline of comparison. Three sealed Ni-Zn cells connected in series were cycled. Each series string was charged at an average c/20 rate, and discharged at a c/2.5 rate to a 75% rated depth. Results indicate that the relatively inexpensive 120 Hz FWRS charger appears feasible for charging 5 amp-hour nickel-zinc cells with no significant loss in average cycle life when compared to constant current charging. The 1-kHz SW charger could also be used with no significant loss in average cycle life, and suggests the possibility of utilizing the existing electric vehicle chopper controller circuitry for an on-board charger. There was an apparent difference using the 120 Hz SCR charger compared to the others, however, this difference could be due to an inadvertent severe overcharge, which occurred prior to cell failure. The remaining two positive pulse charging waveforms, FWRS and 1 kHz, did not improve the cycle life of 5 amp-hour nickel-zinc cells over that of constant current charging.

Smithrick, J. J.↗

NASA NTRS1991

Historical evidence for a connection between volcanic eruptions and climate change

The times of historical volcanic aerosol clouds were compared with changes in atmospheric temperatures on regional, hemispheric, and global scales. These involve either a direct comparison of individual significant eruption years with temperature records, or a comparison of eruption years with composited temperature records for several years before and after chosen sets of eruptions. Some studies have challenged the connection between individual eruptions and climate change. Mass and Portman (1989) recently suggested that the volcanic signal was present, but smaller than previously thought. In a study designed to test the idea that eruptions could cause small changes in climate, Hansen and other (1978) chose one of the best monitored eruptions at the time, the 1963 eruption of Agung volcano on the island of Bali. Using a simple radiation-balance model, in which an aerosol cloud in the tropics was simulated, this basic pattern of temperature change in the tropics and subtropics was reproduced. There may be natural limits to the atmospheric effects of any volcanic eruption. Self-limiting physical and chemical effects in eruption clouds were proposed. Model results suggest that aerosol microphysical processes of condensation and coagulation produce larger aerosols as the SO2 injection rate is increased. The key to discovering the greatest effects of volcanoes on short-term climate may be to concentrate on regional temperatures where the effects of volcanic aerosol clouds can be amplified by perturbed atmospheric circulation patterns, especially changes in mid-latitudes where meridional circulation patterns may develop. Such climatic perturbations can be detected in proxy evidence such as decreases in tree-ring widths and frost damage rings in climatically sensitive parts of the world, changes in treelines, weather anomalies such as unusually cold summers, severity of sea-ice in polar and subpolar regions, and poor grain yields and crop failures.

Rampino, Michael R.↗

NASA NTRS1996

Crack Development in Cross-Ply Laminates Under Uniaxial Tension

This study addresses matrix-dominated failures in carbon fiber/polymer matrix composite laminates in a cross-ply lay-up. The events of interest are interlaminar fracture in the form of transverse cracks in the 90' plies and longitudinal splitting in the 0 deg plies and interlaminar fracture in the form of 0/90 delamination. These events were observed using various nondestructive evaluation (NDE) techniques during static tensile tests. Acoustic emission (AE) x radiography, and edge view microscopy were the principal ones utilized in a real-time environment. A comparison of the NDE results with an analytical model based on the classical linear fracture mechanics concept of strain energy release rate as a criterion for crack growth was performed. The virtual crack closure theory was incorporated with a finite element model to generate strain energy release rate curves for the analytical case. Celion carbon fiber/polyimide matrix (G30-500/PMR-15) was the material tested with cross-ply lay-ups of (0(2)/90(6))s and (0(4)/90(4))s. The test specimens contained thermally induced cracks caused by the high-temperature processing. The analytical model was updated to compensate for the initial damage and to study further accumulation by taking into account the crack interactions. By correlating the experimental and analytical data, the critical energy release rates were found for the observable events of interest.

