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NASA NTRS2019

Achieving Improved Reliability with Failure Analysis

Reliability is the ability of a product to properly function, within specified performance limits, for a specified period of time, under the life cycle application conditions. Failure analysis is a vital tool in the effort to ensure reliability of electronic products and systems throughout their product lifecycle. Today, organizations involved in activities within the electronics supply chain are facing new challenges, not just from complex assembly styles, harsher lifecycle environments, and sophisticated supply chains, but also from customers who are demanding a quicker turn-around. Unfortunately, root cause failure analysis is often performed incompletely, leading to a poor understanding of failure mechanisms and causes and, customer dissatisfaction due to recurring failures. The PDC (Professional Development Course) starts with an introduction to reliability concepts, physics of failure and an overview of failure mechanisms that affect PCBs (Printed Circuit Boards), PCBAs (Printed Circuit Board Assembly) and components. The PDC then dives into root cause hypothesizing techniques (Pareto, FMEA (Failure Modes and Effects Analysis), fishbone (Cause-And-Effect Diagram), FTA (Fault Tree Analysis)), non-destructive and destructive analysis and, materials characterization will be discussed. Numerous failure analysis case studies will be used to illustrate the techniques and analysis principles to arrive at the root cause(s) of field failures on printed circuit boards, active components, and assemblies. What Attendees will Learn: Topics include: Overview of Reliability Concepts Failure mechanisms of electronic products Root cause analysis Failure analysis techniques -Non-destructive techniques (optical, CSAM (Confocal Scanning Electron Microscopy) etc.) -Destructive analysis (DPA (Destructive Physical Analysis), Decap (Decapsulation), FIB (Focused Ion Beam) etc.) -Materials characterization (XRF (X-Ray Fluorescence) , EDS (Error Detection Sequential), TMA/DSC (Thermal Mechanical Analysis/Differential Scanning Calorimetry) etc.)

PCB quality↗

DOE OSTI2024

Liquid lithium divertor analysis using coupled plasma material interaction model

A liquid lithium divertor can improve performance of future fusion devices by creating efficient power exhaust and improving the energy confinement via pumping of the hydrogen isotopes. In addition, significantly higher heat fluxes can be handled if controlled vapor shielding is used to redistribute the divertor heat flux over a wider area. Design and optimization of such a system calls for an analysis model which includes a strong two-way coupling between the plasma and divertor material. The incoming plasma heat and particle flux will affect the divertor surface temperature, which is a defining factor of the lithium evaporative and sputtered flux going into the plasma. Results of the coupled model based on the plasma edge code SOLPS-ITER and the computational fluid dynamics (CFD) code ANSYS-CFX will be presented for different configurations. An analytical slab flow model is used as a heat transfer boundary condition for SOLPS, defining particle flux from the wall via calculation of the surface temperature. At the final step, results of the SOLPS analysis are verified using a 3D CFD magnetohydrodynamics (MHD) analysis which uses heat and particle flux from SOLPS as a boundary condition. In addition to plasma heat flux, both analytical and CFD temperature models include several plasma material interaction effects, such as lithium evaporation, condensation and sputtering based on deuterium target flux. New adatom sputtering model based on the available experimental data is presented. Analytical model is expanded to include free surface axisymmetric configurations. Results of parametric studies of the divertor configurations with different lithium inlet temperature and velocity will be presented leading to the optimal design resulting in the lowest possible lithium contamination in the core.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

NASA NTRS1975

Analytical study of spacecraft deposition contamination by internal reflection spectroscopy

The in-situ vacuum chamber designed around the IRE was tested under vacuum. The contamination analyzer system was tested using two liquid contaminant materials. The analysis of the contaminants on the SL-4 rendezvous window shows that the material has methyl silicone, hydroxyl, and carbonyl radicals. The analysis of the outgassing material from Shuttle TPS shows silicone as the primary product.

