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NASA NTRSDate not supplied

NASA Physics of Failure (PoF) for Reliability

An item’s reliability or longevity is dependent not only on its design but also on how it is used, manufactured, tested, and the stresses it has or will experience. Stresses include operational and environmental exposures to thermal, voltage, current, age/exposure, mechanical, and radiation mechanisms. Therefore, in reliability analysis, it is important to consider the contributions of all these factors when predicting the failure rates of components. Historically, there has been a reliance on handbook data (e.g., MIL-HDBK-217), but experience has shown that these values and distributions are not representative of actual performance. Therefore, to make more credible reliability and risk assessments for its missions, NASA must transition to estimating likelihoods of failure based on an item’s reliability or longevity factors (or the physical susceptibilities and strengths impacting the design’s performance) has or will experience, whenever possible. To facilitate this transition, a Handbook on Methodology for Physics of Failure Based Reliability Assessments has been developed by NASA to assist in applying physics experiences or experimental physics for empirical analysis and conceptualized physics exposures or theoretical physics for deterministic analysis, to develop and aggregate realistic likelihoods of failure leading to more credible forecasts of item performance and longevity. In addition, since it is NASA’s intention that this document continues to evolve based on community lessons learned and the introduction of new assessment methodologies, NASA is encouraging and appreciates the contributions of current and future authors to maintain and enhance this handbook and its supporting case studies.

PoF↗
NASA NTRSDate not supplied

The Competition of Failure Modes in an Additively Manufactured Disk Superalloy

Additive manufacturing of powder metallurgy disk superalloys can produce unique microstructures that are different from those usually encountered in traditional processing by consolidation, forging, and heat treatments. Unusual variations in grain size, major and minor phase precipitate sizes, and defects can occur. The associated failure modes of these unique microstructures are of high interest. The objective of this study was to compare the failure modes for a powder metallurgy disk superalloy LSHR produced by electron beam melting additive manufacturing. Specimens were subsequently given different solution heat treatments and a fixed aging heat treatment. Tensile, creep, and fatigue failure modes were screened in tests at elevated temperatures. Failure modes were considered with respect to these unique microstructures.

additive manufacturing↗
NASA NTRS2023

Competition of Failure Modes in an Additively Manufactured Disk Superalloy

Additive manufacturing of powder metallurgy (PM) disk superalloys can produce unique microstructures that differ from those usually encountered in traditional processing as the result of consolidation, forging, and heat treatments. Unusual variations in grain size, major and minor phase precipitate sizes, and defects can occur. The failure modes associated with these unique microstructures are of high interest. The objective of this study was to compare the failure modes for a low solvus, high refractory (LSHR) PM disk superalloy produced by electron-beam-melting additive manufacturing. Specimens were subsequently given different solution heat treatments and a fixed aging heat treatment. Tensile, creep, and fatigue failure modes were screened in tests at elevated temperatures. Failure modes were considered with respect to these unique microstructures.

additive manufacturing↗
DOE OSTI2016

Nitrile O-ring Cracking: A Case of Vacuum Flange O-ring Failures

A review of recent nitrile O-ring failures in ISO-KF vacuum flange connections in glovebox applications is presented. An investigation of a single “isolated” o-ring failure leads to the discovery of cracked nitrile o-rings in a glovebox atmospheric control unit. The initial cause of the o-ring failure is attributed to ozone degradation. However, additional investigation reveals nitrile o-ring cracking on multiple gloveboxes and general purpose piping, roughly 85% of the nitrile o-rings removed for inspection show evidence of visible cracking after being in service for 18 months or less. The results of material testing and ambient air testing is presented, elevated ozone levels are not found. The contributing factors of o-ring failure, including nitrile air sensitivity, inadequate storage practices, and poor installation techniques, are discussed. A discussion of nitrile o-ring material properties, the benefits and limitations, and alternate materials are discussed. Considerations for o-ring material selection, purchasing, storage, and installation are presented in the context of lessons learned from the nitrile o-ring cracking investigation. This paper can be presented in 20 minutes and does not require special accommodations or special audio visual devices.