Gyekenyesi, Andrew L.↗

NASA NTRS1998

U.S. Civil Rotorcraft Accidents, 1963 through 1997

The U.S. National Transportation Safety Board (NTSB) has recorded 8,436 rotorcraft accidents during the period mid - 1963 through the end of 1997. Review and analysis of the NTSB summary narrative for each accident has been completed. In addition, FAA (Federal Aviation Administration) counts of the growing registered rotorcraft fleet over this period has obtained. Taken together, a large and informative data base is now available, which indicates that the accident rate (on a per airframe basis) has changed very little since the mid 1970s. The data base, even in the summary form provided by this paper, offers suggestions for safer designs and improved flight operations. For analysis purposes, each accident has been placed in one of 21 top level categories as defined by the NTSB. Analysis of this grouping shows that 70 percent of rotorcraft accidents are associated with four categories. The accident count in these top four categories are: (1) 2,408 Loss of engine power (2) 1,322 In flight collision with object (3) 1,114 Loss of control (4) 1,083 Airframe/component/system failure or malfunction. Single engine rotorcraft dominate these accident statistics because of their sheer numbers over the study period. One-third of the loss of engine power accidents with these aircraft is fuel/air mixture related and fuel exhaustion is a common event. This appears to be the case whether a piston or turbine engine is installed. This paper provides similar study results in the other major mishap categories. It shows that both minor and major design and flight operations changes can -- and should -- be made to reduce rotorcraft accidents in the future. The paper outlines these changes and suggests how they may be made.

Harris, Franklin D.↗

NASA NTRS1996

NASA's Biomass Production Chamber: a testbed for bioregenerative life support studies

The Biomass Production Chamber (BPC) located at Kennedy Space Center, FL, USA provides a large (20 m2 area, 113 m3 vol.), closed environment for crop growth tests for NASA's Controlled Ecological Life Support System (CELSS) program. Since the summer of 1988, the chamber has operated on a near-continuous basis (over 1200 days) without any major failures (excluding temporary power losses). During this time, five crops of wheat (64-86 days each), three crops of soybean (90 to 97 days), five crops of lettuce (28-30 days), and four crops of potato (90 to 105 days were grown, producing 481 kg of dry plant biomass, 196 kg edible biomass, 540 kg of oxygen, 94,700 kg of condensed water, and fixing 739 kg of carbon dioxide. Results indicate that total biomass yields were close to expected values for the given light input, but edible biomass yields and harvest indices were slightly lower than expected. Stand photosynthesis, respiration, transpiration, and nutrient uptake rates were monitored throughout growth and development of the different crops, along with the build-up of ethylene and other volatile organic compounds in the atmosphere. Data were also gathered on system hardware maintenance and repair, as well as person-hours required for chamber operation. Future tests will include long-term crop production studies, tests in which nutrients from waste treatment systems will be used to grow new crops, and multi-species tests.

NASA Center KSC↗

NASA NTRS2006

STRANAL-PMC Version 2.0

Version 2.0 of the Strain Rate Dependent Analysis of Polymer Matrix Composites (STRANAL-PMC) software has been released. A prior version was reported in Analyzing Loads and Strains in Polymer- Matrix Composites (LEW-17227), NASA Tech Briefs, Vol. 26, No. 11 (November 2002), page 36. To recapitulate: Modified versions of constitutive equations of viscoplasticity of metals are used to represent deformation of a polymeric matrix. The equations are applied in a micromechanical approach, proceeding upward from slices of unit cells, through the ply level, to the laminate level. The constitutive equations are integrated in time by a Runge- Kutta technique. To predict the ultimate strength of each composite ply, failure criteria are implemented within the micromechanics. The inputs to STRANAL-PMC are the laminate geometry, properties of the fiber and matrix materials, and applied stress or strain versus time. The outputs are time-dependent stresses and strains at the slice, ply, and laminate levels. The improvements in version 2.0 include more rigorous representation of hydrostatic- stress effects in the matrix, refinement and extension of ply failure models, and capabilities to analyze transverse shear stresses. Version 2.0 can be implemented as a material-model code within transient dynamic finite-element codes.

Goldberg, Robert↗

NASA NTRS1984

Optical and other property changes of M-50 bearing steel surfaces for different lubricants and additive prior to scuffing

An ester lubricant base oil containing one or more standard additives to protect against wear, corrosion, and oxidation was used in an experimental ball/plate elastohydrodynamic contact under load and speed conditions such as to induce scuffing failure in short times. Both the ball and the plate were of identically treated M-50 steel. After various periods of operating time the wear track on the plate was examined with an interference microscope of plus or minus 30 A depth resolution and sometimes also with a scanning ellipsometer and an Auger spectrometer. The optically deduced surface profiles varied with wavelength, indicating the presence of surface coatings, which were confirmed by the other instruments. As scuffing was approached, a thin (approximately A) oxide layer and a carbide layer formed in the wear track in particular when tricresylphosphate antiwear additive was present in the lubricant. The rates of the formation of these layers and their reactivity toward dilute alcholic HCl depended strongly on the lubricant and additives. Based on these results suggestions for improved formulations and a test method for bearing reliability could be proposed.