Mookherji, T. K.↗

NASA NTRS1998

Theoretical Accuracy for ESTL Bit Error Rate Tests

"Bit error rate" [BER] for the purposes of this paper is the fraction of binary bits which are inverted by passage through a communication system. BER can be measured for a block of sample bits by comparing a received block with the transmitted block and counting the erroneous bits. Bit Error Rate [BER] tests are the most common type of test used by the ESTL for evaluating system-level performance. The resolution of the test is obvious: the measurement cannot be resolved more finely than 1/N, the number of bits tested. The tolerance is not. This paper examines the measurement accuracy of the bit error rate test. It is intended that this information will be useful in analyzing data taken in the ESTL. This paper is divided into four sections and follows a logically ordered presentation, with results developed before they are evaluated. However, first-time readers will derive the greatest benefit from this paper by skipping the lengthy section devoted to analysis, and treating it as reference material. The analysis performed in this paper is based on a Probability Density Function [PDF] which is developed with greater detail in a past paper, Theoretical Accuracy for ESTL Probability of Acquisition Tests, EV4-98-609.

Lansdowne, Chatwin↗

NASA NTRSDate not supplied

Ion Gun for In Situ Resource Identification

Identification of surface resources localized to landing sites is a critical need for future lunar exploration. Crews will need small, lightweight instrumentation that can be easily carried to identify potential resources in situ without extraction of samples for testing. This project aimed to conduct a proof-of-concept of using ion sputtering coupled with mass spectroscopy to provide in situ composition analysis of surface materials with no need to collect and/or return samples. Ion beam sputtering is a mature ground-based technique that ablates material surfaces for analysis.

ion sputtering↗

NASA NTRS2010

An Analysis of the Selected Materials Used in Step Measurements During Pre-Fits of Thermal Protection System Tiles and the Accuracy of Measurements Made Using These Selected Materials

The goal of this research project was be to compare and contrast the selected materials used in step measurements during pre-fits of thermal protection system tiles and to compare and contrast the accuracy of measurements made using these selected materials. The reasoning for conducting this test was to obtain a clearer understanding to which of these materials may yield the highest accuracy rate of exacting measurements in comparison to the completed tile bond. These results in turn will be presented to United Space Alliance and Boeing North America for their own analysis and determination. Aerospace structures operate under extreme thermal environments. Hot external aerothermal environments in high Mach number flights lead to high structural temperatures. The differences between tile heights from one to another are very critical during these high Mach reentries. The Space Shuttle Thermal Protection System is a very delicate and highly calculated system. The thermal tiles on the ship are measured to within an accuracy of .001 of an inch. The accuracy of these tile measurements is critical to a successful reentry of an orbiter. This is why it is necessary to find the most accurate method for measuring the height of each tile in comparison to each of the other tiles. The test results indicated that there were indeed differences in the selected materials used in step measurements during prefits of Thermal Protection System Tiles and that Bees' Wax yielded a higher rate of accuracy when compared to the baseline test. In addition, testing for experience level in accuracy yielded no evidence of difference to be found. Lastly the use of the Trammel tool over the Shim Pack yielded variable difference for those tests.

Kranz, David William↗

NASA NTRS2017

Material Characterization for the Analysis of Skin/Stiffener Separation

Test results show that separation failure in co-cured skin/stiffener interfaces is characterized by dense networks of interacting cracks and crack path migrations that are not present in standard characterization tests for delamination. These crack networks result in measurable large-scale and sub-ply-scale R curve toughening mechanisms, such as fiber bridging, crack migration, and crack delving. Consequently, a number of unknown issues exist regarding the level of analysis detail that is required for sufficient predictive fidelity. The objective of the present paper is to examine some of the difficulties associated with modeling separation failure in stiffened composite structures. A procedure to characterize the interfacial material properties is proposed and the use of simplified models based on empirical interface properties is evaluated.

Davila, Carlos G.↗

NASA NTRS1971

Estimating Weibull parameters for materials

The statistical analysis of strength and fracture of materials in general, with application to fiber composites are discussed. The weakest link model is considered in a fairly general form, and the resulting equations are demonstrated by using a Weibull distribution for flaws. This distribution appears naturally in a variety of problems, and therefore additional attention is devoted to analysis and statistical estimation connected with this distribution. Special working charts are included to facilitate interpretation of observed data and estimation of parameters. Implications of the size effect are considered for various kinds of flaw distributions. Failure and damage in a fiber-reinforced system are described. Some useful graphs are included for predicting the strength of such a system. Recent data on organic-fiber (PRD 49) composite material is analyzed by the Weibull distribution with the methods presented.

