SEARCH · Engineering Papers

Results for “failure simulation”

Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

SourceResearch connectionFrom yearThrough year

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 1,531 records · Page 85

All sources NASA NTRS DOE OSTI

NASA NTRS1993

Fractography handbook of spaceflight metals

This handbook was produced with the intention of providing failure analysts who work with space flight metals a reference of scanning electron microscope (SEM) fractographs of fracture surfaces produced under known condition. The metals and the fracture conditions were chosen to simulate situations that are encountered in spaceflight applications. This includes tensile overload at both room temperature and liquid nitrogen temperature, and fatigue at room temperature.

Derro, Rebecca J.↗

NASA NTRS2000

COSIM: A Finite-Difference Computer Model to Predict Ternary Concentration Profiles Associated with Oxidation and Interdiffusion of Overlay-Coated Substrates

A finite-difference computer program (COSIM) has been written which models the one-dimensional, diffusional transport associated with high-temperature oxidation and interdiffusion of overlay-coated substrates. The program predicts concentration profiles for up to three elements in the coating and substrate after various oxidation exposures. Surface recession due to solute loss is also predicted. Ternary cross terms and concentration-dependent diffusion coefficients are taken into account. The program also incorporates a previously-developed oxide growth and spalling model to simulate either isothermal or cyclic oxidation exposures. In addition to predicting concentration profiles after various oxidation exposures, the program can also be used to predict coating fife based on a concentration dependent failure criterion (e.g., surface solute content drops to two percent). The computer code, written in an extension of FORTRAN 77, employs numerous subroutines to make the program flexible and easily modifiable to other coating oxidation problems.

Nesbitt, James A.↗

NASA NTRS2001

Characterization of Ceramic Matrix Composite Combustor Components: Pre and Post Exposure

The pursuit of lower emissions and higher performance from gas turbine engines requires the development of innovative concepts and the use of advanced materials for key engine components. One key engine component is the combustor, where innovative design and material improvements have the potential to lower emissions. Efforts to develop a High Speed Civil Transport with low emissions were focused on the evaluation of combustor concepts with liners fabricated from a ceramic matrix composite of silicon carbide fibers in a silicon carbide matrix (SiC/SiC). The evaluation of SiC/SiC composites progressed from simple coupons (to establish a first-order database and identify operant failure mechanisms and damage accumulation processes), to feature-based subelements (to assess fabricability and in situ material response), to actual components (to assess structural integrity, dimensional, and compositional fidelity) tested under simulated engine conditions. As in the case of all evolutionary material and process work, a key element to resolving fabrication issues is the evaluation of witness areas taken from fabricated components before testing the actual component. The witness material from these components allowed microstructural and mechanical testing to be performed and compared to the ideal, flat panel, conditions and data that are typical of basic characterization. This also allowed samples of similar design to be taken from components after 115 hours of combustion exposure. Testing consisted of tensile, double notch shear, ring burst, and thermal conductivity that sampled various regions of the components. The evaluation of the witness material allowed an understanding of the fabrication process, highlighting critical issues, in an early phase of the learning curve development of these configuration and material unique parts. Residual property testing, after exposure, showed if degradation of the material under actual service conditions was occurring. This paper will present the results of this critical testing. Evaluations that consider the degree of complexity of the fabricated part were established to relate in situ performance to that of flat panel based coupons. Nondestructive evaluation was used throughout the evaluation process. These results will also be discussed as an aid in understanding the test results.

Ojard, G.↗

NASA NTRS2001

COSIM: A Finite-Difference Computer Model to Predict Ternary Concentration Profiles Associated With Oxidation and Interdiffusion of Overlay-Coated Substrates

A finite-difference computer program (COSIM) has been written which models the one-dimensional, diffusional transport associated with high-temperature oxidation and interdiffusion of overlay-coated substrates. The program predicts concentration profiles for up to three elements in the coating and substrate after various oxidation exposures. Surface recession due to solute loss is also predicted. Ternary cross terms and concentration-dependent diffusion coefficients are taken into account. The program also incorporates a previously-developed oxide growth and spalling model to simulate either isothermal or cyclic oxidation exposures. In addition to predicting concentration profiles after various oxidation exposures, the program can also be used to predict coating life based on a concentration dependent failure criterion (e.g., surface solute content drops to 2%). The computer code is written in FORTRAN and employs numerous subroutines to make the program flexible and easily modifiable to other coating oxidation problems.

