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DOE OSTI2026

Understanding failure in austenitic steels: Key considerations for molten salt storage in CSP applications

Owing to their excellent properties, austenitic stainless steels are extensively used in boilers, furnaces, molten salt tanks, and other applications that are subjected to extreme mechanical loads and high-temperature conditions. Their high corrosion and creep resistance make them suitable for high-temperature operating environments. Additionally, good fatigue resistance and favorable mechanical and visual properties are essential. However, the premature failure of several components at elevated temperatures has been previously reported. Although the failure analysis of components in service is complex, processes such as cold work and welding have been identified as contributing factors to the performance degradation of these steels. This study aims to analyze the various documented failure modes and mechanisms in austenitic steels, including creep, cracking, stress relaxation cracking, and fatigue, to better understand the multi-objective design requirements for these alloys as structural materials for high-temperature molten salt tanks in Concentrating Solar Power (CSP) plants. Stabilized austenitic grades, such as AISI 347H, demonstrate superior resistance to creep and corrosion-related degradation when compared to non-stabilized grades like AISI 316L at temperatures relevant to concentrated solar power (CSP) applications. In contrast, nickel-based alloys offer enhanced corrosion resistance, albeit at a higher cost. This review underscores that creep, stress relaxation cracking, and thermo-mechanical fatigue are the predominant long-term failure risks in CSP hot tanks.

14 SOLAR ENERGY↗

DOE OSTI2025

In-device Battery Failure Analysis

Lithium-ion batteries are indispensable power sources for a wide range of modern electronic devices. However, battery lifespan remains a critical limitation, directly affecting the sustainability and user experience. Conventional battery failure analysis in controlled lab settings may not capture the complex interactions and environmental factors encountered in real-world, in-device operating conditions. Here, this study analyzes the failure of commercial wireless earbud batteries as a model system within their intended usage context. Through multiscale and multimodal characterizations, the degradations from the material level to the device level are correlated, elucidating a failure pattern that is closely tied to the specific device configuration and operating conditions. The findings indicate that the ultimate failure mode is determined by the interplay of battery materials, cell structural design, and the in-device microenvironment, such as temperature gradients and their fluctuations. This holistic, in-device perspective on environmental influences provides critical insights for battery integration design, enhancing the reliability of modern electronics.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Non-destructive electrochemical diagnosis of failure mechanisms in aqueous zinc batteries

The early detection of secondary reactions that affect the life and performance of zinc manganese oxide batteries requires a shift from conventional time-consuming and often destructive procedures to rapid lifetime-predictive techniques. In this work, an electrochemical approach is employed to elucidate independent signatures for four common types of failure mechanisms in zinc manganese dioxide (Zn||MnO2) batteries—namely, the loss of zinc inventory, the loss of active material at the cathode, electrolyte depletion, and increased cell impedance. Our findings, specific to coin cell configurations, reveal that each induced failure mechanism can be distinctively modeled and identified based on responses from the rest voltage and columbic-efficiency data for prompt detection. For instance, electrolyte depletion response manifests a distinctive abrupt (>80 %) decrease in columbic efficiency (CE) and charge-rest voltage (Vc) while the discharge-rest voltage remained constant at ~1.3 V. Furthermore, electrolyte rejuvenation of the cell increased the CE to >95 % and restored Vc from ~0.3 to >1.7 V. Recovery experiments and reference performance tests demonstrated consistency between electrochemical descriptors and their associated failure mechanisms. Further, the outcomes of this work provide valuable insights and data models for some of the dominant failure mechanisms present in zinc manganese battery chemistries, which are beneficial to accelerated early-lifetime diagnosis and advancement of Zn batteries development.