Robinson, E. Y.↗

NASA NTRS2013

The Detection of Evolved Oxygen from the Rocknest Eolian Bedform Material by the Sample Analysis at Mars(SAM) instrument at the Mars Curiosity Landing Site

The Sample Analysis at Mars (SAM) instrument onboard the Curiosity rover detected an O2 gas release from the Rocknest eolain bedform (Fig. 1). The detection of perchlorate (ClO4-) by the Mars Phoenix Lander s Wet Chemistry Laboratory (WCL) [1] suggests that perchlorate is a possible candidate for evolved O2 release detected by SAM. The perchlorate would also serve as a source of chlorine in the chlorinated hydrocarbons detected by the SAM quadrupole mass spectrometer (QMS) and gas chromatography/mass spectrometer (GCMS) [2,3]. Chlorates (ClO3-) [4,5] and/or superoxides [6] may also be sources of evolved O2 from the Rocknest materials. The work objectives are to 1) evaluate the O2 release temperatures from Rocknest materials, 2) compare these O2 release temperatures with a series of perchlorates and chlorates, and 3) evaluate superoxide O2- sources and possible perchlorate interactions with other Rocknest phases during QMS analysis.

Sutter, B.↗

DOE OSTI2025

Clustering Algorithm for AM Parts using GSH and EDT with Autoencoder

SAND2025-10103O The Clustering Algorithm for AM Parts Using GSH and (EDT With Autoencoder is a software tool. It uses a clustering algorithm for additive manufacturing (AM) parts using generalized spherical harmonics (GSH) and Euclidean distance transform (EDT) with an autoencoder to quantify material microstructure. The tool offers improved sensitivity to microstructural changes compared to traditional approaches. The tool integrates multiple microstructural properties, such as grain morphology, crystallographic orientation, and material phase information, to provide a comprehensive analysis of material microstructures. Sandia National Laboratories is a multimission laboratory managed and operated by National Technology & Engineering Solutions of Sandia, LLC, a wholly owned subsidiary of Honeywell International Inc., for the U.S. Department of Energy’s National Nuclear Security Administration under contract DE-NA0003525.

Rodgers, Theron [Sandia National Lab. (SNL-CA), Li↗

NASA NTRS1990

Materials degradation in low earth orbit (LEO); Proceedings of the Symposium, 119th Annual Meeting of the Minerals, Metals, and Materials Society, Anaheim, CA, Feb. 17-22, 1990

The current understanding of the effect of space environment on materials and the development of protective coatings is examined in reviews and reports. Consideration is given to hyperthermal atomic oxygen reactions, the effect of atomic oxygen on altered and coated Kapton surfaces for spacecraft applications in LEO, silicon dioxide space coatings studied ellipsometrically, atomic oxygen effects on spacecraft materials, atomic oxygen beam source for erosion simulation, and atomic oxygen effects on refractory materials. Particular attention is given to ellipsometric analysis of materials degradation in space, studies of the interaction of 8 km/s oxygen atoms with selected materials, characterization and calibration of the EOIM-III flight mass spectrometer in a high velocity oxygen atom beam, the reaction efficiency of thermal energy oxygen atoms with polymeric materials, and effects of simulated space environments on the properties of selected materials.

Srinivasan, V.↗

NASA NTRS2015

Nanophase Carbonates on Mars: Does Evolved Gas Analysis of Nanophase Carbonates Reveal a Large Organic Carbon Budget in Near-Surface Martian Materials?

