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At least 145 records · Page 8

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NASA NTRS1992

An improved approach for flight readiness certification: Methodology for failure risk assessment and application examples. Volume 2: Software documentation

An improved methodology for quantitatively evaluating failure risk of spaceflight systems to assess flight readiness and identify risk control measures is presented. This methodology, called Probabilistic Failure Assessment (PFA), combines operating experience from tests and flights with engineering analysis to estimate failure risk. The PFA methodology is of particular value when information on which to base an assessment of failure risk, including test experience and knowledge of parameters used in engineering analyses of failure phenomena, is expensive or difficult to acquire. The PFA methodology is a prescribed statistical structure in which engineering analysis models that characterize failure phenomena are used conjointly with uncertainties about analysis parameters and/or modeling accuracy to estimate failure probability distributions for specific failure modes, These distributions can then be modified, by means of statistical procedures of the PFA methodology, to reflect any test or flight experience. Conventional engineering analysis models currently employed for design of failure prediction are used in this methodology. The PFA methodology is described and examples of its application are presented. Conventional approaches to failure risk evaluation for spaceflight systems are discussed, and the rationale for the approach taken in the PFA methodology is presented. The statistical methods, engineering models, and computer software used in fatigue failure mode applications are thoroughly documented.

Moore, N. R.↗

NASA NTRS1992

An improved approach for flight readiness certification: Methodology for failure risk assessment and application examples. Volume 3: Structure and listing of programs

An improved methodology for quantitatively evaluating failure risk of spaceflight systems to assess flight readiness and identify risk control measures is presented. This methodology, called Probabilistic Failure Assessment (PFA), combines operating experience from tests and flights with engineering analysis to estimate failure risk. The PFA methodology is of particular value when information on which to base an assessment of failure risk, including test experience and knowledge of parameters used in engineering analyses of failure phenomena, is expensive or difficult to acquire. The PFA methodology is a prescribed statistical structure in which engineering analysis models that characterize failure phenomena are used conjointly with uncertainties about analysis parameters and/or modeling accuracy to estimate failure probability distributions for specific failure modes. These distributions can then be modified, by means of statistical procedures of the PFA methodology, to reflect any test or flight experience. Conventional engineering analysis models currently employed for design of failure prediction are used in this methodology. The PFA methodology is described and examples of its application are presented. Conventional approaches to failure risk evaluation for spaceflight systems are discussed, and the rationale for the approach taken in the PFA methodology is presented. The statistical methods, engineering models, and computer software used in fatigue failure mode applications are thoroughly documented.

Moore, N. R.↗

NASA NTRS1983

A numerical procedure for predicting creep and delayed failures in laminated composites

A numerical procedure is described for predicting the viscoelastic response of general laminates. A nonlinear compliance model is used to predict the creep response of the individual laminae. A biaxial delayed failure model predicts ply failure. The numerical procedure, based on lamination theory, increases by increments through time to predict creep compliance and delayed failures in laminates. Numerical stability problems and experimental verification are discussed. Although the program has been quite successful in predicting creep of general laminates, the assumptions associated with lamination theory have resulted in erroneous bounds on the predicted material response. Delayed failure predictions have been conservative. Several improvements are suggested to increase the accuracy of the procedure.

Dillard, D. A.↗

DOE OSTI2024

Calibration of Al7075 with Plate-Puncture Predictions

The following details calibration of a material model for Al7075-T6511. This aluminum alloy is commonly used across a host of engineering applications. Owing to its widespread prevalence, there is great benefit in improving simulation predictions for this alloy. In the present effort, a calibration is performed of its elastic-plastic response accounting for both rate and temperature dependence. The calibration is informed by a series of tests that include specimens of different geometries tested at different rates and temperatures. All specimens are derived from the same barstock, 3.5 inches in diameter. The fitted model itself uses an anisotropic, Hill yield surface coupled with a Johnson-Cook hardening model. Failure predictions are had by means of a modified Wilkins failure criterion. Following calibration of the material model, a validation exercise is performed against platepuncture experiments. These experiments include multiple probe shapes, probe diameters, and plate thicknesses. The puncture experiments are replicated in simulation with mesh studies performed to assess uncertainty. Key quantities of interest, notably the absorbed energy up to failure, are compared between simulation and experiment providing a means to assess the suitability of the calibration in puncture simulations.