25 ENERGY STORAGE↗

DOE OSTI2025

Numerical and experimental analysis of mechanically induced failure in electric vehicle battery modules

Mitigating thermal runaway and cell-to-cell propagation is essential for improving the safety of electric and hybrid vehicles. Enhancing digital twin capabilities to predict battery mechanical abuse is particularly critical for automotive and aerospace applications, where crashworthiness is a key concern. Understanding failure conditions and propagation in battery modules during mechanical abuse is complex due to interactions between structural deformation, heat transfer, electrochemical processes, exothermic reactions and mechanical fracture. While prior studies have focused on modeling cell-level behavior, extending these models to module or pack level is necessary for a system level understating of electric vehicle safety. This study develops coupled large deformation finite element models that simultaneously solve for electrochemistry, material failure, internal short circuit and thermal runaway propagation. The models account for mechanical and thermal interactions between lithium-ion cells and other battery components while the contact interfaces are evolving with time. Model-predicted voltage, temperature and force responses are compared with experimental data for validation. The results demonstrate that the approach captures key failure mechanisms, including thermal propagation through heat transfer, electrical propagation from short circuits in parallel-connected cells, and mechanical propagation via penetration and crack formation. These findings show that computational models are valuable tools for understanding battery module failure and providing insight that can reduce the need for extensive experimental testing.

25 ENERGY STORAGE↗

DOE OSTI2025

Rapid characterization and failure analysis of 6276 rooftop-harvested photovoltaic connectors

Photovoltaic (PV) connectors, which link modules in series and connect PV strings in parallel, have increasingly been recognized as a primary contributor to PV system failures and a source of numerous fire incidents. However, publicly available data on the rates and types of connector failures are scarce, primarily due to the proprietary nature of the information and the need for comprehensive analysis. This study represents the first large-scale investigation of harvested PV connectors, drawing from a dataset of 6276 connectors from residential rooftop solar systems across the United States. The outcome of this work is twofold: 1) we have established a rapid characterization method for large populations of harvested connectors, incorporating visual inspection, resistance measurements, and X-ray imaging; and 2) the analysis made possible by our rapid-processing method has revealed, for a population of connector models provided by a single rooftop installer, failure statistics and insights for various connector makes and models, installation practices, operating currents, and internal component displacements. This research identifies common failure modes that could be considered in future connector designs standards, and operations and maintenance practices, to ultimately improve the reliability of this vital component of PV infrastructure.

MC4↗

DOE OSTI2026

Hoop Tensile Failure Stress of 500 µm-Diameter Ceramic Spheres

The tensile failure stress of a brittle-material sphere is important to the survival of the sphere itself but is particularly relevant to systems that employ such spheres for applications in which the sphere exterior is subjected to tension during system fabrication or operation. That maximum hoop or tangential stress can be measured by diametrally compressing a C-sphere specimen directly machined from such spheres. This combination of specimen geometry and test method was conceived at Oak Ridge National Laboratory around 20 years ago. Although the C-sphere geometry has been tested with larger spheres, the ease and efficacy of its testing are unknown for submillimeter sphere diameters. To consider this, C-sphere specimens were machined from yttria-stabilized zirconia (YSZ) spheres of ∼500 µm diameter. The maximum (hoop or tangential) tensile stress was determined as a function of compressive failure force and specimen dimensions using finite element analysis. Companion effective area and volume as a function of Weibull modulus were computed. Hoop tensile failure stresses were then measured and fractography conducted to examine flaw type and location and to estimate the mirror constant of this YSZ grade. This novel study demonstrates that hoop tensile failure stress can be determined with sub-millimeter brittle-material spheres.

Delia, Daniel [ORNL] (ORCID:0000000209023239)↗

DOE OSTI2025

Preliminary System Interface Failure Mode Analysis for Two Advanced Reactors

This study explores two distinct Balance of Plant (BOP) configurations: the Rankine cycle for a sodium-cooled fast reactor (SFR) and the Brayton cycle for a gas-cooled reactor (GCR). As representative designs, the Power Reactor Innovative Small Module (PRISM) by GE Hitachi Nuclear Energy was selected for the SFR, while the Gas Turbine Modular Helium Reactor (GT MHR) by General Atomics was chosen for the gas-cooled reactor. Both configurations were adapted to deliver high-quality heat for industrial applications. A Failure Modes and Effects Analysis (FMEA) was conducted for each system to identify critical failure modes affecting key components. This study marks the first phase of a two-step design optimization approach, integrating FMEA into the design process. Based on the analysis, design modifications and mitigation strategies were proposed to enhance system resilience. The second phase, to be detailed in a subsequent report, will focus on the role of the control system in mitigating these failures. The FMEA serves as a foundation for defining the control topology, ensuring system resilience against component failures that could compromise essential functions, such as electricity and heat production.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2026

