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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.

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At least 469 records · Page 26

Detecting Hidden Failure Modes in Critical, Embedded Software

This experience report describes a method that has been used successfully to detect hidden failure modes in critical, embedded spacecraft software. The method is an adaptation of an earlier, controversial approach called failure modes and effects analysis. The adapted method was found to be well-suited to identifying latent software design weaknesses involving complex system interactions and dependencies in the two applications described here. This experience may be useful for other high-integrity software systems in which the possibility of hidden failure modes is a major concern.

detecting software failure design analysis↗

Some Observations of Solder Joint Failure Under Tensile-Compressive Stress

It has long been known that solder joints under mechanical stress are subject to failure. In early electronic systems, such failures were avoided primarily by avoiding the use of solder as a mechanical structural component. The rule was to first make sound wire connections that did not depend mechanically on solder, and only then to solder them. Careful design and miniaturization in modern electronic systems limits the mechanical stresses exerted on solder joints to values less than their yield points, and these joints have become integral parts of the mechanical structures. Unfortunately, while these joints are strong enough when new, they have proven vulnerable to fatigue failures as they age.Details of the fatigue process are poorly understood, making predictions of expected lifetimes difficult.

solder joints fatigue failure thermal cycling test↗

Multiscale Failure Analysis of a 3D Woven Unit Cell Containing Defects

Multiscale failure simulations have been performed for a Three-dimensional woven composite unit cell considering five, or more, length scales spanning the woven composite mesoscale to the sub-microscale voids. The multiscale recursive micromechanics approach, which enables recursive integration of general micromechanics theories over an arbitrary number of length scales, has been employed within the NASA Multiscale Analysis Tool. The multiscale model uses both the generalized method of cells and Mori-Tanaka micromechanics theories, and considers failure in the constituent materials using a simple damage model. Baseline results, containing distributed voids, are compared to uniaxial experimental data for an AS4 carbon fiber/ RTM6 epoxy matrix 3D orthogonal woven composite with good agreement in terms of global stiffness and global failure stress. The simulations demonstrate that the 3D woven composite exhibits damage tolerance through sustaining increasing axial load far beyond the first initiation of damage. The multiscale model is used to examine the nonlinear response of the material to other loading conditions. Case studies, motivated by X-ray computed tomography data, are presented on the effects of manufacturing induced voids and cracks.

3D woven↗

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↗

Popcorning Failures in Polymer and MnO2 Tantalum Capacitors

Popcorning is a well-known effect in plastic encapsulated microcircuits (PEM) and it occurs in chip tantalum capacitors. The sensitivity of components to the presence of moisture during soldering is characterized by the moisture sensitivity level (MSL); however, contrary to PEMs, there is no standard procedure for establishing MSL for tantalum capacitors.The effect of absorbed moisture on soldering related degradation and failures in tantalum capacitors have not been studied properly yet, and there is no sufficient information regarding the difference in the sensitivity to soldering between polymer and MnO2 capacitors. In this work, 16 types of polymer and 9 types of MnO2 tantalum capacitors with different moisture content have been tested before and after reflow soldering. The level of moisture release during soldering has been estimated and thermo-mechanical analysis used to assess deformation of capacitorsduring soldering simulations. Results show that moisture uptake in similar parts is approximately two times greater in polymer than in MnO2 capacitors. Cracking of the case and degradation of parameters can occur in both types of parts, but MnO2 capacitors are much more likely to fail catastrophically with a short circuit and possible ignition during the first power-on cycle. This type of failure in MnO2 capacitors is lot-related, can occur even at derated voltages and relatively low levels of moisture sorption that corresponds to room conditions. Baking before soldering is an effective measure to prevent failures even in lots susceptible to popcorning damage.

Capacitor↗

NASA Engineering and Safety Center Technical Bulletin No. 21-05: Industry Recommendations from Arecibo Observatory Zinc Spelter Socket Joint Failure Analysis

A structural analysis and forensic investigation concluded that the Arecibo Observatory M4N socket joint failure in August 2020 was primarily due to cumulative damage caused by initially low structural design margins and a high percentage of sustained load, resulting in zinc creep deformation, progressive internal socket wire damage, and eventual loss of joint capacity. Open spelter sockets of this type are used throughout industry in stay cables. Recommendations are proposed to prevent failures of similar socket joints, including verification of positive stress margins in socket joint wires for all failure modes, periodic visual inspections with pass/fail criteria for zinc extrusion that are tied to structural qualification, and revisiting codes/ industry standards to capture lessons learned.

Arecibo Observatory↗

What is “First Ply Failure” in a Unidirectionally Loaded Quasi-Isotropic Composite (and does it exist)?

This study presents experimental results of unidirectional tension tests on quasi-isotropic laminates to observe so called “first ply failure” (FPF). The modulus of the laminates was measured throughout the test to observe any ply degradation. Quasi-isotropic (QI) laminates were tested since this is the most common layup sequence of a laminate in industry and FPF, if it exists to any practical extent, should be observed. The authors are unaware of any claim that only bi-axial loads are needed to cause FPF, thus uniaxial testing was performed since this is much simpler than bi-axial testing. Laminates can be engineered to cause anomalies (“knees” or abrupt change in modulus) in a stress-strain curve (such as sandwiching multiple 90° plies between a couple of 0° plies) but such laminates should never be used in practice. The search for FPF was examined in simple 8 ply QI laminates by stopping tension tests at various levels post predicted FPF and examining the specimen for “ply failure” and ascertaining its effect (if any) on the modulus of the laminate. The ultimate strength values were found for some specimens. Results showed that for 8 ply QI laminates, no FPF of note was found and challenges the whole notion of FPF and thus “progressive failure”.

