Site-Specific Sectioning and SEM Imaging of MOSFET Active Regions for Device Failure Analysis
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Nichols, Sean Michael [Sandia National Laboratorie↗
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Results for “Failure analysis”
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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Symbol-oriented failure analysis in multicomponent systems
Computer oriented error analysis of electrical circuits and nonlinear system performance
Happ, W. W.↗
Failure analysis of solid rocket apogee motors
The analysis followed five selected motors through initial design, development, test, qualification, manufacture, and final flight reports. An audit was conducted at the manufacturing plants to complement the literature search with firsthand observations of the current philosophies and practices that affect reliability of the motors. A second literature search emphasized acquisition of spacecraft and satellite data bearing on solid motor reliability. It was concluded that present practices at the plants yield highly reliable flight hardware. Reliability can be further improved by new developments of aft-end bonding and initiator/igniter nondestructive test methods, a safe/arm device, and an insulation formulation. Minimum diagnostic instrumentation is recommended for all motor flights. Surplus motors should be used in margin testing. Criteria should be established for pressure and zone curing. The motor contractor should be represented at launch. New design analyses should be made of stretched motors and spacecraft/motor pairs.
Martin, P. J.↗
Engineering sciences area and module performance and failure analysis area
Photovoltaic-array/power-conditioner interface studies are updated. An experiment conducted to evaluate different operating-point strategies, such as constant voltage and pilot cells, and to determine array energy losses when the array is operated off the maximum power points is described. Initial results over a test period of three and a half weeks showed a 2% energy loss when the array is operated at a fixed voltage. Degraded-array studies conducted at NE RES that used a range of simulated common types of degraded I-V curves are reviewed. The instrumentation installed at the JPL field-test site to obtain the irradiance data was described. Experiments using an optical filter to adjust the spectral irradiance of the large-area pulsed solar simulator (LAPSS) to AM1.5 are described. Residential-array research activity is reviewed. Voltage isolation test results are described. Experiments performed on one type of module to determine the relationship between leakage current and temperature are reviewed. An encapsulated-cell testing approach is explained. The test program, data reduction methods, and initial results of long-duration module testing are described.
Ross, R. G., Jr.↗
J-series ion thruster isolator failure analysis
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Campbell, J. W.↗
Module performance and failure analysis area: Flat-plate solar array project
A redesign of the initial (Group I) Mobile Solar Block V module was done and documented. Manufacturing experience and accelerated test data from Group I formed the basis for the redesign. Ten Block V Group II modules were submitted for evaluation and the results are presented.
Tornstrom, E.↗
Failure analysis of blistered gold plating on spot welded electrical relays
Gold-plated stainless-steel sideplates, part of a JPL Galileo spacecraft electronic-relay assembly, exhibited blistering after resistance spot welding. Unacceptable relays had heavy nonuniform gold electrodeposited layers with thicknesses 4.5-11.5 microns. SEM and metallographic investigations indicated much higher heat input generated during the resistance spot welding in unacceptable relays. The attributes of acceptable welded relays are contrasted with unacceptable relays; the possible mechanism of laminar formation of polymeric material in the gold plating is discussed; and some recommendations are provided to prevent similar problems.
Sokolowski, Witold↗
Evaluation of the heat transfer module (FAHT) of Failure Analysis Nonlinear Thermal And Structural Integrated Code (FANTASTIC)
The heat transfer module of FANTASTIC Code (FAHT) is studied and evaluated to the extend possible during the ten weeks duration of this project. A brief background of the previous studies is given and the governing equations as modeled in FAHT are discussed. FAHT's capabilities and limitations based on these equations and its coding methodology are explained in detail. It is established that with improper choice of element size and time step FAHT's temperature field prediction at some nodes will be below the initial condition. The source of this unrealistic temperature prediction is identified and a procedure is proposed for avoiding this phenomenon. It is further shown that the proposed procedure will converge to an accurate prediction upon mesh refinement. Unfortunately due to lack of time FAHT's ability to accurately account for pyrolysis and surface ablation has not been verified. Therefore, at the present time it can be stated with confidence that FAHT can accurately predict the temperature field for a transient multi-dimensional, orthotropic material with directional dependence, variable property, with nonlinear boundary condition. Such a prediction will provide an upper limit for the temperature field in an ablating decomposing nozzle liner. The pore pressure field, however, will not be known.