Modeling the PV System Level Economic Impact of PV Connector Failure Modes

Photovoltaic (PV) connectors must maintain mechanical integrity for over 25 years while operating under UV exposure, elevated temperature, and mechanical loading. Connector degradation increases with electrical resistance, leading to energy losses, unplanned downtime, and higher operation and maintenance (O&M) costs and in severe cases, safety risks from overhearing or arcing. Connector related failures remain among the most frequent causes of disruption in utility-scale PV (UPV) systems, yet their lifetime economic impacts are poorly quantified. This work presents a techno-economic analysis (TEA) framework that links identified connector failure modes to system level energy losses and lifetime cost impacts using identified resistance measurements and failure rates from 6,2761 PV connectors inspected. Connector failures increase system level O&M costs, raising LCOE by roughly 5%. Downtime driven availability losses dominate economic impact. Resistance-driven I2R and IV-curve losses are secondary, but remain non-negligible. Thermal damage, bend-radius violations, and loose connections drive the majority of LCOE uplift Improving connector reliability through better installation quality, inspection, and design can meaningfully reduce lost energy, O&M costs, and LCOE.

14 SOLAR ENERGY↗

DOE OSTI2024

Failure investigation and mitigation after experimental research reactor fuel plate deformation in an irradiation device

Experimental research reactor fuel testing is conducted in the Belgian Reactor 2 (BR2) of the Belgian Nuclear Research Centre (SCK CEN) in dedicated irradiation vehicles or rigs. One such vehicle allows flat full-size fuel plates to be irradiated by inserting them into slotted baskets that captures a narrow portion of the longitudinal edges of the plates. The motion of the fuel plates within the baskets is possible within the narrow slots and thus, the plate is considered to be unattached. The design intentionally omits fixing mechanisms of the fuel plates to the baskets to facilitate the inspection and repositioning of the plates between the irradiation cycles and the accommodation of thermal expansion of the plates in the lateral direction. However, loosely inserted fuel plates have weak structural boundary conditions allowing for larger out-of-plane deflections caused by hydrodynamic loads exerted by the flowing coolant, as compared to those of fixed plates. Unexpected large deformations of plates occurred in several irradiation cycles that further resulted in a loss of cladding integrity. These deformations could not be attributed to a single source. This triggered a series of thermal hydraulic, structural, and fluid-structure interaction analyses aiming at understanding the observed phenomenon. The analyses revealed that, for a certain combination of unfavorable manufacturing and assembly tolerances, fuel plate edges could escape out of the slots in the irradiation basket due to the hydrodynamic load. Subsequently, the plate could become wedged inside the basket coolant channel opening. This resulted in reduced coolant flow and accelerated temperature increase and thermal expansion of the plate while under irradiation. This unfavorable feedback loop could then lead to excessive plate surface temperatures, deformed plates and cladding failure, as was observed in the experiments. These analyses not only provided a probable cause of the fuel plate failures, but also resulted in a new and improved design of the irradiation basket to avoid these issues in the future. In conclusion, a series of recent successful irradiations confirm that the sources of failures were identified correctly, and the implemented mitigations were adequate.

BR2↗

DOE OSTI2024

Full-field quantitative visualization of shock-driven pore collapse and failure modes in PMMA

The dynamic collapse of pores under shock loading is thought to be directly related to hot spot generation and material failure, which is critical to the performance of porous energetic and structural materials. However, the shock compression response of porous materials at the local, individual pore scale is not well understood. This study examines, quantitatively, the collapse phenomenon of a single spherical void in PMMA at shock stresses ranging from 0.4 to 1.0 GPa. Using a newly developed internal digital image correlation technique in conjunction with plate impact experiments, full-field quantitative deformation measurements are conducted in the material surrounding the collapsing pore for the first time. The experimental results reveal two failure mode transitions as shock stress is increased: (i) the first in situ evidence of shear localization via adiabatic shear banding and (ii) dynamic fracture initiation at the pore surface. Numerical simulations using thermo-viscoplastic dynamic finite element analysis provide insights into the formation of adiabatic shear bands (ASBs) and stresses at which failure mode transitions occur. Further numerical and theoretical modeling indicates the dynamic fracture to occur along the weakened material inside an adiabatic shear band. Finally, analysis of the evolution of pore asymmetry and models for ASB spacing elucidate the mechanisms for the shear band initiation sites, and elastostatic theory explains the experimentally observed ASB and fracture paths based on the directions of maximum shear.

