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At least 145 records · Page 8
All sourcesNASA NTRSDOE OSTI
NASA NTRS2000

A Study of Single Crystal Fatigue Failure Criteria

This paper presents the results of a study whose objective was to study the applicability of different failure equations in modeling low cycle fatigue (LCF) test data for single crystal test specimens. A total of four failure criteria were considered in this study. One of the failure equations was developed by Pratt & Whitney and is based on normal and shear strains on the primary crystallographic slip planes of the single crystal material. Other failure equations considered are based on isotropic criteria. Because these failure equations were originally developed for isotropic materials such as structural steel, they were modified to be applicable to the single crystal slip systems of the LCF specimen material. By observing how closely the various equations were able to reduce the scatter in the LCF test data, the applicability of those equations in modeling the LCF test data was assessed. It is desired to subsequently use the failure equation with the highest correlation in the development of a new single crystal failure criterion for the Alternative Turbopump Development (ATD) for the space shuttle main engine (SSME) High Pressure Fuel Turbopump (HPFTP).

Sayyah, Tarek↗
NASA NTRS2001

A Study of Failure Criteria of Fibrous Composite Materials

The research described in this paper is focused on two areas: (1) evaluation of existing composite failure criteria in the nonlinear, explicit transient dynamic finite element code, MSC.Dytran, and (2) exploration of the possibilities for modification of material and failure models to account for large deformations, progressive failure, and interaction of damage accumulation with stress/strain response of laminated composites. Following a review of the MSC.Dytran user manual, a bibliographical review of existing failure criteria of composites was performed. The papers considered most interesting for the objective of this report are discussed in section 2. The failure criteria included in the code under consideration are discussed in section 3. A critical summary of the present procedures to perform analysis and design of composites is presented in section 4. A study of the most important historical failure criteria for fibrous composite materials and some of the more recent modifications proposed were studied. The result of this analysis highlighted inadequacies in the existing failure criteria and the need to perform some numerical analyses to elucidate the answer to questions on which some of the proposed criteria are based. A summary of these ideas, which is a proposal of studies to be developed, is presented in section 5. Finally, some ideas for future developments are summarized in section 6.

Paris, Federico↗
NASA NTRS2001

High Fidelity Failure Analysis for a Composite Fuselage Section

A high fidelity delamination failure analysis was developed by combining a local failure analysis with a global full-scale finite element structural analysis to address strength and delamination failure in a single package. The methodology was demonstrated through a local three-dimensional pull-off failure analysis and a geometrically nonlinear structural analysis of a five-foot composite helicopter fuselage section. Pull-off specimens were used to identify potential debonding failure of co-cured skin-stringer/frame fuselage structures. An investigation of the failed pull-off specimens was performed to determine the location of the failure initiation. Three-dimensional strain energy release rate analysis indicates that the delamination initiation and growth is controlled by Mode 1 opening mode. The bending moment at the delamination tip was identified as the crucial factor controlling the failure. The geometrically nonlinear structural analysis of a five-foot composite fuselage section was performed using a detailed finite element model. Loads were applied along the periphery of the subcomponent using displacement fields generated from solutions of a full-vehicle model.

Li, Jain↗
NASA NTRS2001

Global Failure Modes in Composite Structures

Composite materials provide well-known advantages for space and aeronautical applications in terms of strength and rigidity to weight ratios and other mechanical properties. As a consequence, their use has experienced a constant increase in the past decades and it is anticipated that this trend will be maintained in the near future. At the same time, being these materials relatively new compared to metals, and having failure characteristics completely different from them, their damage growth and their failure mechanisms are not as well understood in a predictive sense. For example, while in metals fracture produces "clean" cracks with their well defined analytically stress fields at the crack tip, composite fracture is a more complex phenomenon. Instead of a crack, we confront a "damage zone" that may include fiber breakage, fiber microbuckling, fiber pullout, matrix cracking, delamination, debonding or any combination of all these different mechanisms. These phenomena are prevalent in any failure process through an aircraft structure, whether one addresses a global failure such as the ripping of a fuselage or wing section, or whether one is concerned with the failure initiation near a thickness change at stringers or other reinforcement. Thus the topic that has been under consideration has wide application in any real structure and is considered an essential contribution to the predictive failure analysis capability for aircraft containing composite components. The heterogeneity and the anisotropy of composites are not only advantageous but essential characteristics, yet these same features provide complex stress fields, especially in the presence of geometrical discontinuities such as notches, holes or cutouts or structural elements such as stiffeners, stringers, etc. To properly address the interaction between a damage/crack front and a hole with a stringer it is imperative that the stress and deformation fields of the former be (sufficiently well) characterized. The question of "scaling" is an essential concern in any structural materials investigation. For example, experiments in the past have shown that the "strength" of a composite depends on hole size. As a consequence the validity of traditional fracture mechanics concepts applied to composite materials failure must be questioned. The size of the fibers, the dimensions of the laminae, etc. together with the fact that, because of the layered anisotropy, the stress field is no longer two-dimensional, prevent the otherwise obviously confident use of "similarity concepts". Therefore, the question needs to be raised of whether in composites "size matters or not", i.e., whether the results obtained in a laboratory using small coupons are truly representative of the situation involving a full scale component.