38 RADIATION CHEMISTRY, RADIOCHEMISTRY, AND NUCLEA↗
DOE OSTI2017

Failure, modal, and vibration analysis of a reactor pool cooling pump

Two 75 HP pumps redundantly supply cooling water to the reactor pool of the High Flux Isotope Reactor (HFIR) at the Oak Ridge National Laboratory (ORNL). Due to a recent history of premature bearing failures, one of these pumps has undergone maintenance to deal with possible issues of misalignment and base looseness. Vibration analysis and modal analysis including steady state spectrum, operational deflection shape, run up and down order tracking, and modal impact have been utilized to verify the effectiveness of the maintenance and identify possible remaining failure modes. The studies conclude that the pump is, after the maintenance, in an overall good conditional state as per ISO 10816, but a few failure modes remain. These modes consist of some shaft unbalance, considerable shaft misalignment intensified by piping movement, possible motor ground fault, hydrodynamic issues such as cavitation with modal interaction, and base looseness. These failure modes and their supporting data have been used to make suggestions for future maintenance, to verify the effectiveness of the previous maintenance, and to provide a base on which to check future data. This report will cover the testing setup, methodology, analysis results, and maintenance suggestions.

42 ENGINEERING↗
DOE OSTI2018

Assessment of failure modes of monolithic fuel plates

Monolithic fuel is a fuel form that is considered for the conversion of high performance research reactors. In order to qualify this new fuel system, the fuel plates should meet the safety standards and perform well in reactor. The fuel system must maintain its mechanical integrity, sustain a geometric stability and should have stable and predictable irradiation behavior. The requirement to maintain mechanical integrity under normal operating conditions is primarily demonstrated by a successful testing of fuel plates up to the limiting conditions defined by the fuel performance envelope, including an adequate margin. Although large number of plates have been tested with satisfactory thermo-mechanical performance, post-irradiation examination of plates from previous RERTR-12 experiments have revealed that pillowing occurred in several plates, rendering performance of these plates unacceptable. To address such failures, efforts are underway to define the mechanisms responsible for the in-reactor pillowing, and suggest improvements to the fuel plate design and operational envelope. For this purpose, selected plates from previous experiments were simulated to understand the thermo-mechanical response of the plates to the fission density and thermally induced stresses. Simulation results were then comparatively evaluated with post-irradiation examinations of selected plates. The simulation results and experimental observations established a possible correlation between failure by plate pillowing, high porosity and a presence of tensile stress state. The study has implied that porosity leading to degradation of material properties, accompanied by a sufficiently large tensile stress state can lead to a pillowing-type failure at reactor shutdown. This paper presents these findings, discusses such failure modes, and the influence of fuel burn-up and power on the magnitude of the shutdown-induced tensile stresses.

42 ENGINEERING↗
DOE OSTI2022

Failure Mechanism Traceability and Application in Human System Interface of Nuclear Power Plants using RESHA

In recent years, there has been considerable effort to modernize existing and new nuclear power plants with digital instrumentation and control systems (DI&C). However, there has also been considerable concern both by industry and regulatory bodies for the risk and consequence analysis of these systems. Of particular concern are digital common cause failures (CCFs) specifically related to software defects. These “misbehaviors” by the software can occur in both the control and monitoring of a system. While many new methods have been proposed to identify potential software failure modes, such as Systems-theoretic Process Analysis (STPA), Hazard and Consequence Analysis for Digital Systems (HAZCADS), etc., these methods are focused primarily on the control action pathway of a system. In contrast, the information feedback pathway lacks unsafe control actions (UCAs), which are typically related to software basic events; thus, assessment of software basic events in such systems is unclear. In this work, we present the idea of intermediate processors and unsafe information flow (UIF) to help safety analysts trace failure mechanisms in the feedback pathway and how they can be integrated into a fault tree for improved assessment capability. The concepts presented are demonstrated in two comprehensive case studies, a smart sensor integrated platform for unmanned autonomous vehicles and another on a representative advanced human system interface (HSI) for safety critical plant monitoring. The qualitative software basic events are identified, and a fault tree analysis is conducted based on a modified Redundancy-guided Systems-theoretic Hazard Analysis (RESHA) methodology. The case studies demonstrate the use of UIF and intermediate processors in the fault tree to improve traceability of software failures in highly complex digital instrumentation feedback. The improved method can also clarify fault tree construction when multiple component dependencies are present in the system.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2022