42 ENGINEERING↗

NASA NTRS1927

Duralumin - Defects and Failures

It is proposed in this paper to identify some of the defects and failures in duralumin most frequently encountered by the aircraft industry with a view to indicate their importance. The defects and failures in duralumin may be classified into the following groups: 1) defects produced during manufacture; 2) defects produced during fabrication; 3) corrosion and erosion; and 4) fatigue failures. Only the first two will be covered in this report.

DURALUMIN - DEFECTS & FAILURES↗

NASA NTRSDate not supplied

Battery Failure Databank

The Battery Failure Databank contains thermal runaway results gathered from nearly 300 small format fractional thermal runaway calorimetry (S-FTRC) experiments. A majority of these experiments were conducted at synchrotron facilities where high-speed x-ray videography was conducted of the cell while tested inside of the S-FTRC. The databank is a two-component system which consists of a Microsoft ExcelTM spreadsheet which provides S-FTRC results in tabular format and a radiographic video library containing the high-speed x-ray videos. Overall, the databank provides thermal results from S-FTRC experiments conducted on a mixture of commercially available lithium-ion (Li-ion) cells and specialized Li-ion test cells with varying cell format (18650, 21700, and D-cell) and trigger mechanism (heaters, heaters plus internal short circuiting device, and nail penetration). The radiography video component provides insight into the initiation and propagation of TR in the cells, in addition to consequences of TR measured by the FTRC. Fractions of mass ejected for the cell types are separated into regimes based on the different failure modes of the cells, such as purely venting, partial ejection, and total ejection. With knowledge of the rate and characterization of the internal degradation of the cells during TR, and the amounts of mass ejected and unrecovered, the extent of TR, and therefore the mitigation of TR, is revealed relative to cell types and failure modes.

Lithium-ion battery↗

DOE OSTI2025

Hydromechanical Modeling of Fault Rupture in Geologic CO 2 Sequestration: A Comparison of Two Failure Criteria

Abstract The large‐scale implementation of geological carbon sequestration has raised concerns about potential fault activation and induced seismicity, which could compromise storage integrity and pose seismic risks. We theoretically compared two failure criteria, Mohr‐Coulomb (MC) and Modified Cam‐Clay criteria (MCC), to assess fault rupture during CO 2 storage. Both criteria characterize fault behavior in a specific stress regime but differ in reducing the complexity of fault rupture to a few key mechanisms. Using a coupled hydromechanical model, we demonstrate that the choice of a failure criterion and the physics of fault weakening associated with these criteria strongly condition fault response to a given fluid injection. MC mainly relates rupture to friction, while MCC relates rupture to fault poro‐plasticity. Our findings highlight that the selection of a failure criterion, being inherently subjective, can significantly alter the predicted fault behavior during CO 2 storage, thereby impacting the reliability of geomechanical risk assessments.

Cao, M. [Energy Geosciences Division Lawrence Berk↗

DOE OSTI2025

Identification of Important Phenomena for Light Water Reactors During Heat Transport System Failure Events in Integrated Energy Systems

This work adapts historical literature and existing phenomena identification and ranking tables (PIRT) to be applicable to a novel nuclear power plant (NPP) and chemical or thermal process integrated energy system (IES), particularly focusing on the process heat and heat transport system failure events that are not a concern during normal NPP operation but become vital when an IES is considered. Nuclear energy has been suggested to go beyond base-load applications and be used for hydrogen co-generation systems, amongst other IESs. Prior to the implementation of nuclear IESs, sufficient analysis must be performed on accident events to ensure public safety. The events considered were deemed important because of their potential to damage systems, structures, and components (SSCs). Process thermal events of concern include loss of heat load and temperature transient events. Loss of heat load events were characterized as having high importance and being well understood. Temperature transient events may be further categorized by the cyclic loading and harmonics phenomena. Cyclic loading issues were classified as medium to high importance with knowledge gaps existing regarding fatigue and low power operation, while harmonics phenomena were classified as low importance and are well understood. Heat transport system failure events of concern include intermediate and process heat exchanger failures, mass addition to reactor coolant, ingress of material from thermal manifold/energy storage, and loss of intermediate fluid. Furthermore, these events tended to be of high or medium importance, with some knowledge gaps needing to be filled for individual reactor systems due to unique designs.

