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All sources NASA NTRS DOE OSTI

DOE OSTI2016

TH-EF-BRC-04: Quality Management Program

This Hands-on Workshop will be focused on providing participants with experience with the principal tools of TG 100 and hence start to build both competence and confidence in the use of risk-based quality management techniques. The three principal tools forming the basis of TG 100’s risk analysis: Process mapping, Failure-Modes and Effects Analysis and fault-tree analysis will be introduced with a 5 minute refresher presentation and each presentation will be followed by a 30 minute small group exercise. An exercise on developing QM from the risk analysis follows. During the exercise periods, participants will apply the principles in 2 different clinical scenarios. At the conclusion of each exercise there will be ample time for participants to discuss with each other and the faculty their experience and any challenges encountered. Learning Objectives: To review the principles of Process Mapping, Failure Modes and Effects Analysis and Fault Tree Analysis. To gain familiarity with these three techniques in a small group setting. To share and discuss experiences with the three techniques with faculty and participants. Director, TreatSafely, LLC. Director, Center for the Assessment of Radiological Sciences. Occasional Consultant to the IAEA and Varian.

60 APPLIED LIFE SCIENCES↗

NASA NTRS1979

Behavior of composite bolted joints at elevated temperature

Experimental results from an investigation which examines the combined effects of temperature, joint geometry and out-of-plane constraint upon the response of mechanically fastened composite joints are presented. Data are presented for simulated mechanically fastened joint conditions in two laminate configurations fabricated from Hercules AS/3501-6 graphite-epoxy. Strength and failure mode results are presented for the test temperatures of 21 C, 121 C and 177 C and for a range of the geometric parameters W/D and e/D from 3.71 to 7.43 and 1.85 to 3.69, respectively. A hole diameter, D of 5.16 mm was utilized for all tests. Pin bearing tests with out-of-plane constraint were conducted at room temperature only. All elevated temperature data were generated for pin bearing conditions. Ultrasonic C scan inspection of the failed specimens was employed to assess the damage region and to determine failure mode. Comparative data are presented for pin bearing and out-of-plane constraint conditions for the above mentioned joint configurations. The joint under pin loading was modeled by two dimensional finite element methods. Predicted net section strain concentrations were compared with experimental results.

Wilson, D. W.↗

DOE OSTI2012

Contact method to allow benign failure in ceramic capacitor having self-clearing feature

A capacitor exhibiting a benign failure mode has a first electrode layer, a first ceramic dielectric layer deposited on a surface of the first electrode, and a second electrode layer disposed on the ceramic dielectric layer, wherein selected areas of the ceramic dielectric layer have additional dielectric material of sufficient thickness to exhibit a higher dielectric breakdown voltage than the remaining majority of the dielectric layer. The added thickness of the dielectric layer in selected areas allows lead connections to be made at the selected areas of greater dielectric thickness while substantially eliminating a risk of dielectric breakdown and failure at the lead connections, whereby the benign failure mode is preserved.

47 OTHER INSTRUMENTATION↗

DOE OSTI2015

Degradation of transparent conductive oxides: Interfacial engineering and mechanistic insights

Transparent conductive oxides (TCOs) are a known failure mode in a variety of thin film photovoltaic (PV) devices, through mechanisms such as resistivity increase and delamination. Degradation science studies of these materials, as well as most PV systems, have primarily utilized industry standard qualification protocols, which are not designed to be used as lifetime prediction tests. Here, this work applies a data science approach to this engineering challenge, utilizing commercially available TCOs and subjecting them to an array of stressors, including environmental and material stressors. Optical, electrical and surface sensitive TCO property metrics were monitored and analyzed en mass. Different degradation mechanisms and modes were observed when different stressor combinations were applied; TCO surfaces are sensitive to the proportion of water and light in an exposure, yellowing of the TCO only occurs when humidity and UV light are combined, and PEDOT:PSS (poly(3,4-ethylenedioxythiophene) poly(styrenesulfonate)) application results in hazing and roughening of aluminum-doped zinc oxide (AZO). Using multi-variate analytics and plotting critical material properties against one another in a mechanistic plot, trade-offs between properties and the activation of different degradation mechanisms become readily apparent. In addition to a survey of failure modes of TCOs, a possible solution to the degradation of AZO was examined: the application of an organofunctional silane layer. The application of a thin APTES (3-aminopropyltriethoxysilane) film nearly eliminated the observed edge effects and greatly reduced the resistivity increase caused by damp heat exposure of AZO.