Failure Mechanism Traceability and Application in Human System Interface of Nuclear Power Plants using RESHA

In recent years, there has been considerable effort to modernize existing and new nuclear power plants with digital instrumentation and control systems (DI&C). However, there has also been considerable concern both by industry and regulatory bodies for the risk and consequence analysis of these systems. Of particular concern are digital common cause failures (CCFs) specifically related to software defects. These “misbehaviors” by the software can occur in both the control and monitoring of a system. While many new methods have been proposed to identify potential software failure modes, such as Systems-theoretic Process Analysis (STPA), Hazard and Consequence Analysis for Digital Systems (HAZCADS), etc., these methods are focused primarily on the control action pathway of a system. In contrast, the information feedback pathway lacks unsafe control actions (UCAs), which are typically related to software basic events; thus, assessment of software basic events in such systems is unclear. In this work, we present the idea of intermediate processors and unsafe information flow (UIF) to help safety analysts trace failure mechanisms in the feedback pathway and how they can be integrated into a fault tree for improved assessment capability. The concepts presented are demonstrated in two comprehensive case studies, a smart sensor integrated platform for unmanned autonomous vehicles and another on a representative advanced human system interface (HSI) for safety critical plant monitoring. The qualitative software basic events are identified, and a fault tree analysis is conducted based on a modified Redundancy-guided Systems-theoretic Hazard Analysis (RESHA) methodology. The case studies demonstrate the use of UIF and intermediate processors in the fault tree to improve traceability of software failures in highly complex digital instrumentation feedback. The improved method can also clarify fault tree construction when multiple component dependencies are present in the system.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
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 OSTI2018

Failure stress comparison of different pairings of Ag-plating and reflow-oven-processed pressureless-sintered-Ag interconnects

Here, sintered-silver is a candidate material to supplant solders for interconnects in power electronic packaging for many reasons including its desirably high electrical and thermal conductivities and compliance to Restriction of Hazardous Substances (RoHS) guidelines. The shear failure stress of interconnects though is limited by whatever constituent is the weakest, and that includes any employed plating. In the present study, silver-platings were processed electrolytically, electrolessly, and through sputter deposition and their influence on the entire “interconnect system” shear strength was examined. Test sets employing gold plating and no plating were included for comparison and to aid interpretation. Ambient-air, reflow-oven-processed, pressureless-sintered-silver interconnects were identically fabricated with all plating test sets. It was found that all considered silver-plating methods produced consistently strong (characteristic failure stresses > 55 MPa) sintered-silver interconnects. Because failures tended to be adhesive in all six sets, differences in failure stress among the silver-plated sets and the gold-plated or unplated sets were likely due to differences in the adhesive strength of the sintered silver with silver-plating, gold-plating, or direct bonding with copper.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Anisotropic spall failure of additively manufactured 316L stainless steel

The dynamic high strain rate tensile (spall) failure of additively manufactured (AM) materials is an area of great interest but much less understood than material failure under other loading regimes. The research presented here examines the effects of microstructure anisotropy in 316L stainless steel fabricated by laser powder bed fusion (LPBF) on its spall failure and properties. In this work, plate-on-plate impact experiments were performed using an 80-mm gas gun to investigate the spall behavior of AM fabricated sample discs with impact along the perpendicular and parallel orientations relative to build directions. Experiments were also performed on wrought 316L stainless steel as baseline material with uniform equiaxed grain microstructure for comparison with the AM material of same composition. The spall experiments involved free-surface velocity profiles measured using Photon Doppler Velocimetry (PDV) to capture the spall pull-back signals, combined with post-mortem analysis of the microstructure of soft-recovered impacted samples. In the case of AM samples, spall failure initiated preferentially at melt pool boundaries in both impact directions. The spall plane location and spall strength, however, were both heavily influenced by the orientation of the impact direction relative to the build direction in the AM samples. The spall behavior is also observed to be more complex in the samples impacted perpendicular to the build (through-thickness) direction, due in large part to the orientation of the microstructural features such as melt pool boundaries, laser scan tracks, and general grain morphology.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Deconvoluting sources of failure in lithium metal batteries containing NMC and PEO-based electrolytes