Nesbitt, James A.↗

NASA NTRS2002

On the Numerical Convergence to Steady State of Hypersonic Flows Over Bodies with Concavities

Two recent numerical studies of hypersonic flows over bodies with concavities revealed problems with convergence to a steady state with an oft-used application of local-time-stepping. Both simulated flows showed a time-like, periodic shedding of vortices in a subsonic domain bounded by supersonic external flow although the simulations, using local-time-stepping, were not time accurate. Simple modifications to the numerical algorithm were implemented to enable implicit, first-order accurate in time simulations. Subsequent time-accurate simulations of the two test problems converged to a steady state. The baseline algorithm and modifications for temporal accuracy are described. The requirement for sub-iterations to achieve convergence is demonstrated. Failure to achieve convergence without time accuracy is conjectured to arise from temporal errors being continuously refocused into a subsonic domain.

Gnoffo, Peter A.↗

NASA NTRS2003

Intelligent Control Approaches for UAVs

This talk will present overviews of various intelligent control technologies currently being developed and studied at the NASA Ames Research Center as applicable to Unmanned Aerial Vehicles (UAVs), Mars flyers, and to the next generation of flight controllers for manned aircraft. The approaches being examined include: (a) direct adaptive dynamic inverse controller, (b) adaptive critic-based optimal trajectory generator; (c) optimal allocation technique based on linear programming; (4) immunized maneuvering using autopilot building blocks. These approaches can utilize, but do not require, fault detection and isolation information. Piloted and unmanned simulation studies are performed to examine if the intelligent flight control techniques adequately: 1) match flying qualities of modem fly-by-wire flight controllers under nominal conditions; 2) improve performance under failure conditions when sufficient control authority is available; and 3) achieve intelligent maneuvering capabilities for unmanned vehicles. Results obtained so far will be presented and discussed.

KrisnaKumar, Kalmanje↗

NASA NTRS2010

Definition and Demonstration of a Methodology for Validating Aircraft Trajectory Predictors

This paper presents a new methodology for validating an aircraft trajectory predictor, inspired by the lessons learned from a number of field trials, flight tests and simulation experiments for the development of trajectory-predictor-based automation. The methodology introduces new techniques and a new multi-staged approach to reduce the effort in identifying and resolving validation failures, avoiding the potentially large costs associated with failures during a single-stage, pass/fail approach. As a case study, the validation effort performed by the Federal Aviation Administration for its En Route Automation Modernization (ERAM) system is analyzed to illustrate the real-world applicability of this methodology. During this validation effort, ERAM initially failed to achieve six of its eight requirements associated with trajectory prediction and conflict probe. The ERAM validation issues have since been addressed, but to illustrate how the methodology could have benefited the FAA effort, additional techniques are presented that could have been used to resolve some of these issues. Using data from the ERAM validation effort, it is demonstrated that these new techniques could have identified trajectory prediction error sources that contributed to several of the unmet ERAM requirements.

Vivona, Robert A.↗

NASA NTRS2011

Pattern Recognition for a Flight Dynamics Monte Carlo Simulation

The design, analysis, and verification and validation of a spacecraft relies heavily on Monte Carlo simulations. Modern computational techniques are able to generate large amounts of Monte Carlo data but flight dynamics engineers lack the time and resources to analyze it all. The growing amounts of data combined with the diminished available time of engineers motivates the need to automate the analysis process. Pattern recognition algorithms are an innovative way of analyzing flight dynamics data efficiently. They can search large data sets for specific patterns and highlight critical variables so analysts can focus their analysis efforts. This work combines a few tractable pattern recognition algorithms with basic flight dynamics concepts to build a practical analysis tool for Monte Carlo simulations. Current results show that this tool can quickly and automatically identify individual design parameters, and most importantly, specific combinations of parameters that should be avoided in order to prevent specific system failures. The current version uses a kernel density estimation algorithm and a sequential feature selection algorithm combined with a k-nearest neighbor classifier to find and rank important design parameters. This provides an increased level of confidence in the analysis and saves a significant amount of time.