14 SOLAR ENERGY↗

DOE OSTI2018

Fail-Slow at Scale: Evidence of Hardware Performance Faults in Large Production Systems

Fail-slow hardware is an under-studied failure mode. We present a study of 114 reports of fail-slow hardware incidents, collected from large-scale cluster deployments in 14 institutions. We show that all hardware types such as disk, SSD, CPU, memory, and network components can exhibit performance faults. We made several important observations such as faults convert from one form to another, the cascading root causes and impacts can be long, and fail-slow faults can have varying symptoms. From this study, we make suggestions to vendors, operators, and systems designers.

fail-slow↗

DOE OSTI2022

Microstructure changes during failure of PVDF-based photovoltaic backsheets

The backsheet layer of a solar module provides a safety and environmental barrier to the high voltages running through the photovoltaic (PV) cells and electrical contacts within the core of the module. However, in the past decade, backsheet cracking has become one of the most observed failure modes in PV module field surveys. In this work, the degradation of polyvinylidene fluoride (PVDF)-based backsheets is explored. Backsheet samples are either exposed to accelerated laboratory aging (UV light, heat, and moisture) or collected from the field. Fourier transform infrared and Raman spectroscopy, fragmentation testing, atomic force and scanning electron microscopy, and small-angle neutron scattering are combined to develop an understanding of how chemistry and microstructure evolve during aging. Chemical degradation, surface pitting, polymer phase changes, and anisotropic polymer domains are all observed in aged backsheet samples. The results provide insight into the degradation mechanisms that lead to cracking and field failure of PVDF-based backsheets. The comparison of aged PVDF-based backsheets helps to lay the groundwork for limiting polymer-based failure modes in PV modules.

PVDF↗

DOE OSTI2016

SU-F-T-241: Reduction in Planning Errors Via a Process Control Developed Using the Eclipse Scripting API

Purpose: Errors found during initial physics plan checks frequently require replanning and reprinting, resulting decreased departmental efficiency. Additionally, errors may be missed during physics checks, resulting in potential treatment errors or interruption. This work presents a process control created using the Eclipse Scripting API (ESAPI) enabling dosimetrists and physicists to detect potential errors in the Eclipse treatment planning system prior to performing any plan approvals or printing. Methods: Potential failure modes for five categories were generated based on available ESAPI (v11) patient object properties: Images, Contours, Plans, Beams, and Dose. An Eclipse script plugin (PlanCheck) was written in C# to check errors most frequently observed clinically in each of the categories. The PlanCheck algorithms were devised to check technical aspects of plans, such as deliverability (e.g. minimum EDW MUs), in addition to ensuring that policy and procedures relating to planning were being followed. The effect on clinical workflow efficiency was measured by tracking the plan document error rate and plan revision/retirement rates in the Aria database over monthly intervals. Results: The number of potential failure modes the PlanCheck script is currently capable of checking for in the following categories: Images (6), Contours (7), Plans (8), Beams (17), and Dose (4). Prior to implementation of the PlanCheck plugin, the observed error rates in errored plan documents and revised/retired plans in the Aria database was 20% and 22%, respectively. Error rates were seen to decrease gradually over time as adoption of the script improved. Conclusion: A process control created using the Eclipse scripting API enabled plan checks to occur within the planning system, resulting in reduction in error rates and improved efficiency. Future work includes: initiating full FMEA for planning workflow, extending categories to include additional checks outside of ESAPI via Aria database queries, and eventual automated plan checks.