Integrated Energy System (IES)↗

DOE OSTI2026

Failure Mode and Effects Analysis (FMEA) for Photovoltaic Inverter

Photovoltaic (PV) inverters are critical yet vulnerable components in modern energy systems, often acting as reliability bottlenecks that increase the levelized cost of energy (LCOE). To address this, this paper presents a comprehensive Failure Mode and Effects Analysis (FMEA) tailored for PV inverters. Leveraging field data and literature, we identify failure-prone components, such as capacitors,, and relays, and prioritize their risks based on quantitative Risk Priority Numbers (RPNs). The analysis reveals that surge-induced MOV short circuits, capacitor degradation, and environmental cooling fan failures dominate the risk profile. These findings provide a targeted framework for reliability improvement, guiding future efforts in predictive diagnostics, design optimization, and accelerated life testing strategies.

14 SOLAR ENERGY↗

DOE OSTI2025

Reliability Analysis of Power Grids Considering Component Failures of Variable Energy Resources

This paper proposes an improved model for the reliability assessment of power systems considering component failures of variable energy resources (VER). The inherent intermittency of VER such as solar photovoltaic (PV) and wind farms, along with their susceptibility to component failures, present significant challenges to reliable system operation. These issues, combined with power grid operation and network constraints, complicate the reliable operation of VER-integrated power systems. Here, to address these concerns, this paper introduces a reliability assessment framework that considers VER input variability, its impact on component availability, and their resulting impact on overall system reliability. Stochastic models based on discrete Markov processes are developed to incorporate variable irradiance, wind speeds, and their effects on PV and wind component failure rates. A next-event and state transition-based approach is then developed to integrate the stochastic models into a mixed-timing sequential Monte Carlo simulation framework for composite reliability assessment. Case studies on the RTS-GMLC system demonstrate the effectiveness of the proposed model in evaluating the reliability of VER-integrated systems.

Pandit, Dilip [Sandia National Laboratories (SNL-N↗

NASA NTRS1993

Failure Modes of Reduced-Order Orbit Determination Filters and Their Remedies

Ways in which failure can occur in reduced-order, orbit determination filter, error covariance calculations are discussed. In the context of this article, reduced-order filters denote nonoptimal filters which include fixed levels of uncertainty in some parameters of the measurement models or in the spacecraft dynamical model which are not explicitly estimated in the filter equations. Failure is defined as an increase in the orbit determination covariance with the addition of data or as an unreasonable growth in the covariance with time, i.e., nonasymptotic behavior of the covariance. Some simple, known cases of failure are discussed along with their traditional remedies. In addition, more modern remedies are discussed which are currently under development at the Jet Propulsion Laboratory. The article first describes the known problems of reduced-order filters when they are employed for orbit determination, and their traditional remedies. Then, having defined these, the relevancy and desirability of the more modern remedies are made apparent.

D J Scheeres↗

DOE OSTI2024

Generic and ML Workloads in an HPC Datacenter: Node Energy, Job Failures, and Node-Job Analysis

HPC datacenters offer a backbone to the modern digital society. Increasingly, they run Machine Learning (ML) jobs next to generic, compute-intensive workloads, supporting science, business, and other decision-making processes. However, understanding how ML jobs impact the operation of HPC datacenters, relative to generic jobs, remains desirable but understudied. In this work, we leverage long-term operational data, collected from a national-scale production HPC datacenter, and statistically compare how ML and generic jobs can impact the performance, failures, resource utilization, and energy consumption of HPC datacenters. Our study provides key insights, e.g., ML-related power usage causes GPU nodes to run into temperature limitations, median/mean runtime and failure rates are higher for ML jobs than for generic jobs, both ML and generic jobs exhibit highly variable arrival processes and resource demands, significant amounts of energy are spent on unsuccessfully terminating jobs, and concurrent jobs tend to terminate in the same state. We open-source our cleaned-up data traces on Zenodo (https://doi. org/10.5281/zenodo.13685426), and provide our analysis toolkit as software hosted on GitHub (https://github.com/atlarge-research/2024-icpads-hpc-workload-characterization). This study offers multiple benefits for data center administrators, who can improve operational efficiency, and for researchers, who can further improve system designs, scheduling techniques, etc.

crossanalysis↗