Evolved Gas Analysis (EGA), which involves heating a sample and monitoring the gases released, has been performed on Mars by the Viking gas chromatography/mass spectrometry instruments, the Thermal and Evolved Gas Analyzer (TEGA) on the Phoenix lander, and the Sample Analysis at Mars (SAM) instrument on the Mars Science Laboratory. All of these instruments detected CO2 released during sample analysis at abundances of approx. 0.1 to 5 wt% assuming a carbonate source. The source of the CO2 can be constrained by evaluating the temperature of the gas release, a capability of both the TEGA and SAM instruments. The samples analyzed by SAM show that the majority of the CO2 is released below 400C, much lower than traditional carbonate decomposition temperatures which can be as low as 400C for some siderites, with magnesites and calcites decomposing at even higher temperatures. In addition to mineralogy, decomposition temperature can depend on particle size (among other factors). If carbonates formed on Mars under low temperature and relative humidity conditions, the resulting small particle size (nanophase) carbonates could have low decomposition temperatures. We have found that calcite can be synthesized by exposing CaO to water vapor and CO2 and that the resulting mineral has an EGA peak of approx. 550C for CO2, which is about 200C lower than for other calcites. Work is ongoing to produce Fe and Mg-bearing carbonates using the same process. Current results suggest that nanophase calcium carbonates cannot explain the CO2 released from martian samples. If the decomposition temperatures of Mg and Fe-bearing nanophase carbonates are not significantly lower than 400C, other candidate sources include oxalates and carboxylated organic molecules. If present, the abundance of organic carbon in these samples could be greater than 0.1 wt % (1000s of ppm), a signficant departure from the paradigm of the organic-poor Mars based on Viking results.

Archer, P. Douglas, Jr.↗

NASA NTRS2016

Substructure Versus Property-Level Dispersed Modes Calculation

This paper calculates the effect of perturbed finite element mass and stiffness values on the eigenvectors and eigenvalues of the finite element model. The structure is perturbed in two ways: at the "subelement" level and at the material property level. In the subelement eigenvalue uncertainty analysis the mass and stiffness of each subelement is perturbed by a factor before being assembled into the global matrices. In the property-level eigenvalue uncertainty analysis all material density and stiffness parameters of the structure are perturbed modified prior to the eigenvalue analysis. The eigenvalue and eigenvector dispersions of each analysis (subelement and property-level) are also calculated using an analytical sensitivity approximation. Two structural models are used to compare these methods: a cantilevered beam model, and a model of the Space Launch System. For each structural model it is shown how well the analytical sensitivity modes approximate the exact modes when the uncertainties are applied at the subelement level and at the property level.

Stewart, Eric C.↗

DOE OSTI2024

A Method for Producing Hierarchical and Statistically Calibrated Predictions of Nuclear Material Properties from Existing Models

Computer vision-based analysis of micrographs of nuclear materials is an emerging technique for property prediction, synthetic route identification, and other material analysis tasks. These analysis tasks play a pivotal role in many material characterization applications such as signature development for treaty verification, process optimization, etc. The backbone in many of the recent computer vision-based techniques is a deep learning model, which takes a fixed-size set of pixels and provides a class prediction for that set of pixels. For example, previous work developed a deep convolutional neural network (CNN) to predict the synthetic route from a 256 px x 256 px patch taken from a larger image of uranium ore concentrates. In this work, we present several methods for first calibrating these models in a manner that they can provide accurate probabilities of their predictions’ veracity, and several methods of combining these probabilities. Overall, the combination of these two steps into a pipeline allows for full-image and even full-sample (where a sample has many images) predictions with associated confidence values. Finally, we show that one can also use the patch predictions and confidence to produce a visualization to map predicted constituents through the image. Results and examples for predicting and mapping uranium ore concentrates’ synthetic process from imagery will be presented.

artificial intelligence↗

NASA NTRS2016

Organic Analysis in Miller Range 090657 and Buckley Island 10933 CR2 Chondrites: Part 1 In-Situ Observation of Carbonaceous Material

Primitive carbonaceous chondrites contain a wide variety of organic material, ranging from soluble discrete molecules to insoluble unstructured kerogen-like component as well as structured nano-globules of macromolecular carbon. The relationship between the soluble organic molecules, macromolecular organic material, and host minerals are poorly understood. Due to the differences in extractability of soluble and insoluble organic materials, the analysis methods for each differ and are often performed independently. The combination of soluble and insoluble analyses, when performed concurrently, can provide a wider understanding on spatial distribution, and elemental, structural and isotopic composition of organic material in primitive meteorites. Furthermore, they can provide broader perspective on how extraterrestrial organic ma-terials potentially contributed to the synthesis of life's essential compounds such as amino acids, sugar acids, activated phosphates and nucleobases.