Restrepo, Carolina↗

NASA NTRS2014

Morpheus Vertical Test Bed Flight Testing

NASA's Morpheus Project has developed and tested a prototype planetary lander capable of vertical takeoff and landing, that is designed to serve as a testbed for advanced spacecraft technologies. The lander vehicle, propelled by a LOX/Methane engine and sized to carry a 500kg payload to the lunar surface, provides a platform for bringing technologies from the laboratory into an integrated flight system at relatively low cost. Morpheus onboard software is autonomous from ignition all the way through landing, and is designed to be capable of executing a variety of flight trajectories, with onboard fault checks and automatic contingency responses. The Morpheus 1.5A vehicle performed 26 integrated vehicle test flights including hot-fire tests, tethered tests, and two attempted freeflights between April 2011 and August 2012. The final flight of Morpheus 1.5A resulted in a loss of the vehicle. In September 2012, development began on the Morpheus 1.5B vehicle, which subsequently followed a similar test campaign culminating in free-flights at a simulated planetary landscape built at Kennedy Space Center's Shuttle Landing Facility. This paper describes the integrated test campaign, including successes and setbacks, and how the system design for handling faults and failures evolved over the course of the project.

Hart, Jeremy↗

NASA NTRS2016

Investigation of Performance Envelope for Phenolic Impregnated Carbon Ablator (PICA)

The present work provides the results of a short exploratory study on the performance of Phenolic Impregnated Carbon Ablator, or PICA, at high heat flux and pressure in an arcjet facility at NASA Ames Research Center. The primary objective of the study was to explore the thermal response of PICA at cold-wall heat fluxes well in excess of 1500 W/cm (exp 2). Based on the results of a series of flow simulations, multiple PICA samples were tested at an estimated cold wall heat flux and stagnation pressure of 1800 W/cm (exp 2) and 130 kPa, respectively. All samples survived the test, and no failure was observed either during or after the exposure. The results indicate that PICA has a potential to perform well at environments with significantly higher heat flux and pressure than it has currently been flown.

Ablative Material↗

NASA NTRSDate not supplied

Bootstrapping Multi-Agent Unmanned Aerial Vehicle (UAV) System Integration Using Ground-Based Assets: Lessons Learned

The highly dynamic nature of UAVs imposes significant challenges when conducting initial testing ranging from safety risks posed by high-capacity lithium batteries and spinning propellers to rigorous timing demands on controllers and the consequences of failures mid-air. Flight testing of a single vehicle is time and labor intensive due to these challenges and more, and the complexity increases exponentially with the number of vehicles. While simulations and hardware-in-the-loop bench testing can provide adequate environments for preliminary validation, differences in system deployment architecture, software interfaces, and hardware infrastructure between simulation and a fleet of real UAVs create a sizable gap that must be navigated carefully during system integration. In support of the Autonomy Teaming and TRAjectories for Complex Trusted Operational Reliability (ATTRACTOR) project, which had the goal of establishing a basis of certification of trust and trustworthiness in multi-agent autonomous systems, this gap was tackled from two directions. First, a novel mixed-reality simulation environment was engineered to blur the transition from simulation to flight hardware. Second, a fleet of Unmanned Surface Vehicles (USVs) was developed as a test and evaluation platform that more closely represented the final aerial fleet while eliminating many of the risks associated with air vehicles. This paper delves into the second element, analyzing the efficacy of the USV platform in performing system integration testing for the UAV system. In this paper we present the USV fleet and its role in reducing the aforementioned gaps in deployment architecture, software interfaces, and hardware infrastructure when moving from simulation to flight. An overview of the hardware and software onboard the vehicles will be provided along with supporting infrastructure. The system integration process will be documented including results in supporting both the overarching design reference mission (DRM) of ATTRACTOR and individual research efforts conducted during the project. Finally, we will discuss some of the practical lessons learned regarding the testing, deployment, and operation of multi-agent autonomous systems.