Knauss, W. G.↗
NASA NTRS2003

Failure Criteria for FRP Laminates in Plane Stress

A new set of six failure criteria for fiber reinforced polymer laminates is described. Derived from Dvorak's fracture mechanics analyses of cracked plies and from Puck's action plane concept, the physically-based criteria, denoted LaRC03, predict matrix and fiber failure accurately without requiring curve-fitting parameters. For matrix failure under transverse compression, the fracture plane is calculated by maximizing the Mohr-Coulomb effective stresses. A criterion for fiber kinking is obtained by calculating the fiber misalignment under load, and applying the matrix failure criterion in the coordinate frame of the misalignment. Fracture mechanics models of matrix cracks are used to develop a criterion for matrix in tension and to calculate the associated in-situ strengths. The LaRC03 criteria are applied to a few examples to predict failure load envelopes and to predict the failure mode for each region of the envelope. The analysis results are compared to the predictions using other available failure criteria and with experimental results. Predictions obtained with LaRC03 correlate well with the experimental results.

Davila, Carlos G.↗
NASA NTRS1997

Evaluation of a Progressive Failure Analysis Methodology for Laminated Composite Structures

A progressive failure analysis methodology has been developed for predicting the nonlinear response and failure of laminated composite structures. The progressive failure analysis uses C plate and shell elements based on classical lamination theory to calculate the in-plane stresses. Several failure criteria, including the maximum strain criterion, Hashin's criterion, and Christensen's criterion, are used to predict the failure mechanisms. The progressive failure analysis model is implemented into a general purpose finite element code and can predict the damage and response of laminated composite structures from initial loading to final failure.

Sleight, David W.↗
NASA NTRS2008

Approximation of Failure Probability Using Conditional Sampling

In analyzing systems which depend on uncertain parameters, one technique is to partition the uncertain parameter domain into a failure set and its complement, and judge the quality of the system by estimating the probability of failure. If this is done by a sampling technique such as Monte Carlo and the probability of failure is small, accurate approximation can require so many sample points that the computational expense is prohibitive. Previous work of the authors has shown how to bound the failure event by sets of such simple geometry that their probabilities can be calculated analytically. In this paper, it is shown how to make use of these failure bounding sets and conditional sampling within them to substantially reduce the computational burden of approximating failure probability. It is also shown how the use of these sampling techniques improves the confidence intervals for the failure probability estimate for a given number of sample points and how they reduce the number of sample point analyses needed to achieve a given level of confidence.

Giesy. Daniel P.↗
NASA NTRS2009

Lunar Base Life Support Failures

Dynamic simulation of the lunar outpost habitat life support was undertaken to investigate the impact of life support failures and to investigate responses. Some preparatory static analysis for the Lunar Outpost life support model, an earlier version of the model, and an investigation into the impact of Extravehicular Activity (EVA) were reported previously. (Jones, 2008-01-2184, 2008-01-2017) The earlier model was modified to include possible resupply delays, power failures, recycling system failures, and atmosphere and other material storage failures. Most failures impact the lunar outpost water balance and can be mitigated by reducing water usage. Food solids, nitrogen can be obtained only by resupply from Earth. The most time urgent failure is a lass of carbon dioxide removal capability. Life support failures might be survivable if effective operational solutions are provided in the system design.

