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At least 145 records · Page 8
All sourcesNASA NTRSDOE OSTI
NASA NTRS2019

Progressive Damage and Failure Analysis of Bonded Composite Joints at High Energy Dynamic Impacts

Both wing and fuselage structures utilize bonded composite joints for structural efficiency in modern commercial and military aircraft. To ensure compliance with certification requirements mechanical fasteners are typically used as a failsafe mechanism for appropriate strength in the event of complete stiffener disbond. However, the use of fasteners decreases the structural efficiency of the structure by adding weight. This establishes the requirement to better exploit the efficiency of bonded structures and fully understand the failure behavior of adhesively bonded composite structures, particularly when subjected to elevated loading rates due to high energy dynamic impacts (HEDI). For this reason, the NASA Advanced Composite Consortium (ACC) HEDI team developed an experimentation and numerical modeling program for high rate loading of composite joints. In the present work, the response of adhesively bonded composite joints subjected to elevated loading rates is studied numerically and validated against experimental results. Due to dynamic considerations of experiments, the idea of wedge insert was extended to use with Split Hopkinson Pressure Bar (SHPB) testing techniques. Mode-I and Mode-II test configurations were simulated to evaluate the capability of two continuum damage material (CDM) models in LS-DYNA, namely MAT162 and MAT261. Three different levels of fidelity were considered to investigate the level of detail required to numerically predict the failure behavior and the results from high fidelity analysis are presented.

MAT261↗
NASA NTRS1981

The application of fracture mechanics to failure analysis of photovoltaic solar modules

Cracking of silicon solar cells and solar module transparent cover panels such as glass or polymethylmethacrylate (PMMA) is a major cause of photovoltaic solar module failure in field service. Silicon and cover materials are brittle, and cracking of these materials is expected to result from the extension of preexisting flaws under stress. Study of the cracking mechanisms is therefore an appropriate area for the application of fracture mechanics principles. In this study, fracture mechanics techniques were employed to identify the mode of crack propagation, to examine the fracture-initiating flaw, to estimate the nature and magnitude of fracture stress in the field, and to predict analytically the service lifetime. Recommendations for corrective actions are also made.

Chen, C. P.↗
DOE OSTI2024

Brittle failure analysis and modeling of high-burnup PWR fuel cladding alloys

The aim of this research is the development of methods for predicting mechanical behavior and identification of limiting conditions to prevent brittle failure of high-burnup (HBU) pressure water reactor (PWR) fuel cladding alloys. A finite element (FE) model of the ring compression test (RCT) was created to analyze the failure behavior of zirconium-based alloys with radial hydrides during the RCT. An elastic-plastic material model describes the zirconium alloy. The stress-strain curve needed for the elastic-plastic material model was derived by inverse finite element analyses. Cohesive zone modeling is used to reproduce sudden load drops during RCT loading. Based on the failure mechanism in non-irradiated ZIRLO (R) claddings, a micro-mechanical model was developed that distinguishes between brittle failure along hydrides and ductile failure of the zirconium matrix. Two different cohesive laws representing these types of failure are present in the same cohesive interface. The key differences between these constitutive laws are the cohesive strength, the stress at which damage initiates, and the cohesive energy, which is the damage energy dissipated by the cohesive zone. Statistically generated matrix-hydride distributions were mapped onto the cohesive elements and simulations with focus on the first load drop were performed. Computational results are in good agreement with the RCT results conducted on high-burnup M5 (R) samples. It could be shown that crack initiation and propagation strongly depend on the specific configuration of hydrides and matrix material in the fracture area.