60 APPLIED LIFE SCIENCES↗

DOE OSTI2020

High-burnup Experiments in Reactivity Initiated Accidents (HERA)

HERA is a joint experimental program (JEEP) operating within the Nuclear Energy Agency’s (NEA’s) framework for irradiation experiments (FIDES). HERA is dedicated to the understanding of light water reactor (LWR) fuel performance at high burnup under reactivity-initiated accidents (RIA). During RIAs the fuel cladding can be breached by one of two mechanisms; pellet-cladding mechanical interaction or high temperature balloon and rupture. Pellet-cladding mechanical interaction (PCMI) failure occurs in the early phase of an RIA transient where the fuel pellet expands rapidly into the cladding prior to any meaningful heat transfer from the pellet to the cladding. This results in high stresses in the cladding resulting in crack propagation through the base Zircaloy metal and axially along the cladding tube. Failure by PCMI is a brittle failure mode and occurs at low cladding strains, approximately 2% hoop strain. If the cladding survives the PCMI phase of the transient, it may still fail due to ballooning and rupture induced by extended exposure to high temperature. Thermal transport from the fuel pin to the coolant is significantly reduced if a transition to film boiling on the cladding surface occurs. This result in both a rapid increase in fuel temperature, which drives fission gas release, and a spike in cladding temperature, which results in loss of mechanical strength. If the internal pressure of the fuel rod is greater than the system pressure the cladding can inelastically deform and eventually rupture. Failure by swelling and rupture occurs at larger strains, generally greater than 5% hoop strain. While PCMI failures are generally seen as more limiting, the dominance of one failure mode over the other can be affected by both the cladding material conditions, and the transient evolution.

(HERA)↗

DOE OSTI2023

High-burnup Experiments in Reactivity Initiated Accidents (HERA)

(HERA)↗

NASA NTRS2021

Molecular dynamics simulations of ultrafast radiation induced melting at metal–semiconductor interfaces

Metal–semiconductor contacts in silicon carbide (SiC) diodes endure damages at the interface when exposed to harsh radiation environments. Due to the rapid rise in temperature and ultrafast cooling that follows the radiation impact, the structural properties of the materials can be altered through melting, recrystallization, and amorphization. A detailed understanding of the material failure modes at the interface is lacking, specifically at the nanoscale. We use molecular simulations to investigate the ultrafast melting at tungsten (W)–SiC interfaces following radiation damage and apply deep learning techniques to track the transient evolution of the local molecular structures. We show that W near the radiation track undergoes melting and, eventually, most of it recrystallizes with a noticeable degree of undercooling, while SiC is rendered permanently amorphous. The observation of local undercooling in W films is important as it can affect the device performance even before the bulk melting temperature of the material is reached. We also show that at high temperatures, the interface undergoes a fracture-like failure. The results presented here are significant in understating the different failure modes of SiC diode materials.

Ashwin Ravichandran↗

NASA NTRSDate not supplied

Lessons Learned from the Arecibo Observatory Auxiliary M4N Socket Analysis and Implications for Future Observatory Designs

The Arecibo Observatory collapsed after a progressive structural failure stemming from the failure of a single socket joint cable termination. A failure investigation was conducted to identify the cause of the first failed cable termination socket. Due to the nature of the suspended observatory receiver, the dominant source of loading in the suspension cables was due to deadload, with secondary contributions coming from environmental effects and observatory operation. The high ratio of deadload vs. live load applied to the cable over many years resulted in a creep failure mode of the cast zinc within the socket which further induced stress into the highly stress wires at the entrance of the socket. The design of the socket joint did not explicitly consider socket constituent stress margins and time-dependent damage mechanisms such as creep. Lessons learned from this investigation led to recommendations for revising civil engineering cable standards, and recommendations for manufacturers and designers. The design of cables employing socket terminations should consider the cumulative damage effects from creep and cyclic loading identify their corresponding worst-case inspectable defects or establish a sufficiently high factor of safety so that the design is sufficiently robust to defects and time-dependent failure modes. The design should specify end-of-life capability and set service life inspection intervals with pass/fail inspection criteria. Finally, trial studies on design iterations were conducted to increase the reliability of cables with socket joints.