Jones, Harry W.↗
NASA NTRS2010

Probabilistic Design Analysis (PDA) Approach to Determine the Probability of Cross-System Failures for a Space Launch Vehicle

Quantifying the probability of significant launch vehicle failure scenarios for a given design, while still in the design process, is critical to mission success and to the safety of the astronauts. Probabilistic risk assessment (PRA) is chosen from many system safety and reliability tools to verify the loss of mission (LOM) and loss of crew (LOC) requirements set by the NASA Program Office. To support the integrated vehicle PRA, probabilistic design analysis (PDA) models are developed by using vehicle design and operation data to better quantify failure probabilities and to better understand the characteristics of a failure and its outcome. This PDA approach uses a physics-based model to describe the system behavior and response for a given failure scenario. Each driving parameter in the model is treated as a random variable with a distribution function. Monte Carlo simulation is used to perform probabilistic calculations to statistically obtain the failure probability. Sensitivity analyses are performed to show how input parameters affect the predicted failure probability, providing insight for potential design improvements to mitigate the risk. The paper discusses the application of the PDA approach in determining the probability of failure for two scenarios from the NASA Ares I project

Shih, Ann T.↗
NASA NTRS2010

Life Support with Failures and Variable Supply

The life support system for long duration missions will recycle oxygen and water to reduce the material resupply mass from Earth. The impact of life support failures was investigated by dynamic simulation of a lunar outpost habitat life support model. The model was modified to simulate resupply delays, power failures, recycling system failures, and storage failures. Many failures impact the lunar outpost water supply directly or indirectly, depending on the water balance and water storage. Failure effects on the water supply are reduced if Extra Vehicular Activity (EVA) water use is low and the water supply is ample. Additional oxygen can be supplied by scavenging unused propellant or by production from regolith, but the amounts obtained can vary significantly. The requirements for oxygen and water can also vary significantly, especially for EVA. Providing storage buffers can improve efficiency and reliability, and minimize the chance of supply failing to meet demand. Life support failures and supply variations can be survivable if effective solutions are provided by the system design

Jones, Harry↗
NASA NTRS2010

Failure Analysis at the Kennedy Space Center

History has shown that failures occur in every engineering endeavor, and what we learn from those failures contributes to the knowledge base to safely complete future missions. The necessity of failure analysis is at its apex at the end of one aged program and at the beginning of a new and untested program. The information that we gain through failure analysis corrects the deficiencies in the current vehicle to make the next generation of vehicles more efficient and safe. The Failure Analysis and Materials Evaluation Branch in the Materials Science Division at the Kennedy Space Center performs metallurgical, mechanical, electrical, and non-metallic materials failure analyses and accident investigations on both flight hardware and ground support equipment for the Space Shuttle, International Space Station, Constellation, and Launch Services Programs. This paper will explore a variety of failure case studies at the Kennedy Space Center and the lessons learned that can be applied in future programs.

Salazar, Victoria L.↗
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 NTRS2012

Failure detection system risk reduction assessment

A process includes determining a probability of a failure mode of a system being analyzed reaching a failure limit as a function of time to failure limit, determining a probability of a mitigation of the failure mode as a function of a time to failure limit, and quantifying a risk reduction based on the probability of the failure mode reaching the failure limit and the probability of the mitigation.

Aguilar, Robert B.↗
NASA NTRS2010

Failure Analysis at the Kennedy Space Center

History has shown that failures occur in every engineering endeavor, and what we learn from those failures contributes to the knowledge base to safely complete future missions. The necessity of failure analysis is at its apex at the end of one aged program (i.e. Shuttle) and at the beginning of a new and untested program (i.e. Constellation). The information that we gain through failure analysis corrects the deficiencies in the current vehicle to make the next generation of vehicles more efficient and safe. The Failure Analysis and Materials Evaluation section in the Materials Science Division at the Kennedy Space Center performs metallurgical, mechanical, electrical, and non-metallic failure analysis and accident investigations on both flight hardware and ground support equipment (GSE) for the Shuttle, International Space Station, Constellation, and Launch Services Programs. This presentation will explore a variety of failure case studies at KSC and the lessons learned that can be applied in future programs.

Salazar, Victoria L.↗
NASA NTRS2015

Common Cause Failure Modeling

Common Cause Failures (CCFs) are a known and documented phenomenon that defeats system redundancy. CCFS are a set of dependent type of failures that can be caused by: system environments; manufacturing; transportation; storage; maintenance; and assembly, as examples. Since there are many factors that contribute to CCFs, the effects can be reduced, but they are difficult to eliminate entirely. Furthermore, failure databases sometimes fail to differentiate between independent and CCF (dependent) failure and data is limited, especially for launch vehicles. The Probabilistic Risk Assessment (PRA) of NASA's Safety and Mission Assurance Directorate at Marshall Space Flight Center (MFSC) is using generic data from the Nuclear Regulatory Commission's database of common cause failures at nuclear power plants to estimate CCF due to the lack of a more appropriate data source. There remains uncertainty in the actual magnitude of the common cause risk estimates for different systems at this stage of the design. Given the limited data about launch vehicle CCF and that launch vehicles are a highly redundant system by design, it is important to make design decisions to account for a range of values for independent and CCFs. When investigating the design of the one-out-of-two component redundant system for launch vehicles, a response surface was constructed to represent the impact of the independent failure rate versus a common cause beta factor effect on a system's failure probability. This presentation will define a CCF and review estimation calculations. It gives a summary of reduction methodologies and a review of examples of historical CCFs. Finally, it presents the response surface and discusses the results of the different CCFs on the reliability of a one-out-of-two system.

