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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 145 records · Page 8

Study of intermittent field hardware failure data in digital electronics

The collection and analysis of data concerning intermittent dailures in digital devices was performed using data from a computer design for shipboard usage. The failure data consisted of actual field failures classified by failure mechanisms and their likelihood of having been intermittent, potentially intermittent, or hard. Each class was studies with respect to computer operation in the ranges of 0 to 2,000 hours, 0 to 5, hours, and 0 to 10,000 hours. The study was done at the computer level as well as the microcircuit level. Results indicate that as age increases, the quasi-intermittent failure rate increases and the mean time to failure descreases.

Oneill, E. J.↗

Low-Earth orbit satellite servicing economics

Servicing economics of low Earth orbit satellites were studied. The following topics are examined: the economic importance of the repair missions; comparison of mission cost as opposed to satellite modulation transfer functions over a 10 year period; the effect of satellite flight rate change due to changes in satellite failure rate; estimated satellite cost reduction with shuttle operation projects from the 1960's to the 1970's; design objectives of the multimission modular spacecraft; and the economic importance of the repair mission.

Davis, R. F.↗

Development of STS/Centaur failure probabilities liftoff to Centaur separation

The results of an analysis to determine STS/Centaur catastrophic vehicle response probabilities for the phases of vehicle flight from STS liftoff to Centaur separation from the Orbiter are presented. The analysis considers only category one component failure modes as contributors to the vehicle response mode probabilities. The relevant component failure modes are grouped into one of fourteen categories of potential vehicle behavior. By assigning failure rates to each component, for each of its failure modes, the STS/Centaur vehicle response probabilities in each phase of flight can be calculated. The results of this study will be used in a DOE analysis to ascertain the hazard from carrying a nuclear payload on the STS.

Hudson, J. M.↗

Interconnect fatigue design for terrestrial photovoltaic modules

The results of comprehensive investigation of interconnect fatigue that has led to the definition of useful reliability-design and life-prediction algorithms are presented. Experimental data indicate that the classical strain-cycle (fatigue) curve for the interconnect material is a good model of mean interconnect fatigue performance, but it fails to account for the broad statistical scatter, which is critical to reliability prediction. To fill this shortcoming the classical fatigue curve is combined with experimental cumulative interconnect failure rate data to yield statistical fatigue curves (having failure probability as a parameter) which enable (1) the prediction of cumulative interconnect failures during the design life of an array field, and (2) the unambiguous--ie., quantitative--interpretation of data from field-service qualification (accelerated thermal cycling) tests. Optimal interconnect cost-reliability design algorithms are derived based on minimizing the cost of energy over the design life of the array field.

Mon, G. R.↗

A comprehensive analysis of the performance characteristics of the Mount Laguna solar photovoltaic installation

This paper represents the first comprehensive survey of the Mount Laguna Photovoltaic Installation. The novel techniques used for performing the field tests have been effective in locating and characterizing defective modules. A comparative analysis on the two types of modules used in the array indicates that they have significantly different failure rates, different distributions in degradational space and very different failure modes. A life cycle model is presented to explain a multimodal distribution observed for one module type. A statistical model is constructed and it is shown to be in good agreement with the field data.

Shumka, A.↗

Benefits assessment of active control technology and related cockpit technology for rotorcraft

Two main-rotor active control concepts, one incorporating multicyclic actuators located just below the swashplate, and the other providing for the actuators and power supplies to be located in the rotating frame are considered. Each design concept is integrated with cockpit controllers and displays appropriate to the actuation concept in each case. The benefits of applying the defined ACT/RCT concepts to rotorcraft are quantified by comparison to the baseline model 412 helicopter. These benefits include, in the case of one active control concept; (1) up to 91% reduction in 4/rev hub shears; (2) a flight safety failure rate of 1.96 x 10 to the 8th power failures per flight-hour; (3) rotating controls/rotor hub drag reduction of 40%; (4) a 9% reduction in control system weight; and (5) vibratory deicing. The related cockpit concept reduces pilot workload for critical mission segments as much as 178% visual and 25% manual.

Hampton, B. J.↗

Statistical analysis of failure data on controllers and SSME turbine blade failures

The expressions for the maximum likelihood functions are given when the failure data are censored at a given point or at multiple points, or when the data come in groups. Different models applicable to failure data are presented with their characteristics. A graphical method of distinguishing different models by using cumulative hazard fucnction is discussed. For the failure data on controllers the model is determined by cumulative hazard function and chi-square goodness of fit. Using the Weibull Model the maximum likelihood estimators of the shape parameter and the failure rate parameter are obtained. The confidence intervals, meantime between failures, and B1 are determined. Similarly, for the data on Space Shuttle Main Engine (SSME) blade failures the maximum likelihood estimators are obtained for the Weibull parameters. The variances, confidence intervals, meantime between failures, and reliability are determined. The analysis is performed under assumption of grouped data as well as randomly placed data.

