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At least 253 records · Page 14
All sourcesNASA NTRSDOE OSTI
NASA NTRS2006

A Comparison of Functional Models for Use in the Function-Failure Design Method

When failure analysis and prevention, guided by historical design knowledge, are coupled with product design at its conception, shorter design cycles are possible. By decreasing the design time of a product in this manner, design costs are reduced and the product will better suit the customer s needs. Prior work indicates that similar failure modes occur with products (or components) with similar functionality. To capitalize on this finding, a knowledge base of historical failure information linked to functionality is assembled for use by designers. One possible use for this knowledge base is within the Elemental Function-Failure Design Method (EFDM). This design methodology and failure analysis tool begins at conceptual design and keeps the designer cognizant of failures that are likely to occur based on the product s functionality. The EFDM offers potential improvement over current failure analysis methods, such as FMEA, FMECA, and Fault Tree Analysis, because it can be implemented hand in hand with other conceptual design steps and carried throughout a product s design cycle. These other failure analysis methods can only truly be effective after a physical design has been completed. The EFDM however is only as good as the knowledge base that it draws from, and therefore it is of utmost importance to develop a knowledge base that will be suitable for use across a wide spectrum of products. One fundamental question that arises in using the EFDM is: At what level of detail should functional descriptions of components be encoded? This paper explores two approaches to populating a knowledge base with actual failure occurrence information from Bell 206 helicopters. Functional models expressed at various levels of detail are investigated to determine the necessary detail for an applicable knowledge base that can be used by designers in both new designs as well as redesigns. High level and more detailed functional descriptions are derived for each failed component based on NTSB accident reports. To best record this data, standardized functional and failure mode vocabularies are used. Two separate function-failure knowledge bases are then created aid compared. Results indicate that encoding failure data using more detailed functional models allows for a more robust knowledge base. Interestingly however, when applying the EFDM, high level descriptions continue to produce useful results when using the knowledge base generated from the detailed functional models.

Stock, Michael E.↗
NASA NTRS1981

Lessons from NASA

Particular requirements related to the design and the operation of spacecraft have forced NASA to take a reliability approach that differs somewhat from that used in many other applications. NASA has found that some of the traditional tools of reliability engineering, such as life testing, reliability demonstration testing, maintainability analysis, and direct failure analysis, are impractical for spacecraft. In place of a statistical approach, the space agency uses an engineering approach to mission reliability. Reliability is to be obtained with the aid of three different approaches, including the application of effective design principles, the control and screening of all parts, and the testing of the entire spacecraft or its prototype for predicted capabilities. Attention is given to failure-mode analysis, the enhancement of Voyager reliability by autonomous operation, the redundancy in Shuttle design, the weeding out of bad hardware, and the preference for off-the-shelf devices.

Williams, W. C.↗
NASA NTRSDate not supplied

Analysis of a Dynamic Flexed Flat Cable Harness

A dynamic flex test was performed on a spacecraft instrument harness composed of multiple individual flex cables, with each flex cable containing multiple copper traces. The purpose of the test was to demonstrate the capability of the harness to survive the number of expected flex cycles during the planned mission with appropriate margin. However, during testing, increased trace resistances and open circuits were observed beginning at approximately 10% of the total number of planned flex cycles. This paper discusses the various proximate causes that contributed to increased and open resistance in the flex cables and the subsequent redesign, manufacturing, reliability, and quality-related changes that were instituted. An analysis process, including failure analysis, non-destructive evaluation, digital imaging correlation, and parametric modeling, will also be discussed. The paper will cover the development of a robust dynamic flex harness design and include recommendations to extend flex harness life; make changes to the flex harness life test; and improve flex cable manufacturing, quality, and reliability.

Flexible PCB↗
NASA NTRSDate not supplied

Analysis of a Dynamic Flexed Flat Cable Harness

A dynamic flex test was performed on a spacecraft instrument harness composed of multiple individual flex cables, with each flex cable containing multiple copper traces. The purpose of the test was to demonstrate the capability of the harness to survive the number of expected flex cycles during the planned mission with appropriate margin. However, during testing, increased trace resistances and open circuits were observed beginning at approximately 10% of the total number of planned flex cycles. This paper discusses the various proximate causes that contributed to increased and open resistance in the flex cables and the subsequent redesign, manufacturing, reliability, and quality-related changes that were instituted. An analysis process, including failure analysis, non-destructive evaluation, digital imaging correlation, and parametric modeling, will also be discussed. The paper will cover the development of a robust dynamic flex harness design and include recommendations to extend flex harness life; make changes to the flex harness life test; and improve flex cable manufacturing, quality, and reliability.

Flexible PCB↗
NASA NTRS1979

Mod 1 wind turbine generator failure modes and effects analysis

A failure modes and effects analysis (FMEA) was directed primarily at identifying those critical failure modes that would be hazardous to life or would result in major damage to the system. Each subsystem was approached from the top down, and broken down to successive lower levels where it appeared that the criticality of the failure mode warranted more detail analysis. The results were reviewed by specialists from outside the Mod 1 program, and corrective action taken wherever recommended.