Solid-state lithium metal batteries (SSLMBs) containing polyethylene oxide (PEO)-derived polymer electrolytes and high-voltage (> 4 V vs. Li/Li + ) cathode materials suffer from three sources of failure: (1) instability between the polymer electrolyte and cathode at high voltage, (2) instability of the polymer electrolyte with Li metal, and (3) poorly-designed cathodes. In this study, these three sources of failure are deconvoluted by studying Ni-rich LiNi x Mn y Co 1-x-y O 2 (NMC, x ≥ 0.6) cathodes and a gel polymer electrolyte (GPE) derived from PEO. Initial cycling data reveals that rapid capacity fade occurs regardless of whether soft short circuits form due to Li dendrites. Cyclic voltammetry scans on cells featuring a Li metal electrode, GPE, and a NMC811 electrode free of additives suggest that there are no runaway reactions between the GPE and NMC811 up to 4.5 V vs. Li/Li + . Cathode/cathode symmetric cell cycling demonstrates that Li metal reactivity is a prime source of failure, though a poorly-designed cathode leads to subpar performance. A cathode with single-crystal NMC particles was demonstrated to achieve better initial capacity and longer cycle life, indicating room for improvement in SSLMB cathode design. Therefore, the sources of failure as enumerated may be ranked as follows from most to least concerning: 2 > 3 > 1.

25 ENERGY STORAGE↗
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 OSTI2018

The potential for avoiding hydrogen release from cryogenic pressure vessels after vacuum insulation failure

This paper presents an analysis of vacuum insulation failure in an automotive cryogenic pressure vessel (also known as cryo-compressed vessel) storing hydrogen. Vacuum insulation failure increases heat transfer into cryogenic vessels by about a factor of 100, potentially leading to rapid pressurization and venting of the cryogen to avoid exceeding maximum allowable working pressure (MAWP). Hydrogen release to the environment may be dangerous, especially if the vehicle is located in a closed space (e.g. a garage or tunnel) at the moment of insulation failure. We therefore consider utilization of the hydrogen in the vehicle fuel cell and dissipation of the electricity by operating vehicle accessories or electric resistances as an alternative to releasing hydrogen to the environment. We consider two strategies: initiating hydrogen extraction immediately after vacuum insulation failure or waiting until maximum operating pressure is reached before extraction. The results indicate that cryogenic pressure vessels have thermodynamic advantages that enable slowing down hydrogen release to moderate levels that can be consumed in the fuel cell and dissipated in vehicle accessories supplemented by electric resistances, even in the worst case when the insulation fails at the moment when the vessel stores hydrogen near its maximum density (70 g/L at 300 bar). As a result, the two proposed strategies are therefore feasible, and the best alternative can be chosen based on economic and/or implementation constraints.

08 HYDROGEN↗
DOE OSTI2014

Outcomes and Patterns of Failure for Grade 2 Meningioma Treated With Reduced-Margin Intensity Modulated Radiation Therapy