Patil, S. A.↗

A Metric to Quantify Shared Visual Attention in Two-Person Teams

Introduction: Critical tasks in high-risk environments are often performed by teams, the members of which must work together efficiently. In some situations, the team members may have to work together to solve a particular problem, while in others it may be better for them to divide the work into separate tasks that can be completed in parallel. We hypothesize that these two team strategies can be differentiated on the basis of shared visual attention, measured by gaze tracking. 2) Methods: Gaze recordings were obtained for two-person flight crews flying a high-fidelity simulator (Gontar, Hoermann, 2014). Gaze was categorized with respect to 12 areas of interest (AOIs). We used these data to construct time series of 12 dimensional vectors, with each vector component representing one of the AOIs. At each time step, each vector component was set to 0, except for the one corresponding to the currently fixated AOI, which was set to 1. This time series could then be averaged in time, with the averaging window time (t) as a variable parameter. For example, when we average with a t of one minute, each vector component represents the proportion of time that the corresponding AOI was fixated within the corresponding one minute interval. We then computed the Pearson product-moment correlation coefficient between the gaze proportion vectors for each of the two crew members, at each point in time, resulting in a signal representing the time-varying correlation between gaze behaviors. We determined criteria for concluding correlated gaze behavior using two methods: first, a permutation test was applied to the subjects' data. When one crew member's gaze proportion vector is correlated with a random time sample from the other crewmember's data, a distribution of correlation values is obtained that differs markedly from the distribution obtained from temporally aligned samples. In addition to validating that the gaze tracker was functioning reasonably well, this also allows us to compute probabilities of coordinated behavior for each value of the correlation. As an alternative, we also tabulated distributions of correlation coefficients for synthetic data sets, in which the behavior was modeled as a first-order Markov process, and compared correlation distributions for identical processes with those for disparate processes, allowing us to choose criteria and estimate error rates. 3) Discussion: Our method of gaze correlation is able to measure shared visual attention, and can distinguish between activities involving different instruments. We plan to analyze whether pilots strategies of sharing visual attention can predict performance. Possible measurements of performance include expert ratings from instructors, fuel consumption, total task time, and failure rate. While developed for two-person crews, our approach can be applied to larger groups, using intra-class correlation coefficients instead of the Pearson product-moment correlation.

Gontar, Patrick↗

Useful Life of Tantalum Capacitors

Currently, the major reliability characteristic of tantalum capacitors is the failure rate, which is a constant used to characterize random failures of electronic components. However, contemporary MnO2 and polymer tantalum capacitors have both infant mortality (IM) and wear-out (WO) failures. This requires assessments of the useful life of the parts that is limited by the time of inception of WO failures that can be determined using an adequate reliability model and results of highly accelerated life testing (HALT). In this presentation, a modified time dependent dielectric breakdown (TDDB) model is used to describe both IM and WO failures during HALT. Specifics of physical processes resulting in degradation and failures in polymer and MnO2 tantalum capacitors are discussed, and the increase of IM failures with the level of stress is explained. The model justifies exponential dependence of the acceleration factors on voltage and predicts higher values of the voltage acceleration constant for IM compared to WO failures.

tantalum capacitors↗

JANTX1N5550 switching diode

Tested devices were manufactured by Semtech and Micro Semiconductor. Failure rate of Semtech diodes exceeded 50% in all three test groups. Failure mode could not be precisely determined.

Source record↗

JANTX2N2945A transistor

Report describes effects of power and temperature overstress on Raytheon and Teledyne devices. Increasing T in 16 hour steps damaged both manufacturers' lots. Raytheon lot exceeded 50 percent failure rate 160 hours before completion of test due to current gain failure. Teledyne samples completed test but had more catastrophic failures.

Source record↗

A stress index model for balloon design

A NASA stress index model, SINDEX, is discussed which establishes the relative stress magnitudes along a balloon gore as a function of altitude. Application of the model to a data base of over 550 ballon flights demonstrates the effectiveness of the method. The results show a strong correlation between stress levels, failure rates, and the point of maximum stress coinciding with the observed failure locations. It is suggested that the model may be used during the balloon design process to lower the levels of stress in the balloon.