Cao, T.↗

DOE OSTI2025

Enhancing supply resilience for critical materials: case study of gallium supply in the United States

Accelerating energy technology development will increase demand for critical raw materials, such as gallium, that enable clean energy technologies. Processing of gallium is concentrated in mainland China (98 % of global production in 2023), resulting in high supply risks for importing countries. To investigate pathways for more resilient supply, we develop a material flow analysis and apply it to the United States, showing the impacts of future domestic primary raw material production and end-of-life (EoL) product recycling on reducing import reliance of raw gallium metal. We complement this analysis with a techno-economic assessment of North American gallium production costs under various demand growth scenarios. Our results indicate that sufficient domestic feedstocks exist to meet U.S. demand under most scenarios by 2035, while EoL recycling can supply up to 50 % under a low-demand growth scenario. Domestic primary production shows significant cost advantages over gallium recycling.

Cost analysis↗

NASA NTRS2008

User-defined Material Model for Thermo-mechanical Progressive Failure Analysis

Previously a user-defined material model for orthotropic bimodulus materials was developed for linear and nonlinear stress analysis of composite structures using either shell or solid finite elements within a nonlinear finite element analysis tool. Extensions of this user-defined material model to thermo-mechanical progressive failure analysis are described, and the required input data are documented. The extensions include providing for temperature-dependent material properties, archival of the elastic strains, and a thermal strain calculation for materials exhibiting a stress-free temperature.

Knight, Norman F., Jr.↗

DOE OSTI2025

PV backsheets survey protocol: A framework for geo-spatial field surveys for bulk material characterization and reliability analysis applied across 41 PV systems

As widespread adoption of photovoltaic (PV) technologies continues, understanding the lifetime of modules is paramount to the viability of the industry as an environmentally conscious alternative to traditional energy generation. Although power degradation can affect the total energy production of a module over its lifetime, module safety failures necessitate the removal of a module leading to a loss of not only the particular asset, but the earning potential of the device. Therefore, it is critical to ensure that the components that provide essential safety functions for PV module operate for their entire rated lifetime. PV backsheets provide necessary electrical insulation to the completed device and failure of this component is cause for a immediate removal of the module. Degradation of the PV module backsheet has led to module safety failures in large-scale installations, costing millions of dollars in damages and lost potential revenue. The spatio-temporal degradation of fielded PV modules is important to study in order to identify which modules within installations are experiencing the greatest exposure conditions and in turn have the highest chance of failure. This paper describes a comprehensive field survey protocol developed for monitoring PV module backsheet performance using solely non-destructive methods in commercial PV fields. The protocol establishes a field naming convention, sampling method, data handling requirements, and measurement procedures. By ensuring consistent data collection practices, the field survey protocol enables research groups to obtain data of uniform quality on backsheet performance over multiple years and locations. In this study, the developed protocol was implemented at forty-one PV sites. Eight different types of airside layer backsheet materials including poly(vinylidene fluoride) (PVDF), acrylic PVDF, poly(tetrafluoroethylene-co-hexafluoropropylene-co-vinylidene fluoride) (THV), poly(vinyl fluoride) (PVF), poly(ethylene terephthalate) (PET), fluoroethylene vinyl ether (FEVE), polyethylene naphthalate (PEN), and glass were identified using attenuated total reflection Fourier transform infrared (ATR-FTIR) spectroscopy. The field survey results show that the spatial distribution of degradation indicators are non-uniform within a particular module, individual site, and across site locations. The degradation of PV modules increased in severity for modules mounted at the edge of rows (across a field) and near the junction box (within a module). This study demonstrates the sensitivity of material performance to exposure length across different materials and climates.

14 SOLAR ENERGY↗