Matthew P Vaughan↗

NASA NTRSDate not supplied

Cost and Throughput Analysis for the NASA Ames Arc Jet Modernization Program

NASA Ames Center is currently evaluating alternatives to modernize the Arc Jet Complex, a critical part of testing for NASA’s planetary missions. NASA’s Arc Jet Complex facilities “are used to simulate the aerothermodynamic heating that a spacecraft endures throughout hypersonic atmospheric entry, and to test candidate thermal protection system (TPS) materials and systems. “Because planetary mission schedules often have tight windows due to planetary alignment constraints, a small increase in schedule could result in a two-year delay. Such a delay could increase the cost of a $1billionmissionbyhundreds of millions of dollars due to project personnel pay and clean room storage. To avoid these costs, the authors support NASA Ames in evaluating return on investment (ROI) and effectiveness of alternatives for modernizing the complex. The first input into the ROI is the deconstruction and construction cost estimates, which are developed using independent research on highly specialized subsystems, vendor quotes, and Unified Facilities Criteria (UFC), depending on the facility and work package. One of the measures of effectiveness is throughput analysis of the test bays, as a main goal of the modernization is to increase the number of possible test runs per year. This analysis is conducted via a probabilistic simulation and accounts for a variety of stochastic factors that influence the sequence of test runs, such as the facility availability; test complexity; the need to pause to assess test results; test failure; and the possibility of a system failure. The methodologies for both these analyses are discussed, along with the challenges presented due to the unique nature of the highly specialized test equipment.

Jennifer Scheel↗

NASA NTRS2022

Analyzing the Efficacy of Flexible Execution, Replanning, and Plan Optimization for a Planetary Lander

Plan execution in unknown environments poses a number of challenges: uncertainty in domain modeling, stochasticity at execution time, and the presence of exogenous events. These challenges motivate an integrated approach to planning and execution that is able to respond intelligently to variation. We examine this problem in the context of the Europa Lander mission concept, and evaluate a planning and execution framework that responds to feedback and task failure using two techniques: flexible execution and replanning with plan optimization. We develop a theoretical framework to estimate gains from these techniques, and we compare these predictions to empirical results generated in simulation. These results indicate that an integrated approach to planning and execution leveraging flexible execution, replanning, and utility maximization shows significant promise for future tightly-constrained space missions that must address significant uncertainty.

Chien, Steve↗

DOE OSTI2024

Initial Assessment of CTF for Time-at-Temperature Applications

The US nuclear industry is interested in improving the economics of their fleet of light-water reactors (LWRs) by uprating US plants. One option being considered is to regain lost margin from overly conservative fuel safety limits. The current limit requires avoidance of critical heat flux (CHF) and prevents further operation of fuel that experiences a dry-out in boiling water reactors (BWRs) or departure from nucleate boiling (DNB) in pressurized water reactors (PWRs); however, it has been shown that temporary, mild dry-out of the fuel does not necessarily increase the risk of fuel failure during its normal anticipated operating life. Such mild dry-out or DNB events may occur during a plant anticipated operational occurrence (AOO), such as a locked rotor in a PWR or a pump trip in a BWR. The time-at-temperature (TAT) approach to regulating fuel operation aims to demonstrate that the fuel rod’s integrity is not challenged during such a mild transient that leads to CHF in which the fuel operates at an elevated temperature for a brief period of time. However, implementing this approach will require extensive fuel material experimental data, as well as supporting modeling and simulation (M&S) predictions, to ensure that the predicted fuel response during AOOs, with all applicable uncertainty considered, will not threaten the safety of the fuel during the transient or the remainder of its anticipated lifecycle. To address this need, a comprehensive effort is being proposed that includes generating cladding material data under TAT conditions, assessment of available code capabilities for TAT conditions, development of new mechanistic models, and demonstration of the M&S capabilities for AOOs of interest. This will require a joint effort between the Nuclear Energy Advanced Modeling and Simulation (NEAMS) and Advanced Fuels Campaign (AFC) programs, as well as close collaboration with nuclear industry stakeholders. The outcome of this collaboration will result in development and assessment of capabilities that can be used by the nuclear industry to support qualification of a TAT-based fuel failure criteria safety limit. This report focuses on the thermal hydraulics (T/H) modeling capabilities and summarizes currently available data for validating the T/H subchannel code CTF for TAT conditions, as well as preliminary assessment results of the code. The initial assessment also resulted in implementation of an alternative post-CHF heat transfer package, which has been shown to significantly improve accuracy. This report is not a final assessment and does not consider all available validation data; it is intended that a future assessment will more fully validate the code for this application.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

NASA NTRS1999

Electrostatic Discharge Effects on Thin Film Resistors

Recently, open circuit failures of individual elements in thin film resistor networks have been attributed to electrostatic discharge (ESD) effects. This paper will discuss the investigation that came to this conclusion and subsequent experimentation intended to characterize design factors that affect the sensitivity of resistor elements to ESD. The ESD testing was performed using the standard human body model simulation. Some of the design elements to be evaluated were: trace width, trace length (and thus width to length ratio), specific resistivity of the trace (ohms per square) and resistance value. However, once the experiments were in progress, it was realized that the ESD sensitivity of most of the complex patterns under evaluation was determined by other design and process factors such as trace shape and termination pad spacing. This paper includes pictorial examples of representative ESD failure sites, and provides some options for designing thin film resistors that are ESD resistant. The risks of ESD damage are assessed and handling precautions suggested.