Smith, I. S.↗

The Use of Probabilistic Methods to Evaluate the Systems Impact of Component Design Improvements on Large Turbofan Engines

Probabilistic Structural Analysis (PSA) is now commonly used for predicting the distribution of time/cycles to failure of turbine blades and other engine components. These distributions are typically based on fatigue/fracture and creep failure modes of these components. Additionally, reliability analysis is used for taking test data related to particular failure modes and calculating failure rate distributions of electronic and electromechanical components. How can these individual failure time distributions of structural, electronic and electromechanical component failure modes be effectively combined into a top level model for overall system evaluation of component upgrades, changes in maintenance intervals, or line replaceable unit (LRU) redesign? This paper shows an example of how various probabilistic failure predictions for turbine engine components can be evaluated and combined to show their effect on overall engine performance. A generic model of a turbofan engine was modeled using various Probabilistic Risk Assessment (PRA) tools (Quantitative Risk Assessment Software (QRAS) etc.). Hypothetical PSA results for a number of structural components along with mitigation factors that would restrict the failure mode from propagating to a Loss of Mission (LOM) failure were used in the models. The output of this program includes an overall failure distribution for LOM of the system. The rank and contribution to the overall Mission Success (MS) is also given for each failure mode and each subsystem. This application methodology demonstrates the effectiveness of PRA for assessing the performance of large turbine engines. Additionally, the effects of system changes and upgrades, the application of different maintenance intervals, inclusion of new sensor detection of faults and other upgrades were evaluated in determining overall turbine engine reliability.

Packard, Michael H.↗

Reliability Impacts in Life Support Architecture and Technology Selection

Equivalent System Mass (ESM) and reliability estimates were performed for different life support architectures based primarily on International Space Station (ISS) technologies. The analysis was applied to a hypothetical 1-year deep-space mission. High-level fault trees were initially developed relating loss of life support functionality to the Loss of Crew (LOC) top event. System reliability was then expressed as the complement (nonoccurrence) this event and was increased through the addition of redundancy and spares, which added to the ESM. The reliability analysis assumed constant failure rates and used current projected values of the Mean Time Between Failures (MTBF) from an ISS database where available. Results were obtained showing the dependence of ESM on system reliability for each architecture. Although the analysis employed numerous simplifications and many of the input parameters are considered to have high uncertainty, the results strongly suggest that achieving necessary reliabilities for deep-space missions will add substantially to the life support system mass. As a point of reference, the reliability for a single-string architecture using the most regenerative combination of ISS technologies without unscheduled replacement spares was estimated to be less than 1%. The results also demonstrate how adding technologies in a serial manner to increase system closure forces the reliability of other life support technologies to increase in order to meet the system reliability requirement. This increase in reliability results in increased mass for multiple technologies through the need for additional spares. Alternative parallel architecture approaches and approaches with the potential to do more with less are discussed. The tall poles in life support ESM are also reexamined in light of estimated reliability impacts.

Lange, Kevin E.↗

Analytical technique permits comparison of reliability of alternate mechanical designs

Failure Rate Index analysis permits comparison of reliability of alternate mechanical designs. All failure modes for a mechanical component are identified, and computed on an index which relates the failure mode to failure of the component. The summation of all failure mode indexes relates the potential reliability of the component.

Henning, F. W.↗

The relationship between reliability and bonding techniques in hybrid microcircuits

Differential thermal expansion was shown to be responsible for many observed failures in ceramic chip capacitors mounted on alumina substrates. It is shown that the mounting techniques used in bonding the capacitors have a marked effect upon the thermally induced mechanical stress and thus the failure rate. A mathematical analysis was conducted of a composite model of the capacitor-substrate system to predict the magnitude of thermally induced stresses. It was experimentally observed that the stresses in more compliant bonding systems such as soft lead tin and indium solders are significantly lower than those in hard solder and epoxy systems. The marked dependence upon heating and cooling rate was proven to be a determining factor in the prediction of failure solder systems. It was found that the harder or higher melting solders are less susceptible to thermal cycling effects but that they are more likely to fail during initial processing operations. Strain gage techniques were used to determine thermally induced expansion stresses of the capacitors and the alumina substrates. The compliance of the different bonding mediums was determined. From the data obtained, several recommendations are made concerning the optimum bonding system for the achievement of maximum reliability.

Caruso, S. V.↗

The relationship between reliability and bonding techniques in hybrid systems

Differential thermal expansion has been shown to be responsible for many observed failures in ceramic chip capacitors mounted on alumina substrates. The present work has shown that the mounting techniques used in bonding the capacitors have a marked effect upon the thermally induced mechanical stress and thus the failure rate. A mathematical analysis of a composite model of the capacitor-substrate system to predict the magnitude of thermally induced stresses has been conducted. It has been observed that the stresses in more compliant bonding systems such as soft lead/tin and indium solders are significantly lower than those in hard solder and epoxy systems. The marked dependence upon heating and cooling rate has proven to be a determining factor in the prediction of failure in both the indium and tin/lead solder systems. This study has shown that the harder or higher melting solders are less susceptible to thermal cycling effects but that they are more likely to fail during initial processing operations. Recommendations are made concerning the optimum bonding system for the achievement of maximum reliability.

Kinser, D. L.↗