Simbruner, Kai↗
NASA NTRS2017

Failure Analysis of Heavy-Ion-Irradiated Schottky Diodes

In this work, we use high- and low-magnitude optical microscope images, infrared camera images, and scanning electron microscope images to identify and describe the failure locations in heavy-ion-irradiated Schottky diodes.

single-event effect (SEE)↗
NASA NTRS1990

KOH concentration effect on the cycle life of nickel-hydrogen cells. IV - Results of failure analysis

Potassium hydroxide concentration effects on the cycle life of a Ni/H2 cell have been studied by carrying out a cycle life test on ten Ni/H2 boiler plate cells which contain electrolytes of various KOH concentrations. Failure analyses of these cells were carried out after completion of the life test, which accumulated up to 40,000 cycles at an 80-percent depth of discharge over a period of 3.7 years. These failure analyses included studies on changes of electrical characteristics of test cells, and component analyses after disassembly of the cell. The component analyses included visual inspections, dimensional changes, capacity measurements of nickel electrodes, scanning electron microscopy, surface area measurements, and chemical analyses. Results have indicated that failure mode and change in the nickel electrode varied as the concentration was varied, especially when the concentration was changed from 31 percent or higher to 26 percent or lower.

Lim, H. S.↗
NASA NTRS2006

JSC Materials Laboratory Reproduction and Failure Analysis of Cracked Orbiter Reaction Control System Niobium Thruster Injectors

In April 2004 a Space Shuttle Orbiter Reaction Control System (RCS) thruster was found to be cracked while undergoing a nozzle (niobium/C103 alloy) retrofit. As a failure resulting from an in-flight RCS thruster burn-through (initiated from a crack) could be catastrophic, an official Space Shuttle Program flight constraint was issued until flight safety could be adequately demonstrated. This paper describes the laboratory test program which was undertaken to reproduce the cracking in order to fully understand and bound the driving environments. The associated rationale developed to justify continued safe flight of the Orbiter RCS system is also described. The laboratory testing successfully reproduced the niobium cracking, and established specific bounding conditions necessary to cause cracking in the C103 thruster injectors. Each of the following conditions is necessary in combination together: 1) a mechanically disturbed / cold-worked free surface, 2) an externally applied sustained tensile stress near yield strength, 3) presence of fluorine-containing fluids on exposed tensile / cold-worked free surfaces, and 4) sustained exposure to temperatures greater than 400 F. As a result of this work, it was concluded that fluorine-containing materials (e.g. HF acid, Krytox , Brayco etc.) should be carefully controlled or altogether eliminated during processing of niobium and its alloys.

Castner, Willard L.↗
NASA NTRSDate not supplied

Progressive Damage Failure Analysis of a Multi-Stringer Post-Buckled Panel

Validation of a progressive damage finite element analysis model using the CompDam material model was performed on a large multi-stringer panel subjected to compressive loading. The panel had a Teflon insert embedded between the skin panel and stiffener to cause an ultimate failure mode of stiffener separation. The compressive loading of the panel caused the skin between the stiffeners to locally buckle before any damage began to occur. The post-buckled behavior of the panel was the driving mechanism to the onset of damage and the damage growth that led to skin-stiffener separation. An integrated global-local modeling approach was used to validate several aspects the overall behavior of the panel from start to failure. The global region captured the pre-buckled stiffness of the test panel within 10% and the buckling load of the skin panel at the critical location within 2%. The skin’s five half-wave buckled mode shape was accurately predicted by the model. The integrated local model captured the load corresponding to the onset of damage within 5% of the average test data. Comparisons are made for key aspects of the damage morphology, such as a growth pattern that included a significant matrix split in the first ply of the skin and a migration of the delamination from the skin-stiffener interface to the skin’sply1-ply2 interface. The ultimate failure mode was shown to be an unstable growth of delamination damage under the stiffeners which led to a peak load of the analysis that was approximately 5% above the average peak load of the testing. The validated global-local modeling approach used on the multi-stringer post-buckled panel with a Teflon insert used a methodology and lessons learned using smaller specimens applied to a subcomponent that captured several aspects of a modern aircraft design.