First ply failure↗

Basic failure mechanisms in advanced composites

Fundamental failure mechanisms in carbon-epoxy composites were studied for more reliable prediction of the performance of these materials. Single and multiple fiber specimens were tested under tensile loads, and the sequence of failure events was observed. Parameters such as resin crack sensitivity, fiber surface treatment and variations in fibers from batch to batch are being evaluated. The analysis of bulk composite fracture processes using acoustic emission techniques is being studied in order to correlate microscopic observations with bulk composite behavior. Control of the fracture process through matrix and interface modification is being attempted, and study of failure processes in composite/metal specimens is being conducted. Most of the studies involved DEN 438 epoxy novolac as the matrix, but some experiments are now underway using the higher temperature resin ERLA 4617.

Mullin, J. V.↗

Failure-rate computations based on Mariner Mars 1969 spacecraft data

An analysis of in-flight spacecraft part hours and failure data from the Mariner Mars 1969 Project is given. It contains failure rates computed from this data for all electronic and electromagnetic parts on the Mariners 6 and 7 spacecraft. Also included are failure rates based on combining flight data from Mariners 4,5,6, and 7.

Chelson, P. O.↗

Report of the NASA Ad Hoc Committee on failure of high strength structural materials

An analysis of structural failures that have occurred in NASA programs was conducted. Reports of 231 examples of structural failure were reviewed. Attempts were made to identify those factors which contributed to the failures, and recommendations were formulated for actions which would minimize their effects on future NASA programs. Two classes of factors were identified: (1) those associated with deficiencies in existing materials and structures technology and (2) those attributable to inadequate documentation or communication of that technology.

Brown, W. F., Jr.↗

A three-failure-tolerant computer system.

Two basic factors influence the design of highly reliable computer systems: the amount of failures required to be tol erated and the reliability or MTBF required. A computer system designed to tolerate any three single failures in a fail-operational-fail-operational-fail-safe manner for a real-time control application is presented. The design approach uses adaptive majority voting in both hardware and software with a four-level redundant system. Various methods of performing the adaptive majority voting functions were evaluated with the selected approach using a special module termed a voter-comparator switch (VCS). The VCS module allows the computer system to be operated in a variety of redundant modes, depending on the failure tolerance required at any particular time.

Koczela, L. J.↗

Incipient failure detection.

In connection with the preparation for long-range space missions it is highly important to be able to identify potentially failure prone equipment in advance of the launch commitment. Physical phenomena investigated for this purpose include X-ray and gamma radiation, electrical noise, IR and UV radiation, and vibration energy. The technique selected must be capable of detecting the onset and evaluating the progression of conditions that represent basic causes which could lead to failure. As a result of the investigation, techniques based on acoustic energy release were selected as the most promising for incipient failure detection.

Griswold, J. W.↗

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.↗

Failure management of multiple gimbal inertial systems for space shuttle

A failure detection and isolation technique for use with four gimbaled inertial measurement units (IMU) is presented. By using simulated boost and entry shuttle trajectories with specific gimbaled IMU models, failure detection thresholds are developed based on red-line life dependent requirements and warning thresholds within the red-line thresholds based on expected worst case IMU performance. Using these trajectories, established trajectory threshold, and multiple IMU models, various failure detection and isolation techniques are evaluated for application in both powered and unpowered flight phases. The adequacy of the systems for both attitude and velocity detection methods is evaluated and recommendations for space shuttle applications are made.

Dove, D. W.↗

Thesaurus of terms for information on mechanics of structural failure

A Thesaurus of approximately 700 subject terms used to describe the six problem areas in the mechanics of structural failure is presented. The initial criteria for the selection of terms are their significance and frequency of use in the literature describing the mechanics of structural failure. The purpose of the Thesaurus is to provide the Aerospace Safety Research and Data Institute a list of key works and identifiers that afford effective retrieval of information regarding failure modes and mechanisms for aerospace structures. The Thesaurus includes both a conventional listing of subject terms and a Key Words In Context (KWIC) listing.

Carpenter, J. L., Jr.↗

Register of specialized sources for information on mechanics of structural failure

Specialized information sources that generate information relative to six problem areas in aerospace mechanics of structural failure are identified. Selection for inclusion was based upon information obtained from the individual knowledge and professional contacts of Martin Marietta Aerospace staff members and the information uncovered by the staff of technical reviewers. Activities listed perform basic or applied research related to the mechanics of structural failure and publish the results of such research. The purpose of the register is to present, in easy reference form, original sources for dependable information regarding failure modes and mechanisms of aerospace structures.

Carpenter, J. L., Jr.↗

Competitive evaluation of failure detection algorithms for strapdown redundant inertial instruments.

Seven algorithms for failure detection, isolation, and correction of strapdown inertial instruments in the dodecahedron configuration are competitively evaluated by means of a digital computer simulation that provides them with identical inputs. Their performance is compared in terms of orientation errors and computer burden. The analytical foundations of the algorithms are presented. The features that are found to contribute to superior performance are use of a definite logical structure, elimination of interaction between failures, different thresholds for first and second failures, use of the 'parity' test signals, and avoidance of iteration loops.

Wilcox, J. C.↗