Lauer, J. L.↗

NASA NTRS1986

Optical and other properties changes of M-50 bearing steel surfaces for different lubricants and additives prior to scuffing

An ester lubricant base oil containing one or more standard additives to protect against wear, corrosion, and oxidation was used in an experimental ball/plate elastohydrodynamic contact under load and speed conditions such as to induce scuffing failure in short times. Both the ball and the plate were of identically treated M-50 steel. After various periods of operating time the wear track on the plate was examined with an interference microscope of plus or minus 30 A depth resolution and sometimes also with a scanning ellipsometer and an Auger spectrometer. The optically deduced surface profiles varied with wavelength, indicating the presence of surface coatings, which were confirmed by the other instruments. As scuffing was approached, a thin (approximately A) oxide layer and a carbide layer formed in the wear track in particular when tricresylphosphate antiwear additive was present in the lubricant. The rates of the formation of these layers and their reactivity toward dilute alcoholic HCl depended strongly on the lubricant and additives. Based on these results suggestions for improved formulations and a test method for bearing reliability could be proposed.

Lauer, J. L.↗

NASA NTRS1989

Evaluation of the split cantilever beam for Mode 3 delamination testing

A test rig for testing a thick split cantilever beam for scissoring delamination (mode 3) fracture toughness was developed. A 3-D finite element analysis was conducted on the test specimen to determine the strain energy release rate, G, distribution along the delamination front. The virtual crack closure technique was used to calculate the G components resulting from interlaminar tension, GI, interlaminar sliding shear, GII, and interlaminar tearing shear, GIII. The finite element analysis showed that at the delamination front no GI component existed, but a GII component was present in addition to a GIII component. Furthermore, near the free edges, the GII component was significantly higher than the GIII component. The GII/GIII ratio was found to increase with delamination length but was insensitive to the beam depth. The presence of GII at the delamination front was verified experimentally by examination of the failure surfaces. At the center of the beam, where the failure was in mode 3, there was significant fiber bridging. However, at the edges of the beam where the failure was in mode 3, there was no fiber bridging and mode 2 shear hackles were observed. Therefore, it was concluded that the split cantilever beam configuration does not represent a pure mode 3 test. The experimental work showed that the mode 2 fracture toughness, GIIc, must be less than the mode 3 fracture toughness, GIIIc. Therefore, a conservative approach to characterizing mode 3 delamination is to equate GIIIc to GIIc.

Martin, Roderick H.↗

NASA NTRS1991

Evaluation of the split cantilever beam for mode III delamination testing

Martin, Roderick, H.↗

NASA NTRS2003

High-Performance Acousto-Ultrasonic Scan System Being Developed

Acousto-ultrasonic (AU) interrogation is a single-sided nondestructive evaluation (NDE) technique employing separated sending and receiving transducers. It is used for assessing the microstructural condition and distributed damage state of the material between the transducers. AU is complementary to more traditional NDE methods, such as ultrasonic cscan, x-ray radiography, and thermographic inspection, which tend to be used primarily for discrete flaw detection. Throughout its history, AU has been used to inspect polymer matrix composites, metal matrix composites, ceramic matrix composites, and even monolithic metallic materials. The development of a high-performance automated AU scan system for characterizing within-sample microstructural and property homogeneity is currently in a prototype stage at NASA. This year, essential AU technology was reviewed. In addition, the basic hardware and software configuration for the scanner was developed, and preliminary results with the system were described. Mechanical and environmental loads applied to composite materials can cause distributed damage (as well as discrete defects) that plays a significant role in the degradation of physical properties. Such damage includes fiber/matrix debonding (interface failure), matrix microcracking, and fiber fracture and buckling. Investigations at the NASA Glenn Research Center have shown that traditional NDE scan inspection methods such as ultrasonic c-scan, x-ray imaging, and thermographic imaging tend to be more suited to discrete defect detection rather than the characterization of accumulated distributed microdamage in composites. Since AU is focused on assessing the distributed microdamage state of the material in between the sending and receiving transducers, it has proven to be quite suitable for assessing the relative composite material state. One major success story at Glenn with AU measurements has been the correlation between the ultrasonic decay rate obtained during AU inspection and the mechanical modulus (stiffness) seen during fatigue experiments with silicon carbide/silicon carbide (SiC/SiC) ceramic matrix composite samples. As shown in the figure, ultrasonic decay increased as the modulus decreased for the ceramic matrix composite tensile fatigue samples. The likely microstructural reason for the decrease in modulus (and increase in ultrasonic decay) is the matrix microcracking that commonly occurs during fatigue testing of these materials. Ultrasonic decay has shown the capability to track the pattern of transverse cracking and fiber breakage in these composites.