Jason Action↗
NASA NTRS1984

Failure Analysis of Nickel-hydrogen Cell Subjected to Simulated Low Earth Orbit Cycling

A nickel-hydrogen cell completed 10,080 simulated low earth orbit charge/discharge cycles at depths-of-discharge ranging from 50 to 80 percent prior to failure. The cell is of the Air Force design, rated at 50 ampere-hours, 8.9 cm (3.5 inches) in diameter. Upon disassembly, the end of the polysulfone core supporting the electrode stack was found to have fractured. This allowed the electrode stack to expand. A massive short was found at the inner diameter of the electrodes centered roughly at plate set 34 to 37 from the positive end of the electrode stack. The damaged area extended through approximately one third of the electrode stack, with the effect becoming progressively less with distance from plate set 34 to 37. Measured thicknesses of the positive plates were significantly greater than the initial specification values. The postulated cause of failure is that positive plate growth caused fracture of the shoulder from the end of the polysulfone core on which the electrodes are mounted. The electrode stack relieved and pressure points were created at the area near the inner diameter of the plates at the tab attachment. A short occurred at a pressure point between opposing plates and propagated to other electrode sets due to thermal and mechanical stresses caused by the short.

Mueller, V. C.↗
NASA NTRS1981

Failure analysis of a tool steel torque shaft

A low design load drive shaft used to deliver power from an experimental exhaust heat recovery system to the crankshaft of an experimental diesel truck engine failed during highway testing. An independent testing laboratory analyzed the failure by routine metallography and attributed the failure to fatigue induced by a banded microstructure. Visual examination by NASA of the failed shaft plus the knowledge of the torsional load that it carried pointed to a 100 percent ductile failure with no evidence of fatigue. Scanning electron microscopy confirmed this. Torsional test specimens were produced from pieces of the failed shaft and torsional overload testing produced identical failures to that which had occurred in the truck engine. This pointed to a failure caused by a high overload and although the microstructure was defective it was not the cause of the failure.

Reagan, J. R.↗
NASA NTRS1983

Failure analysis of a tool steel torque shaft

A low design load drive shaft used to deliver power from an experimental exhaust heat recovery system to the crankshaft of an experimental diesel truck engine failed during highway testing. An independent testing laboratory analyzed the failure by routine metallography and attributed the failure to fatigue induced by a banded microstructure. Visual examination by NASA of the failed shaft plus the knowledge of the torsional load that it carried pointed to a 100 percent ductile failure with no evidence of fatigue. Scanning electron microscopy confirmed this. Previously announced in STAR as N82-11184

Reagan, J. R.↗
NASA NTRS1976

OH-58 helicopter transmission failure analysis

The OH-58 main transmission gearbox was run at varying output torques, speeds, and oil cooling rates. The gearbox was subsequently run to destruction by draining the oil from the gearbox while operating at a speed of 6200 revs per minute and 36,000 inch-pounds output torque. Primary cause of gearbox failure was overheating and melting of the planet bearing aluminum cages. Complete failure of the gearbox occurred in 28 1/2 minutes after the oil pressure dropped to zero. The alternating and maximum stresses in the gearbox top case were approximately 10 percent of the endurance limit for the material. Deflection of the bevel gear at 67000 inch-pounds output torque indicate a marginal stiffness for the bevel gear supporting system.

Townsend, D. P.↗
NASA NTRS1982

Photovoltaic module reliability improvement through application testing and failure analysis

During the first four years of the U.S. Department of Energy (DOE) National Photovoltatic Program, the Jet Propulsion Laboratory Low-Cost Solar Array (LSA) Project purchased about 400 kW of photovoltaic modules for test and experiments. In order to identify, report, and analyze test and operational problems with the Block Procurement modules, a problem/failure reporting and analysis system was implemented by the LSA Project with the main purpose of providing manufacturers with feedback from test and field experience needed for the improvement of product performance and reliability. A description of the more significant types of failures is presented, taking into account interconnects, cracked cells, dielectric breakdown, delamination, and corrosion. Current design practices and reliability evaluations are also discussed. The conducted evaluation indicates that current module designs incorporate damage-resistant and fault-tolerant features which address field failure mechanisms observed to date.