Hark, Frank↗
NASA NTRS2016

Common Cause Failure Modeling

Common Cause Failures (CCFs) are a known and documented phenomenon that defeats system redundancy. CCFS are a set of dependent type of failures that can be caused by: system environments; manufacturing; transportation; storage; maintenance; and assembly, as examples. Since there are many factors that contribute to CCFs, the effects can be reduced, but they are difficult to eliminate entirely. Furthermore, failure databases sometimes fail to differentiate between independent and CCF (dependent) failure and data is limited, especially for launch vehicles. The Probabilistic Risk Assessment (PRA) of NASA's Safety and Mission Assurance Directorate at Marshal Space Flight Center (MFSC) is using generic data from the Nuclear Regulatory Commission's database of common cause failures at nuclear power plants to estimate CCF due to the lack of a more appropriate data source. There remains uncertainty in the actual magnitude of the common cause risk estimates for different systems at this stage of the design. Given the limited data about launch vehicle CCF and that launch vehicles are a highly redundant system by design, it is important to make design decisions to account for a range of values for independent and CCFs. When investigating the design of the one-out-of-two component redundant system for launch vehicles, a response surface was constructed to represent the impact of the independent failure rate versus a common cause beta factor effect on a system's failure probability. This presentation will define a CCF and review estimation calculations. It gives a summary of reduction methodologies and a review of examples of historical CCFs. Finally, it presents the response surface and discusses the results of the different CCFs on the reliability of a one-out-of-two system.

Hark, Frank↗
NASA NTRS2011

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

Steady step surge testing (SSST) is widely applied to screen out potential power-on failures in solid tantalum capacitors. The test simulates the power supply's on and off characteristics. Power-on failure has been the prevalent failure mechanism for solid tantalum capacitors for decoupling applications. On the other hand, the SSST can also be reviewed as an electrically destructive test under a time-varying stress. 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. Highly accelerated life testing (HALT) is usually a time-efficient method for determining the failure mechanism in capacitors; however, a destructive test under a time-varying stress like SSST is even more effective. It normally takes days to complete a HALT test, but it only takes minutes for a time-varying stress test to produce failures. The advantage of incorporating specific time-varying stress into a statistical model is significant in providing an alternative life test method for quickly revealing the failure modes in capacitors. In this paper, a time-varying stress has been incorporated into the Weibull model to characterize the failure modes. The SSST circuit and transient conditions to correctly test the capacitors is discussed. Finally, the SSST was applied for testing polymer aluminum capacitors (PA capacitors), Ta capacitors, and multi-layer ceramic capacitors with both precious metal electrode (PME) and base-metal-electrodes (BME). It appears that testing results are directly associated to the dielectric layer breakdown in PA and Ta capacitors and are independent on the capacitor values, the way the capacitors being built, and the manufactures. The testing results also reveal that ceramic capacitors exhibit breakdown voltages more than 20 times the rated voltage, and the breakdown voltages are inverse proportional to the dielectric layer thickness. The possibility of ceramic capacitors in front-end decoupling applications to block the surge noise from a power supply is also discussed.

Liu, David (Donhang)↗
NASA NTRS2018

Synthesizing a New Launch Vehicle Failure Probability Based on Historical Flight Data

New launch vehicles have historically had significantly higher failure rates in early flights than what has been predicted using Probabilistic Risk Assessment - PRA. This is because PRAs typically model a mature vehicle where a significant portion of the early failure probability contributors have been eliminated due to testing and improvements after actual field operation. To capture a more accurate early flight failure probability estimate, this paper develops a method that estimates ascent failure probability starting with the first flight based on historical launch vehicle records. With new launch vehicles being developed, such as the Space Launch System - SLS, a PRA model must be extended to cover early flight failure probability contributions that are either not covered in the mature-vehicle PRA or are underestimated. These failure probability contributions include design errors, quality control deficiencies, installation errors, and environmental impacts. There are also failure dependencies due to systemic errors that still exist due to limited entire-system testing.

Cross, Robert B.↗