Keyhani, Majid↗
Failure analysis of the lithium battery: A study of the header deposit on the cell top and diffusion within the electrode glass seal using nuclear microanalysis and FFTIR spectroscopy
The Solid Rocket Booster Range Safety System (SRBRSS) uses a lithium/poly-carbon monofluoride primary battery as a source of electrical power. After cell fabrication and activation, some battery cells have shown self discharge. One possible source of this cell discharge has been suggested to be the formation and growth of a conducting crystallized chemical compound across the glass bead insulator, electrically shorting the glass bead to the casing. This laboratory has begun an analysis of this compound, the glass seal holding the cathode into place, and the cell electrolyte, using Fast Fourier Transform Infrared (FFTIR) Analysis, Rutherford Backscattering Spectroscopy (RBS), and Nuclear Reaction Microanalysis. Preliminary measurements have confirmed the existence of lithium, nitrogen, fluorine, and oxygen on a reddish-brown deposit covering parts of the glass seal holding the positive electrode in place. Cells using Li metal electrodes, have many advantages over conventional primary batteries. One principal disadvantage of using Li batteries on a commercial basis would be the environmental impact of the fluorocarbon material. Another would be the relatively high expense of (CF)n.
Hassan, Razi A.↗
Advanced composites structural concepts and materials technologies for primary aircraft structures. Structural response and failure analysis: ISPAN modules users manual
The ISPAN Program (Interactive Stiffened Panel Analysis) is an interactive design tool that is intended to provide a means of performing simple and self contained preliminary analysis of aircraft primary structures made of composite materials. The program combines a series of modules with the finite element code DIAL as its backbone. Four ISPAN Modules were developed and are documented. These include: (1) flat stiffened panel; (2) curved stiffened panel; (3) flat tubular panel; and (4) curved geodesic panel. Users are instructed to input geometric and material properties, load information and types of analysis (linear, bifurcation buckling, or post-buckling) interactively. The program utilizing this information will generate finite element mesh and perform analysis. The output in the form of summary tables of stress or margins of safety, contour plots of loads or stress, and deflected shape plots may be generalized and used to evaluate specific design.
Hairr, John W.↗
Failure analysis of woven and braided fabric reinforced composites
A general purpose micromechanics analysis that discretely models the yarn architecture within the textile repeating unit cell was developed to predict overall, three dimensional, thermal and mechanical properties, damage initiation and progression, and strength. This analytical technique was implemented in a user-friendly, personal computer-based, menu-driven code called Textile Composite Analysis for Design (TEXCAD). TEXCAD was used to analyze plain weave and 2x2, 2-D triaxial braided composites. The calculated tension, compression, and shear strengths correlated well with available test data for both woven and braided composites. Parametric studies were performed on both woven and braided architectures to investigate the effects of parameters such as yarn size, yarn spacing, yarn crimp, braid angle, and overall fiber volume fraction on the strength properties of the textile composite.
Naik, Rajiv A.↗
Failure Analysis of a Helicopter External Fuel-Tank Pylon
An eight-inch-long (0.2 m) crack was found in an external fuel-tank pylon of a U.S. Coast Guard HH-60 helicopter. The damaged pylon was removed from service and destructively examined at NASA Langley Research Center (LaRC) to determine the cause of the crack. Results of the analysis revealed that crack initiation occurred at corrosion pits in a fastener hole and crack propagation was a result of cyclic loading.