Sampson, Michael J.↗

DOE OSTI2023

Determining Stress in Metallic Conducting Layers of Microelectronics Devices Using High Resolution Electron Backscatter Diffraction and Finite Element Analysis

Delayed failure due to stress voiding is a concern with some aging microelectronics, as these voids can grow large enough to cause an open circuit. Local measurements of stress in the metallic layers are crucial to understanding and predicting this failure, but such measurements are complicated by the fact that exposing the aluminum conducting lines will relieve most of their stress. In this study, we instead mechanically thin the device substrate and measure distortions on the thinned surface using high resolution electron backscatter diffraction (HREBSD). These measurements are then related to the stresses in the metallic layers through elastic simulations. This study found that in legacy components that had no obvious voids, the stresses were comparable to the theoretical stresses at the time of manufacture (≈300 MPa). Distortion fields in the substrate were also determined around known voids, which may be directly compared to stress voiding models. In conclusion, the technique presented here for stress determination, HREBSD coupled with finite element analysis to infer subsurface stresses, is a valuable tool for assessing failure in layered microelectronics devices.

HREBSD↗

DOE OSTI2023

Root Cause Analysis of Degradation in Protonic Ceramic Electrochemical Cell with Interfacial Electrical Sensors Using Data‐Driven Machine Learning

Abstract Protonic ceramic electrochemical cells (PCECs) offer promising paths for energy storage and conversion. Despite considerable achievements made, PCECs still face challenges such as physiochemical compatibility between componenets and suboptimal solid–solid contact at the interfaces between the electrolytes and electrodes. In this study, a novel approach is proposed that combines in situ electrochemical characterization of interfacial electrical sensor embedded PCECs and machine learning to quantify the contributions of different cell components to total degradation, as well as to predict the remaining useful life. The experimental results suggest that the overpotential induced by the oxygen electrode is 48% less than that of oxygen electrode/electrolyte interfacial contact for up to 1171 h. The data‐driven machine learning simulation predicts the RUL of up to 2132 h. The root cause of degradation is overpotential increase induced by oxygen electrode, which accounts for 82.9% of total cell degradation. The success of the failure diagnostic model is demonstrated by its consistency with degradation modes that do not manifest in electrolysis fade during early real operations. This synergistic approach provides valuable insights into practical failure diagnosis of PCECs and has the potential to revolutionize their development by enabling improved performance prediction and material selection for enhanced durability and efficiency.

25 ENERGY STORAGE↗

DOE OSTI2022

Characterization of modeling and experimental data inconsistencies from burst testing for high-burnup commercial fuel rod applications

Fuel fragmentation, relocation, and dispersal are some of the largest issues remaining in the nuclear industry before rod-average burnup can be increased beyond 62 GWd/tU. The issue is primarily related to the potential for fuel to be dispersed into the reactor primary system, which may increase public risk. One way to prevent dispersal is to avoid cladding burst. The objective of this work is to support the high burnup safety case by evaluating cladding burst under high-burnup, full-length fuel rods and to identify uncertainties that could improve model predictions. The results of this analysis will evaluate realistic, prototypic loss-of-coolant accident (LOCA) conditions; support future cladding burst test designs; and inform the development of mechanistic material models. Realistic high-burnup operating conditions were implemented in the BISON fuel performance code to simulate steady-state and LOCA transient fuel rod evolution to the point at which cladding burst occurred. Parametric studies are performed to assess code response to changes in rod internal pressures and heating rates. Results were compared with simulated LOCA experiments to identify inconsistencies between commercial fuel rod analysis and experimental validation. The representative full-length fuel rod LOCA simulation results did not agree with cladding burst tests. Cladding burst tests indicated burst occurring well below (100–150 °C) those calculated in the full-length fuel rod LOCA analysis. Further investigation indicated that the cladding burst tests do not appear to be representative for full-length fuel rods. The inconsistency investigated in this work showed that the differences between the BISON simulation and the experiment's cladding burst conditions arise from an incomplete characterization of the cladding surface temperature, detailed rodlet characterization, lack of cladding strain measurements, and uncertainty in the cladding creep and failure models.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