Pavel Babuska↗

NASA NTRS1965

Ceramic capacitor accelerated life test program Final report

Spacecraft component ceramic capacitor life tests and failure modes

CERAMICS↗

NASA NTRS2004

Current Status of Hybrid Bearing Damage Detection

Advances in material development and processing have led to the introduction of ceramic hybrid bearings for many applications. The introduction of silicon nitride hybrid bearings into the high pressure oxidizer turbopump, on the space shuttle main engine, led NASA to solve a highly persistent and troublesome bearing problem. Hybrid bearings consist of ceramic balls and steel races. The majority of hybrid bearings utilize Si3N4 balls. The aerospace industry is currently studying the use of hybrid bearings and naturally the failure modes of these bearings become an issue in light of the limited data available. In today s turbine engines and helicopter transmissions, the health of the bearings is detected by the properties of the debris found in the lubrication line when damage begins to occur. Current oil debris sensor technology relies on the magnetic properties of the debris to detect damage. Since the ceramic rolling elements of hybrid bearings have no metallic properties, a new sensing system must be developed to indicate the system health if ceramic components are to be safely implemented in aerospace applications. The ceramic oil debris sensor must be capable of detecting ceramic and metallic component damage with sufficient reliability and forewarning to prevent a catastrophic failure. The objective of this research is to provide a background summary on what is currently known about hybrid bearing failure modes and to report preliminary results on the detection of silicon nitride debris, in oil, using a commercial particle counter.

Dempsey, Paula J.↗

NASA NTRS2023

Damage Detection of a Pressure Vessel with Smart Sensing and Deep Learning

Structural Health Monitoring plays a crucial role in ensuring the safety and reliability of critical infrastructure, including pressure vessels involved in various applications. This research reports the damage detection of a pressure box employed in space habitat that operates in harsh environment where both structural failure and bolt joint loosening may occur. These failure modes are extremely hard to model based on first principles. We explore proper sensing mechanism and the associated inverse analysis algorithm that can elucidate the health condition of the pressure box. It is identified that piezoelectric impedance based active interrogation can provide necessary information for damage detection in such a system. Concurrently, deep learning technique leveraging spatial convolutional neural network is synthesized to analyze the raw data acquired and identify different types of damage. By training the deep learning model on a dataset of healthy and various damage scenarios, we can achieve high accuracy in identifying the presence of damage and its type. This research provides a data-driven methodology for structural damage detection using deep learning and has the potential to be extended to various systems with different failure modes.

Yang Zhang↗

DOE OSTI2025

Micromechanical response of SiC-OPyC layers in TRISO fuel particles

Tristructural isotropic (TRISO)–coated particle fuel is a proposed fuel for multiple advanced reactor concepts. The performance of the particle depends on whether the silicon carbide (SiC) layer remains intact to prevent the release of metallic and gaseous fission products. Mechanical fracture of the SiC layer is a potential failure mode under various fuel configurations and operating environments, including the potential transmission of matrix-originating cracks through TRISO particles. Furthermore, this study uses instrumented indentation techniques on cross-sectioned surrogate particles to examine the mechanical stability of the critical interface between SiC and the outer pyrolytic carbon (OPyC) layer. The observed behavior at the interface is rationalized by examining the radially dependent fracture behavior of the SiC layer and performing a numerical analysis to quantify the residual stresses that develop during the processing and cross-sectioning of the as-fabricated particle. Characterizing the SiC-OPyC interface of surrogate TRISO particles using nanoindentation provides unique insight into the interface's room-temperature residual stress and mechanical stability. The modeling efforts were used to investigate the experimental procedure further, and the results are presented herein to validate this fuel form's potential mechanical failure modes.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