36 MATERIALS SCIENCE↗

NASA NTRS1972

Static and dynamic fatigue behavior of glass filament-wound pressure vessels at ambient and cryogenic temperatures.

Investigation of the pressure load carrying capacity and fatigue strength of filament-wound glass-reinforced plastic pressure vessels subjected to static and cyclic loading at ambient and cryogenic (liquid nitrogen) temperature environments. The results indicate that the static fatigue problem is not critical at cryogenic temperatures. Under static loading at liquid nitrogen temperature, a reinforced plastic cylinder sustained pressurization for 88 days without failure at about 90% of the single cycle burst strength. At ambient temperature, the static life at 90% of the burst strength was about 7 min. Under cyclic loading in liquid nitrogen, no failure resulted after 1509 cycles at 55% of the single cycle burst strength. Under the same cyclic loading at ambient temperature, the test results would predict failure in the reinforced plastic. The results of similar tests upon adhesively bonded polyimide aluminum-foil lined cylinders are also reviewed.-

Hanson, M. P.↗

NASA NTRSDate not supplied

Composite Bond Line Measurements Based on A Bayesian Analysis of Flash Thermography Data

For bonded composite materials, an accurate characterization of the adhesive bond line is needed to predict failure modes and fracture toughness. In this paper, bond line thickness was estimated from data obtained using through transmission flash thermography. The forward model that predicts back surface temperature is based on a three layer heat diffusion equation with varying diffusivity and flux boundary conditions. The corresponding inverse problem of estimating bond line thickness from measurement data was solved using a Bayesian approach that assumed Gaussian priors for the bond line thickness and thermal diffusivity of the adherends. Finally, the outputs of the thermography based method were compared to measurements that were collected using a micrometer and ultrasound testing.

Flash thermography↗

NASA NTRSDate not supplied

Composite Bond Line Measurements Based on a Bayesian Analysis of Flash Thermography Data

Flash thermography↗

NASA NTRS1992

Compression failure of angle-ply laminates

Test results from the compression loading of (+ or - Theta/ - or + Theta)(sub 6s) angle-ply IM7-8551-7a specimens, 0 less than or = Theta less than or = 90 degs, are presented. The observed failure strengths and modes are discussed, and typical stress-strain relations shown. Using classical lamination theory and the maximum stress criterion, an attempt is made to predict failure stress as a function of Theta. This attempt results in poor correlation with test results and thus a more advanced model is used. The model, which is based on a geometrically nonlinear theory, and which was taken from previous work, includes the influence of observed layer waviness. The waviness is described by the wave length and the wave amplitude. The theory is briefly described and results from the theory are correlated with test results. It is shown that by using levels of waviness observed in the specimens, the correlation between predictions and observations is good.

Peel, L. D.↗

DOE OSTI2024

A prediction model of failure threshold for shear deformation in a Zr-based bulk metallic glass

The failure of bulk metallic glasses (BMGs) during plastic deformation at room temperature is abrupt and instantaneous, while the analysis of precursor information based on avalanche events helps predict catastrophic failure. An acoustic emission (AE) signal can provide accurate precursor information for material failure, due to its sensitive and high fast calculation ability. In the current study, AE monitoring tests are carried out during uniaxial compression tests of BMGs at different strain rates. The AE experimental failure threshold, E max , is proposed on the basis of AE cumulative energy, which reflects the intensity of damage evolution at different loading conditions. Compared with the critical shear band velocity (CSBV) associated with stick-slip dynamics of serrated flow, E max is a more sensitive failure parameter since it is connected with the local microscopic changes that occur during the material response process. Here, the E max is obtained prior to reaching the CSBV since the calculation of these two avalanches analysis focuses on the different stages of shear band growth. In particular, AE events are related to the “dry” friction process in the first stage, however, the CSBV is responsible for the “viscous” glide in the second stage. Therefore, Emax is not affected by the complex interactions between the shear bands during the stick-slip process. The maximum avalanche of serrated flow, S max , is proposed as the experimental failure threshold, which depends on the applied strain rate as S max ~ $\dot{ε}$ –λ . According to the relationship of E max and S max , the theoretical failure threshold, E max , follows a criterion E max = 2545$\dot{ε}$ –λ - 4468, where λ is equivalent to 0.15 for this work. Finally, combining the different calculations and AE measurements, this model gives new insights to predict the deformation failure behavior of Zr-based BMGs.