Source record↗
NASA NTRS1987

Verification of FANTASTIC integrated code

FANTASTIC is an acronym for Failure Analysis Nonlinear Thermal and Structural Integrated Code. This program was developed by Failure Analysis Associates, Palo Alto, Calif., for MSFC to improve the accuracy of solid rocket motor nozzle analysis. FANTASTIC has three modules: FACT - thermochemical analysis; FAHT - heat transfer analysis; and FAST - structural analysis. All modules have keywords for data input. Work is in progress for the verification of the FAHT module, which is done by using data for various problems with known solutions as inputs to the FAHT module. The information obtained is used to identify problem areas of the code and passed on to the developer for debugging purposes. Failure Analysis Associates have revised the first version of the FANTASTIC code and a new improved version has been released to the Thermal Systems Branch.

Chauhan, Rajinder Singh↗
NASA NTRS2005

On Automating Failure Mode Analysis and Enforcing its Integrity

This paper reports our experience on the development of a design-for-safety (DFS) workbench called Risk Assessment and Management Environment (RAME) for microelectronic avionics systems. Our objective is to transform DFS practice from an ad-hoc, inefficient, error-prone approach to a stringent engineering process such that DFS can keep up with the rapidly growing complexity of avionics systems. In particular, RAME is built upon an information infrastructure that comprises a fault model, a knowledge base, and a failure reporting/tracking system. This infrastructure permits systematic learning from prior projects and enables the automation of failure modes, effects and criticality analysis (FMECA). Among other unique features, the most important advantage of RAME is its capability of directly accepting design source code in hardware description languages (HDLs) for automated failure mode analysis, which enables RAME to be compatible and to evolve with most electronic-computer-aided-design systems. Through an initial experimental evaluation of the RAME prototype, we show that our approach to FMECA automation improves failure mode analysis turn-around-time, completeness, and accuracy.

design for safety↗
NASA NTRS1987

FMEAssist: A knowledge-based approach to Failure Modes and Effects Analysis

A Failure Modes and Effects Analysis workstation (FMESassist) was designed for use during the development of the space station. It assists engineers in the complex task of tracking failures and their effects on the system. Engineers experience increased productivity through reduced clerical loads, reduced data inconsistency, and significantly reduced analysis time. System developments benefit from a more thorough analysis than was available using previous methods.

Carnes, James R.↗
NASA NTRS1986

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.↗
NASA NTRS1995

Comprehension and retrieval of failure cases in airborne observatories

This paper describes research dealing with the computational problem of analyzing and repairing failures of electronic and mechanical systems of telescopes in NASA's airborne observatories, such as KAO (Kuiper Airborne Observatory) and SOFIA (Stratospheric Observatory for Infrared Astronomy). The research has resulted in the development of an experimental system that acquires knowledge of failure analysis from input text, and answers questions regarding failure detection and correction. The system's design builds upon previous work on text comprehension and question answering, including: knowledge representation for conceptual analysis of failure descriptions, strategies for mapping natural language into conceptual representations, case-based reasoning strategies for memory organization and indexing, and strategies for memory search and retrieval. These techniques have been combined into a model that accounts for: (a) how to build a knowledge base of system failures and repair procedures from descriptions that appear in telescope-operators' logbooks and FMEA (failure modes and effects analysis) manuals; and (b) how to use that knowledge base to search and retrieve answers to questions about causes and effects of failures, as well as diagnosis and repair procedures. This model has been implemented in FANSYS (Failure ANalysis SYStem), a prototype text comprehension and question answering program for failure analysis.

Alvarado, Sergio J.↗
NASA NTRS2011

Uncertainty Analysis via Failure Domain Characterization: Unrestricted Requirement Functions

This paper proposes an uncertainty analysis framework based on the characterization of the uncertain parameter space. This characterization enables the identification of worst-case uncertainty combinations and the approximation of the failure and safe domains with a high level of accuracy. Because these approximations are comprised of subsets of readily computable probability, they enable the calculation of arbitrarily tight upper and lower bounds to the failure probability. The methods developed herein, which are based on nonlinear constrained optimization, are applicable to requirement functions whose functional dependency on the uncertainty is arbitrary and whose explicit form may even be unknown. Some of the most prominent features of the methodology are the substantial desensitization of the calculations from the assumed uncertainty model (i.e., the probability distribution describing the uncertainty) as well as the accommodation for changes in such a model with a practically insignificant amount of computational effort.