NASA NTRS2008

NASA Crew Exploration Vehicle, Thermal Protection System, Lessons Learned

The Orion (CEV) thermal protection system (TPS) advanced development project (ADP) was initiated in late 2006 to reduce developmental risk by significant investment in multiple heat shield architectural solutions that can meet the needs both the Low Earth orbit (LEO) and Lunar return missions. At the same time, the CEV TPS ADP was also charged with developing a preliminary design for the heat shield to meet the PDR requirement and at the time of the PDR, transfer the design to Lockheed- Martin, the prime contractor. We reported on the developmental activities of the first 18 months at the IPPW5 in Bordeaux, France, last summer. In June 08, at the time of the IPPW6, the CEV TPS ADP would have nearly completed the preparation for the Orion PDR and would be close to the original three-year mark. We plan to report on the progress at the Atlanta workshop. In the past year, Orion TPS ADP investment in TPS Technology, especially in PICA ablative Heat-shield design, development, testing and engineering (DDTE) has paid off in enabling MSL mission to switch from SLA 561 V heat shield to PICA heat shield. CEV TPS ADP considered SLA 561 V as a candidate for LEO missions and our testing identified failure modes in SLA and as a result, we dropped SLA for further evaluation. This close synergy between two projects is a highly visible example of how investment in technology areas can and does benefit multiple missions. In addition, CEV TPS ADP has been able to revive the Apollo ablative system namely AVCOAT honeycomb architecture as an alternate to the baseline PICA architecture and we plan to report the progress we have made in AVCOAT. CEV TPS ADP has invested considerable resources in developing analytical models for PICA and AVCOAT, material property measurements that is essential to the design of the heat-shield, in arcjet testing, in understanding the differences between different arc jet facilities, namely NASA Ames, NASA JSC and Air Force's AEDC, and in Non-Destructive Evaluation (NDE), and in integration of and manufacturing heat shield as a system. The capabilities of the two heat shield systems including failure modes via testing and analysis, once established, can serve the Probe Community and future mission designers to inner and outer planetary exploration very well. For example, missions to Venus, Mars and Titan can use either one of the system by selecting the mission design parameters that utilizes the full characteristics of these system to make use of system efficiency that will result in reduced heat shield mass, system robustness that will enhance mission success and cost. We plan to present significant progresses of the past three years and highlight the significant contributions CEV TPS ADP Project has made to advance the state of the art in Thermal Protection System technology that has and will continue to benefit future entry probe missions.

NASA Crew Exploration Vehicle↗

DOE OSTI2022

Degradation Mechanisms in Advanced MEAs for PEM Water Electrolyzers Fabricated by Reactive Spray Deposition Technology

Proton exchange membrane water electrolyzers (PEMWEs) have demonstrated enormous potential as the next generation hydrogen production technology. The main challenges that the state-of-the-art PEMWEs are currently facing are excessive cost and poor durability. Understanding the failure modes in PEMWEs is a key factor for improving their durability, lowering the precious metal loading, and hence cost reduction. Here, reactive spray deposition technology (RSDT) has been used to fabricate a membrane electrode assembly (MEA) with one order of magnitude lower Pt and Ir catalyst loadings (0.2–0.3 mg PGM cm –2 ) in comparison to the precious metal loadings in the stat-of-the-art commercial MEAs (2–3 mg PGM cm –2 ). As fabricated MEA with an active area of 86 cm 2 , has been tested for over 5000 h at steady-state conditions that are typical for an industrial hydrogen production system. Herein, we present and discuss the results from a comprehensive post-test analysis of the MEA of interest. The main degradation mechanisms, governing the performance loss in the RSDT fabricated MEA with ultra-low precious metal loadings, have been identified and discussed in detail. All failure modes are critically compared and the main degradation mechanism with the highest impact on the MEA performance loss among the others is identified.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

NASA NTRS2012

Spaceflight Ground Support Equipment Reliability & System Safety Data

Presented were Reliability Analysis, consisting primarily of Failure Modes and Effects Analysis (FMEA), and System Safety Analysis, consisting of Preliminary Hazards Analysis (PHA), performed to ensure that the CoNNeCT (Communications, Navigation, and Networking re- Configurable Testbed) Flight System was safely and reliably operated during its Assembly, Integration and Test (AI&T) phase. A tailored approach to the NASA Ground Support Equipment (GSE) standard, NASA-STD-5005C, involving the application of the appropriate Requirements, S&MA discipline expertise, and a Configuration Management system (to retain a record of the analysis and documentation) were presented. Presented were System Block Diagrams of selected GSE and the corresponding FMEA, as well as the PHAs. Also discussed are the specific examples of the FMEAs and PHAs being used during the AI&T phase to drive modifications to the GSE (via "redlining" of test procedures, and the placement of warning stickers to protect the flight hardware) before being interfaced to the Flight System. These modifications were necessary because failure modes and hazards were identified during the analysis that had not been properly mitigated. Strict Configuration Management was applied to changes (whether due to upgrades or expired calibrations) in the GSE by revisiting the FMEAs and PHAs to reflect the latest System Block Diagrams and Bill Of Material. The CoNNeCT flight system has been successfully assembled, integrated, tested, and shipped to the launch site without incident. This demonstrates that the steps taken to safeguard the flight system when it was interfaced to the various GSE were successful.

Fernandez, Rene↗