36 MATERIALS SCIENCE↗

NASA NTRS1992

A micromechanics-based progressive failure model for laminated composite structures

A micromechanics-based mechanistic model for progressive failure analysis of laminated composite shell structures is developed. A finite-element program for laminated shell analysis is coupled with a micromechanical elasticity solution for predicting failure and effective composite properties. The laminate model is based on a third-order shell theory which allows for both transverse normal and shearing deformations. Results are presented for the progressive failure of a (0/90(4)s graphite/epoxy laminate under uniaxial tension. The effect of fiber volume fraction in the 90-deg plies on laminate behavior was studied, and it was found that decreasing the fiber-volume fraction in the off-axis plies did not affect the laminate stiffness or the ultimate failure load, but significantly increased the load at which initial failure occurred.

Averill, R. C.↗

DOE OSTI2025

Coupled phase field damage and crystal plasticity analysis of intragranular fracture: The role of crystallographic orientation and voids

Damage evolution in engineering metal alloys at the grain scale exhibits significant microstructural heterogeneity and anisotropy. These heterogeneities create local hotspots for stress and strain localization, leading to void nucleation. Crystal orientation influences the active slip systems around voids, affecting lattice rotation and potentially forming discontinuities. At low triaxiality, voids may change shape due to lower stress, rotation, elongation, and coalescence. At high triaxiality, the correlation between crystal orientation and void growth rate becomes stronger, resembling the behavior observed in isolated single crystals. Therefore, understanding the effects of crystal orientation, heterogeneous strain, and defect evolution is crucial for single crystal fracture characterization. Here, in this work, a coupled phase-field damage (PFD) and crystal plasticity (CP) model is implemented within a finite element framework to analyze crystal deformation and failure. The CP method employs a dislocation density-based constitutive model, while intragranular failure is modeled using an anisotropic PFD method. The PFD model considers both the stored energy due to elastic stretching and the energy release due to defect formation and crack formation. A single crystal Al2219 with an intracrystalline spherical void is chosen to analyze fracture. The study finds that fracture propagation is strongly correlated with crystal orientations. This coupled CP-PFD model provides accurate failure prediction in crystalline materials by incorporating the effects of crystal orientations and existing voids. This study demonstrates how the local microstructure and defects influence plastic deformation and failure mechanisms in metal alloys.

Aluminum alloy↗

NASA NTRS1992

Applications of a damage tolerance analysis methodology in aircraft design and production

Objectives of customer mandated aircraft structural integrity initiatives in design are to guide material selection, to incorporate fracture resistant concepts in the design, to utilize damage tolerance based allowables and planned inspection procedures necessary to enhance the safety and reliability of manned flight vehicles. However, validated fracture analysis tools for composite structures are needed to accomplish these objectives in a timely and economical manner. This paper briefly describes the development, validation, and application of a damage tolerance methodology for composite airframe structures. A closed-form analysis code, entitled SUBLAM was developed to predict the critical biaxial strain state necessary to cause sublaminate buckling-induced delamination extension in an impact damaged composite laminate. An embedded elliptical delamination separating a thin sublaminate from a thick parent laminate is modelled. Predicted failure strains were correlated against a variety of experimental data that included results from compression after impact coupon and element tests. An integrated analysis package was developed to predict damage tolerance based margin-of-safety (MS) using NASTRAN generated loads and element information. Damage tolerance aspects of new concepts are quickly and cost-effectively determined without the need for excessive testing.