Crespo, Luis G.↗
NASA NTRS2011

Uncertainty Analysis via Failure Domain Characterization: Polynomial Requirement Functions

This paper proposes an uncertainty analysis framework based on the characterization of the uncertain parameter space. This characterization enables the identification of worst-case uncertainty combinations and the approximation of the failure and safe domains with a high level of accuracy. Because these approximations are comprised of subsets of readily computable probability, they enable the calculation of arbitrarily tight upper and lower bounds to the failure probability. A Bernstein expansion approach is used to size hyper-rectangular subsets while a sum of squares programming approach is used to size quasi-ellipsoidal subsets. These methods are applicable to requirement functions whose functional dependency on the uncertainty is a known polynomial. Some of the most prominent features of the methodology are the substantial desensitization of the calculations from the uncertainty model assumed (i.e., the probability distribution describing the uncertainty) as well as the accommodation for changes in such a model with a practically insignificant amount of computational effort.

Crespo, Luis G.↗
DOE OSTI2025

Preliminary System Interface Failure Mode Analysis for Two Advanced Reactors

This study explores two distinct Balance of Plant (BOP) configurations: the Rankine cycle for a sodium-cooled fast reactor (SFR) and the Brayton cycle for a gas-cooled reactor (GCR). As representative designs, the Power Reactor Innovative Small Module (PRISM) by GE Hitachi Nuclear Energy was selected for the SFR, while the Gas Turbine Modular Helium Reactor (GT MHR) by General Atomics was chosen for the gas-cooled reactor. Both configurations were adapted to deliver high-quality heat for industrial applications. A Failure Modes and Effects Analysis (FMEA) was conducted for each system to identify critical failure modes affecting key components. This study marks the first phase of a two-step design optimization approach, integrating FMEA into the design process. Based on the analysis, design modifications and mitigation strategies were proposed to enhance system resilience. The second phase, to be detailed in a subsequent report, will focus on the role of the control system in mitigating these failures. The FMEA serves as a foundation for defining the control topology, ensuring system resilience against component failures that could compromise essential functions, such as electricity and heat production.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
NASA NTRS2004

Failure of Non-Circular Composite Cylinders

In this study, a progressive failure analysis is used to investigate leakage in internally pressurized non-circular composite cylinders. This type of approach accounts for the localized loss of stiffness when material failure occurs at some location in a structure by degrading the local material elastic properties by a certain factor. The manner in which this degradation of material properties takes place depends on the failure modes, which are determined by the application of a failure criterion. The finite-element code STAGS, which has the capability to perform progressive failure analysis using different degradation schemes and failure criteria, is utilized to analyze laboratory scale, graphite-epoxy, elliptical cylinders with quasi-isotropic, circumferentially-stiff, and axially-stiff material orthotropies. The results are divided into two parts. The first part shows that leakage, which is assumed to develop if there is material failure in every layer at some axial and circumferential location within the cylinder, does not occur without failure of fibers. Moreover before fibers begin to fail, only matrix tensile failures, or matrix cracking, takes place, and at least one layer in all three cylinders studied remain uncracked, preventing the formation of a leakage path. That determination is corroborated by the use of different degradation schemes and various failure criteria. Among the degradation schemes investigated are the degradation of different engineering properties, the use of various degradation factors, the recursive or non-recursive degradation of the engineering properties, and the degradation of material properties using different computational approaches. The failure criteria used in the analysis include the noninteractive maximum stress criterion and the interactive Hashin and Tsai-Wu criteria. The second part of the results shows that leakage occurs due to a combination of matrix tensile and compressive, fiber tensile and compressive, and inplane shear failure modes in all three cylinders. Leakage develops after a relatively low amount of fiber damage, at about the same pressure for three material orthotropies, and at approximately the same location.

Hyer, M. W.↗
NASA NTRS2002

Torque Limits for Fasteners in Composites

The two major classes of laminate joints are bonded and bolted. Often the two classes are combined as bonded-bolted joints. Several characteristics of fiber reinforced composite materials render them more susceptible to joint problems than conventional metals. These characteristics include weakness in in-plane shear, transverse tension/compression, interlaminar shear, and bearing strength relative to the strength and stiffness in the fiber direction. Studies on bolted joints of composite materials have been focused on joining assembly subject to in-plane loads. Modes of failure under these loading conditions are net-tension failure, cleavage tension failure, shear-out failure, bearing failure, etc. Although the studies of torque load can be found in literature, they mainly discussed the effect of the torque load on in-plane strength. Existing methods for calculating torque limit for a mechanical fastener do not consider connecting members. The concern that a composite member could be crushed by a preload inspired the initiation of this study. The purpose is to develop a fundamental knowledge base on how to determine a torque limit when a composite member is taken into account. Two simplified analytical models were used: a stress failure analysis model based on maximum stress criterion, and a strain failure analysis model based on maximum strain criterion.

Yi Zhao↗
NASA NTRS1992

Stress analysis and failure of an internally pressurized composite-jacketed steel cylinder

This paper presents a nonlinear stress analysis of a thick-walled compound tube subjected to internal pressure. The compound tube is constructed of a steel liner and a graphite-bismaleimide outer shell. Analytical expressions for the stresses, strains, and displacements are derived for all loading ranges up to failure. Numerical results for the stresses and the maximum value that the compound tube can contain without failure are presented.

Chen, Peter C. T.↗