Roth, Don J.↗

NASA NTRS2003

Signal-Conditioning Amplifier Recorders

Signal-conditioning amplifier recorders (SCAmpRs) have been proposed as a means of simplifying and upgrading the Kennedy Space Center (KSC) Ground Measurement System (GMS), which is a versatile data-acquisition system that gathers and records a variety of measurement data before and during the launch of a space shuttle. In the present version of the GMS system, signal conditioning amplifiers digitize and transmit data to a VME chassis that multiplexes up to 416 channels. The data is transmitted via a high-speed data bus to a second VME chassis where it is available for snapshots. The data is passed from the second VME chassis to a high-speed data recorder. This process is duplicated for installations at two launch pads and the Vehicle Assembly Building (VAB). Since any failure of equipment in the data path results in loss of data, much of the system is redundant. The architecture of the existing GMS limits expansion or any modification to the system to meet changing requirements because of the cost and time required. A SCAmpR-based system is much more flexible. The basis of the simplification, flexibility, and reliability is the shifting of the recording function to the individual amplifier channels. Each SCAmpR is a self-contained single channel data acquisition system, which in its current implementation, has a data storage capacity of up to 30 minutes when operating at the fastest data sampling rates. The SCAmpR channels are self-configuring and self-calibrating. Multiple SCAmpR channels are ganged on printed circuit boards and mounted in a chassis that provides power, a network hub, and Inter-Range Instrument Group (IRIG) time signals. The SCAmpR channels share nothing except physical mounting on a circuit board. All circuitry is electrically separate for each channel. All that is necessary to complete the data acquisition system is a single master computer tied to the SCAmpR channels by standard network equipment. The size of the data acquisition system dictates the requirements for the specific network equipment.

Medelius, Pedro J.↗

NASA NTRS1973

Reusable surface insulation thermal protection systems test evaluation status

Changes in coating morphology of mullite, silica, and ceramic mullite fiber at two heating rates are described followed by a discussion of the changes in surface chemistry that occur during convective heating tests. Subsequently, the surface chemistry changes observed are compared to similar data obtained from radiantly heated coatings and the significance of the difference between the results is discussed. Finally, the changes in chemistry of the coatings in cross section before and after convectively heated cyclic testing are discussed and the significance of surface chemistry changes are described. Results indicate that the thermal conductivity of mullite surface insulation is higher than that of silica insulation, based on thermal response data. Acoustic excitation of cracked silica tiles does not lead to catastrophic failure such as spallation or tile loss. Cracks in mullite material after thermal exposure lead to fracturing of the coating and surface insulation material after acoustic excitation.

Strouhal, G.↗

NASA NTRS1980

Conceptual model of turbulent flameholding for scramjet combustors

New concepts and approaches to scramjet combustor design are presented. Blowoff was from failure of the recirculation-zone (RZ) flame to reach the dividing streamline (DS) at the rear stagnation zone. Increased turbulent exchange across the DS helped flameholding due to forward movement of the flame anchor point inside the RZ. Modeling of the blowoff phenomenon was based on a mass conservation concept involving the traverse of a flame element across the RZ and a flow element along the DS. The scale required to achieve flameholding, predicted by the model, showed a strong adverse effect of low pressure and low fuel equivalence ratio, moderate effect of flight Mach number, and little effect of temperature recovery factor. Possible effects of finite rate chemistry on flameholding and flamespreading in scramjets are discussed and recommendations for approaches to engine combustor design as well as for needed research to reduce uncertainties in the concepts are made.

Huber, P. W.↗

NASA NTRS1984

POPCORN: a Supervisory Control Simulation for Workload and Performance Research

A multi-task simulation of a semi-automatic supervisory control system was developed to provide an environment in which training, operator strategy development, failure detection and resolution, levels of automation, and operator workload can be investigated. The goal was to develop a well-defined, but realistically complex, task that would lend itself to model-based analysis. The name of the task (POPCORN) reflects the visual display that depicts different task elements milling around waiting to be released and pop out to be performed. The operator's task was to complete each of 100 task elements that ere represented by different symbols, by selecting a target task and entering the desired a command. The simulated automatic system then completed the selected function automatically. Highly significant differences in performance, strategy, and rated workload were found as a function of all experimental manipulations (except reward/penalty).

Hart, S. G.↗