Woodward, M. R.↗

NASA NTRS2020

Design and Analysis of Buckling-Critical Large-Scale Sandwich Composite Cylindrical Test Articles

It has long been established in the literature that the buckling response of thin-shell structures can be very sensitive to the presence of small geometric and loading imperfections. The Shell Buckling Knockdown Factor Project (SBKF) was established by the NASA Engineering and Safety Center (NESC) to develop analysis-based shell buckling design recommendations for stiffened-metallic and composite launch-vehicle shell structures. Large-scale buckling tests were used to validate the modeling and analysis methods applied in developing these analysis-based recommendations. Herein, the test article design methodology for 8-ft-diameter, honeycomb-core sandwich composite cylinder validation tests is discussed and cylinder designs are presented. In this methodology, first, the sandwich composite design space was defined using several nondimensional parameters, and the desired test article design space was determined by examining the designs of launch-vehicle cylinder structures. Essentially all test article designs within certain design parameters were generated and then downselected based on simple closed-form failure calculations and the nondimensional design-space parameters. Four of these designs that spanned a significant portion of the design space of interest and had global buckling as the first predicted failure mode were selected and subjected to higher-fidelity finite element analyses (FEAs): shell-element-based analyses, axisymmetric-element-based analyses, and global-local analyses. The analysis flow discussed in this report supported the design objective. As the analysis flow progressed, designs were downselected so the fidelity of the analysis methods, and consequently their computational cost and accuracy, was increased. The selection of the FEA types created an analysis framework where particular methods complemented each other and reduced the uncertainty of the predicted test article responses. The analysis results are illustrated using several designs when the computationally expeditious closed-form analysis stage is discussed. Once this stage is complete, the higher-fidelity FEA types are illustrated using one selected detailed test article design. Both perfect and imperfect test article geometries were considered.

Buckling↗

NASA NTRS2006

Probabilistic Risk Assessment (PRA): A Practical and Cost Effective Approach

The Lunar Reconnaissance Orbiter (LRO) is the first mission of the Robotic Lunar Exploration Program (RLEP), a space exploration venture to the Moon, Mars and beyond. The LRO mission includes spacecraft developed by NASA Goddard Space Flight Center (GSFC) and seven instruments built by GSFC, Russia, and contractors across the nation. LRO is defined as a measurement mission, not a science mission. It emphasizes the overall objectives of obtaining data to facilitate returning mankind safely to the Moon in preparation for an eventual manned mission to Mars. As the first mission in response to the President's commitment of the journey of exploring the solar system and beyond: returning to the Moon in the next decade, then venturing further into the solar system, ultimately sending humans to Mars and beyond, LRO has high-visibility to the public but limited resources and a tight schedule. This paper demonstrates how NASA's Lunar Reconnaissance Orbiter Mission project office incorporated reliability analyses in assessing risks and performing design tradeoffs to ensure mission success. Risk assessment is performed using NASA Procedural Requirements (NPR) 8705.5 - Probabilistic Risk Assessment (PRA) Procedures for NASA Programs and Projects to formulate probabilistic risk assessment (PRA). As required, a limited scope PRA is being performed for the LRO project. The PRA is used to optimize the mission design within mandated budget, manpower, and schedule constraints. The technique that LRO project office uses to perform PRA relies on the application of a component failure database to quantify the potential mission success risks. To ensure mission success in an efficient manner, low cost and tight schedule, the traditional reliability analyses, such as reliability predictions, Failure Modes and Effects Analysis (FMEA), and Fault Tree Analysis (FTA), are used to perform PRA for the large system of LRO with more than 14,000 piece parts and over 120 purchased or contractor built components.