Purpose: The purpose of this study was to evaluate intracranial control and patterns of local recurrence (LR) for grade 2 meningiomas treated with intensity modulated radiation therapy (IMRT) with limited total margin expansions of ≤1 cm. Methods and Materials: We reviewed records of patients with a neuropathological diagnosis of grade 2 meningioma who underwent IMRT at our institution between 2002 and 2012. Actuarial rates were determined by the Kaplan-Meier method from the end of RT. LR was defined as in-field if ≥90% of the recurrence was within the prescription isodose, out-of-field (marginal) if ≥90% was outside of the prescription isodose, and both if neither criterion was met. Results: Between 2002 and 2012, a total of 54 consecutive patients underwent IMRT for grade 2 meningioma. Eight of these patients had total initial margins >1 cm and were excluded, leaving 46 patients for analysis. The median imaging follow-up period was 26.2 months (range, 7-107 months). The median dose for fractionated IMRT was 59.4 Gy (range, 49.2-61.2 Gy). Median clinical target volume (CTV), planning target volume (PTV), and total margin expansion were 0.5 cm, 0.3 cm, and 0.8 cm, respectively. LR occurred in 8 patients (17%), with 2-year and 3-year actuarial local control (LC) of 92% and 74%, respectively. Six of 8 patients (85%) had a known pattern of failure. Five patients (83%) had in-field LR; no patients had marginal LR; and 1 patient (17%) had both. Conclusions: The use of IMRT to treat grade 2 meningiomas with total initial margins (CTV + PTV) ≤1 cm did not appear to compromise outcomes or increase marginal failures compared with other modern retrospective series. Of the 46 patients who had margins ≤1 cm, none experienced marginal failure only. These results demonstrate efficacy and low risk of marginal failure after IMRT treatment of grade 2 meningiomas with reduced margins, warranting study within a prospective clinical trial.

62 RADIOLOGY AND NUCLEAR MEDICINE↗
DOE OSTI2014

Risk Prediction Models of Locoregional Failure After Radical Cystectomy for Urothelial Carcinoma: External Validation in a Cohort of Korean Patients

Purpose: To evaluate the predictive accuracy and general applicability of the locoregional failure model in a different cohort of patients treated with radical cystectomy. Methods and Materials: A total of 398 patients were included in the analysis. Death and isolated distant metastasis were considered competing events, and patients without any events were censored at the time of last follow-up. The model included the 3 variables pT classification, the number of lymph nodes identified, and margin status, as follows: low risk (≤pT2), intermediate risk (≥pT3 with ≥10 nodes removed and negative margins), and high risk (≥pT3 with <10 nodes removed or positive margins). Results: The bootstrap-corrected concordance index of the model 5 years after radical cystectomy was 66.2%. When the risk stratification was applied to the validation cohort, the 5-year locoregional failure estimates were 8.3%, 21.2%, and 46.3% for the low-risk, intermediate-risk, and high-risk groups, respectively. The risk of locoregional failure differed significantly between the low-risk and intermediate-risk groups (subhazard ratio [SHR], 2.63; 95% confidence interval [CI], 1.35-5.11; P<.001) and between the low-risk and high-risk groups (SHR, 4.28; 95% CI, 2.17-8.45; P<.001). Although decision curves were appropriately affected by the incidence of the competing risk, decisions about the value of the models are not likely to be affected because the model remains of value over a wide range of threshold probabilities. Conclusions: The model is not completely accurate, but it demonstrates a modest level of discrimination, adequate calibration, and meaningful net benefit gain for prediction of locoregional failure after radical cystectomy.

62 RADIOLOGY AND NUCLEAR MEDICINE↗
DOE OSTI2017

Failure statistics for commercial lithium ion batteries: A study of 24 pouch cells

There are relatively few publications that assess capacity decline in enough commercial cells to quantify cell-to-cell variation, but those that do show a surprisingly wide variability. Capacity curves cross each other often, a challenge for efforts to measure the state of health and predict the remaining useful life (RUL) of individual cells. We analyze capacity fade statistics for 24 commercial pouch cells, providing an estimate for the time to 5% failure. Our data indicate that RUL predictions based on remaining capacity or internal resistance are accurate only once the cells have already sorted themselves into “better” and “worse” ones. Analysis of our failure data, using maximum likelihood techniques, provide uniformly good fits for a variety of definitions of failure with normal and with 2- and 3-parameter Weibull probability density functions, but we argue against using a 3-parameter Weibull function for our data. pdf fitting parameters appear to converge after about 15 failures, although business objectives should ultimately determine whether data from a given number of batteries provides sufficient confidence to end lifecycle testing. Increased efforts to make batteries with more consistent lifetimes should lead to improvements in battery cost and safety.

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↗