Newman, John A.↗
Identification of Cyclically Symmetric Resonance in Experimental Data for Engine Failure Analysis
Many structural components are rotationally symmetric. For a perfectly manufactured structure, the modal wave shapes are exactly sinusoidal. These structures can be excited by similarly-shaped forcing functions such as those found frequently in or near turbomachinery. Due to orthogonality, resonance occurs only when the integer wave number of the structure equals the integer wave number of the excitation as well as when the excitation frequency is close to the natural frequency of the mode. This resonance can lead to high-cycle fatigue (HCF) cracking of the structure. To help understand this phenomenon, it is desirable to determine the modal composition of the response and excitation. Once the modal composition is known, either the excitation or the structure can be modified to reduce the response and therefore prevent HCF cracking.
Medley, Steve↗
Accelerated Lifetime Testing and Failure Analysis of Quartz Based GaAs Planar Schottky Diodes
Accelerated lifetime tests have been performed on intergrated planar GaAs Schottky diodes that were bonded to quartz substrates up-side-down with a heat-cured epoxy.
Testing↗
Failure Analysis Study and Long-Term Reliability of Optical Assemblies with End-Face Damage
In June 2005, the NESC received a multi-faceted request to determine the long term reliability of fiber optic termini on the ISS that exhibited flaws not manufactured to best workmanship practices. There was a lack of data related to fiber optic workmanship as it affects the long term reliability of optical fiber assemblies in a harsh environment. A fiber optic defect analysis was requested which would find and/or create various types of chips, spalls, scratches, etc., that were identified by the ISS personnel. Once the defects and causes were identified the next step would be to perform long term reliability testing of similar assemblies with similar defects. The goal of the defect analysis would be for the defects to be observed and documented for deterioration of fiber optic performance. Though this report mostly discusses what has been determined as evidence of poor manufacturing processes, it also concludes the majority of the damage could have been avoided with a rigorous process in place.
Kichak, Robert A.↗
International Space Station Solar Alpha Rotary Joint Failure Analysis: The Materials and Processes Perspective
This paper summarizes the on-orbit structural dynamic data and the related modal analysis, model validation and correlation performed for the ISS configurations spanning ISS Stage 12A. The objective of this analysis is to validate and correlate analytical models used to verify the ISS critical interface dynamic loads and improve its fatigue life prediction. On-Orbit dynamic responses were measured during the ISS configurations throughout ISS Stage 12A by the two main ISS instrumentation systems; Internal Wireless Instrumentation System (IWIS) and the Structural Dynamic Measurement System (SDMS). These nominal on-orbit events include Russian vehicle docking and undockings. Also, the ISS photogrammetric system recorded the movements of the 2A and 4A solar arrays during a modified ISS maneuver. Modal analyses were performed on the measured data to extract modal parameters including frequency, damping and mode shapes. Correlation and comparisons between the test and analytical frequencies and mode shapes were performed to assess the accuracy of the analytical models for the ISS configurations under consideration.
Dasgupta, Rajib↗
The Development of Directional Decohesion Finite Elements for Multiscale Failure Analysis of Metallic Polycrystals
Atomistic simulations of intergranular fracture have indicated that grain-scale crack growth in polycrystalline metals can be direction dependent. At these material length scales, the atomic environment greatly influences the nature of intergranular crack propagation, through either brittle or ductile mechanisms, that are a function of adjacent grain orientation and direction of crack propagation. Methods have been developed to obtain cohesive zone models (CZM) directly from molecular dynamics simulations. These CZMs may be incorporated into decohesion finite element formulations to simulate fracture at larger length scales. A new directional decohesion element is presented that calculates the direction of Mode I opening and incorporates a material criterion for dislocation emission based on the local crystallographic environment to automatically select the CZM that best represents crack growth. The simulation of fracture in 2-D and 3-D aluminum polycrystals is used to illustrate the effect of parameterized CZMs and the effectiveness of directional decohesion finite elements.
Saether, Erik↗