Lee, Lydia L.↗

NASA NTRS1998

Automated System Checkout to Support Predictive Maintenance for the Reusable Launch Vehicle

The Propulsion Checkout and Control System (PCCS) is a predictive maintenance software system. The real-time checkout procedures and diagnostics are designed to detect components that need maintenance based on their condition, rather than using more conventional approaches such as scheduled or reliability centered maintenance. Predictive maintenance can reduce turn-around time and cost and increase safety as compared to conventional maintenance approaches. Real-time sensor validation, limit checking, statistical anomaly detection, and failure prediction based on simulation models are employed. Multi-signal models, useful for testability analysis during system design, are used during the operational phase to detect and isolate degraded or failed components. The TEAMS-RT real-time diagnostic engine was developed to utilize the multi-signal models by Qualtech Systems, Inc. Capability of predicting the maintenance condition was successfully demonstrated with a variety of data, from simulation to actual operation on the Integrated Propulsion Technology Demonstrator (IPTD) at Marshall Space Flight Center (MSFC). Playback of IPTD valve actuations for feature recognition updates identified an otherwise undetectable Main Propulsion System 12 inch prevalve degradation. The algorithms were loaded into the Propulsion Checkout and Control System for further development and are the first known application of predictive Integrated Vehicle Health Management to an operational cryogenic testbed. The software performed successfully in real-time, meeting the required performance goal of 1 second cycle time.

Patterson-Hine, Ann↗

NASA NTRS1972

Failure mode analysis to predict product reliability.

The failure mode analysis (FMA) is described as a design tool to predict and improve product reliability. The objectives of the failure mode analysis are presented as they influence component design, configuration selection, the product test program, the quality assurance plan, and engineering analysis priorities. The detailed mechanics of performing a failure mode analysis are discussed, including one suggested format. Some practical difficulties of implementation are indicated, drawn from experience with preparing FMAs on the nuclear rocket engine program.

Zemanick, P. P.↗

DOE OSTI2023

Infusible Thermoplastic Composites for Wind Turbine Blade Manufacturing: Fatigue Life of Thermoplastic Laminates under Ambient and Low-Temperature Conditions

Traditionally, thermoset resins such as polyesters (PE) and epoxies are used as the polymer matrix for construction of wind turbine blades. However, concern about their end-of-life treatment garners interest to use thermoplastics for increased recyclability. However, the high viscosity of molten thermoplastics inhibits their use in manufacturing wind turbine blades with injection or compression molding. A recently developed, infusible, reactive thermoplastic resin overcomes this technological barrier. Toward verifying that this recyclable resin is suitable for use in wind turbine blades, a dataset of R?=?0.1 and R?=?10 fatigue data for glass fiber-reinforced acrylic composites is provided and equal fatigue life to industry standard epoxy and unsaturated PE resin systems is demonstrated. Specifically, R?=?0.1 fatigue data for acrylic composites at room temperature and -30?degrees C for verification of low-temperature performance are tabulated. To elucidate failure mechanisms, in situ mechanical testing with X-ray computed tomography demonstrates that damage accumulation occurs by crack propagation along the fiber-matrix interface under cyclic loading. Infrared (IR) thermography predicts failure points in composites specimens with porosity defects introduced from nonideal manufacturing processes. Furthermore, these manufacturing defects are shown to compromise the fatigue life of the acrylic laminates by an order of magnitude.

effect of defects↗

NASA NTRS1992

An improved approach for flight readiness certification: Probabilistic models for flaw propagation and turbine blade failure. Volume 1: Methodology and applications

An improved methodology for quantitatively evaluating failure risk of spaceflight systems to assess flight readiness and identify risk control measures is presented. This methodology, called Probabilistic Failure Assessment (PFA), combines operating experience from tests and flights with analytical modeling of failure phenomena to estimate failure risk. The PFA methodology is of particular value when information on which to base an assessment of failure risk, including test experience and knowledge of parameters used in analytical modeling, is expensive or difficult to acquire. The PFA methodology is a prescribed statistical structure in which analytical models that characterize failure phenomena are used conjointly with uncertainties about analysis parameters and/or modeling accuracy to estimate failure probability distributions for specific failure modes. These distributions can then be modified, by means of statistical procedures of the PFA methodology, to reflect any test or flight experience. State-of-the-art analytical models currently employed for designs failure prediction, or performance analysis are used in this methodology. The rationale for the statistical approach taken in the PFA methodology is discussed, the PFA methodology is described, and examples of its application to structural failure modes are presented. The engineering models and computer software used in fatigue crack growth and fatigue crack initiation applications are thoroughly documented.

Moore, N. R.↗