Dumas, L. N.↗
NASA NTRSDate not supplied

FEA-Based Failure Analysis of Post-Buckled Composite Multi-Hat Stiffened Panel Under Static Compression

The aerospace industry uses composite multi-hat stiffened panels for skins because of their high strength-to-weight and stiffness-to-weight ratios. However, laminated composites with initial flaws are susceptible to delamination under buckling loads. The goal is to ensure damage initiation occurs past the buckled state, only stable damage progression at loads below the ultimate compressive load, and debonding failure past the ultimate compressive load. This approach reduces weight and addresses a potential design review for future aircraft repairs. The need exists to better understand damage initiation and growth mechanisms in composite structures while assisting in the design, analysis, and sustainment methods. Teflon inserts simulate damage defects during manufacturing, while barely visible impact helps capture human error during manufacturing. This work shows the interaction between the skin-stringer and ply-ply separations at the post-buckled state for both defect events using Abaqus Virtual Crack Closure Technique (VCCT). The initial configuration for the Teflon case was to leave the Teflon region unbonded, and the initial impact damage region approximation came from the experimental data and was considered the initial configuration. When compared against the experimental data produced through the NASA Advanced Composites Project (ACP), the present model captured damage transition from skin-hat to ply1-ply2. The model validations were within ~5% of the experimental data.

composite↗
NASA NTRS1985

Failure analysis and performance evaluation of NASA inertial reference unit (DRIRU 2) after 50 months of orbital operation

The first production DRIRU 2 (NASA standard high performance inertial reference unit) system was launched as a subsystem of the Modular Attitude Control System for the Solar Maximum Mission (SMM) spacecraft in February 1980. This hardware was retrieved during the repair of the SMM during Shuttle Flight 41-C in April 1984 and returned to Teledyne Systems Company (manufacturer) for investigation and performance measurements as directed by Goddard Space Flight Center. A failure of one of the three gyro channels occurred approximately 6.5 months after launch. The built in redundancy functioned properly, the DRIRU 2 continued to provide the required attitude control function without performance degradation. Subsequent failure of other attitude control subsystems made the SMM a candidate for the first demonstration of the shuttle in-orbit repair capabilty. The in-orbit DRIRU 2 II failure scenario and the results of the analyses/tests conducted after retrieval are discussed. Comparison of this data with similar data prior to launch demonstates the excellent stability of performance parameters achieveable with DRIRU 2.

Green, K. N.↗
NASA NTRS2015

The Evolution of Failure Analysis at NASA's Kennedy Space Center and the Lessons Learned

The United States has had four manned launch programs and three station programs since the era of human space flight began in 1961. The launch programs, Mercury, Gemini, Apollo, and Shuttle, and the station programs, Skylab, Shuttle-Mir, and the International Space Station (ISS), have all been enormously successful, not only in advancing the exploration of space, but also in advancing related technologies. As each subsequent program built upon the successes of previous programs, they similarly learned from their predecessors' failures. While some failures were spectacular and captivated the attention of the world, most only held the attention of the dedicated men and women working to make the missions succeed.

metallography↗
NASA NTRS1976

Rock failure analysis by combined thermal weakening and water jet impact

The influence of preheating on the initiation of fracture in rocks subjected to the impingement of a continuous water jet is studied. Preheating the rock is assumed to degrade its mechanical properties and strength in accordance with existing experimental data. The water jet is assumed to place a quasi-static loading on the surface of the rock. The loading is approximated by elementary functions which permit analytic computation of the induced stresses in a rock half-space. The resulting stresses are subsequently coupled with the Griffith criteria for tensile failure to estimate the change, due to heating, in the critical stagnation pressure and velocity of the water jet required to cause failure in the rock.

Nayfeh, A. H.↗
NASA NTRS1982

Time-to-failure analysis for NiCd batteries in a CPS orbit

Cells operating at five degrees Celsius or less, and going to 60 to 65 percent depth of discharge, were studied as to whether they could achieve a useful working life of 7.5 years in a GPS orbit. The characteristics of various orbits were compared and it is noted that the GPS orbit experiences only 220 cycles a year and must be treated as a geosynchronous rather than a low Earth orbit. Cell degradation is considered to be the result of both trickle-charge degradation and degradation due to cycling. Time-to-failure values are presented for selected temperatures and depth of discharges.

Sense, K. A.↗