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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 271 records · Page 15
All sourcesNASA NTRSDOE OSTI
DOE OSTI2026

Laser interference structuring of Cu for adhesive joining of HVAC equipment

Due to potential energy and cost savings benefits, adhesive joining has been recently considered for heating, ventilation, air conditioning, and refrigeration (HVAC&R) systems. HVAC adhesive bonding requires cost-effective and adequate surface preparations of adherents. Here, this article investigates the use of abrasion, traditional single-beam laser, and a laser-interference technique as surface preparations of copper surfaces. Surface morphology is characterized using scanning electron microscopy (SEM) and atomic force microscopy (AFM). Effective submicrometer peak-to-valley structuring with a periodicity of ∼2.7μ⁢m was demonstrated for laser-interference processing. Single-lap shear tests were conducted for 89 joints made with bondline thicknesses of 0.15 and 0.3 mm. Data on process variables and measured variables included open-time, bond length, maximum load, displacement at failure, shear lap strength, and failure mode. A statistical analysis was conducted on each lot to determine the lower limit with 95% confidence intervals for displacements at failure and shear lap strengths. A comparison is presented between the properties of laser-structured joints with respect to those prepared by abrasion, which is considered the baseline surface preparation technique. Based on this comparison, one single-beam laser technique and two laser-interference techniques were shown to exhibit vastly superior performance over the joints made with abraded specimens.

Sabau, Adrian S. [Oak Ridge National Laboratory (O↗
NASA NTRS1975

Fatigue of notched fiber composite laminates. Part 1: Analytical model

A description is given of a semi-empirical, deterministic analysis for prediction and correlation of fatigue crack growth, residual strength, and fatigue lifetime for fiber composite laminates containing notches (holes). The failure model used for the analysis is based upon composite heterogeneous behavior and experimentally observed failure modes under both static and fatigue loading. The analysis is consistent with the wearout philosophy. Axial cracking and transverse cracking failure modes are treated together in the analysis. Cracking off-axis is handled by making a modification to the axial cracking analysis. The analysis predicts notched laminate failure from unidirectional material fatique properties using constant strain laminate analysis techniques. For multidirectional laminates, it is necessary to know lamina fatique behavior under axial normal stress, transverse normal stress and axial shear stress. Examples of the analysis method are given.

Mclaughlin, P. V., Jr.↗
DOE OSTI2025

Nuclear Reactor Heat Extraction for Synthetic Fuel Plants

This report looks at the viability and best approach when producing synthetic fuels using heat and power supplied by advanced nuclear energy systems. The report looks at a low temperature integration pathway with four types of advanced reactors: a pressurized water reactor (PWR), an advanced light water reactor (A-LWR), a sodium fast reactor (SFR), and a high-temperature gas-cooled reactor (HTGR). A failure modes and effects analysis (FMEA) of the coupling system between the nuclear plant and the synthetic fuel systems is performed with the goal of identifying the reliability of such a thermal delivery system. Furthermore, a high temperature pathway is investigated for synfuel coupling to determine if this is more efficient and more cost effective as a coupling approach.

10 - SYNTHETIC FUELS↗
NASA NTRS1996

An Independent Evaluation of the FMEA/CIL Hazard Analysis Alternative Study

The present instruments of safety and reliability risk control for a majority of the National Aeronautics and Space Administration (NASA) programs/projects consist of Failure Mode and Effects Analysis (FMEA), Hazard Analysis (HA), Critical Items List (CIL), and Hazard Report (HR). This extensive analytical approach was introduced in the early 1970's and was implemented for the Space Shuttle Program by NHB 5300.4 (1D-2. Since the Challenger accident in 1986, the process has been expanded considerably and resulted in introduction of similar and/or duplicated activities in the safety/reliability risk analysis. A study initiated in 1995, to search for an alternative to the current FMEA/CIL Hazard Analysis methodology generated a proposed method on April 30, 1996. The objective of this Summer Faculty Study was to participate in and conduct an independent evaluation of the proposed alternative to simplify the present safety and reliability risk control procedure.

Ray, Paul S.↗
NASA NTRS1980

Orbiter subsystem hardware/software interaction analysis. Volume 8: AFT reaction control system, part 2

The orbiter subsystems and interfacing program elements which interact with the orbiter computer flight software are analyzed. The failure modes identified in the subsystem/element failure mode and effects analysis are examined. Potential interaction with the software is examined through an evaluation of the software requirements. The analysis is restricted to flight software requirements and excludes utility/checkout software. The results of the hardware/software interaction analysis for the forward reaction control system are presented.

Becker, D. D.↗
NASA NTRS2002

Decomposition-Based Failure Mode Identification Method for Risk-Free Design of Large Systems

When designing products, it is crucial to assure failure and risk-free operation in the intended operating environment. Failures are typically studied and eliminated as much as possible during the early stages of design. The few failures that go undetected result in unacceptable damage and losses in high-risk applications where public safety is of concern. Published NASA and NTSB accident reports point to a variety of components identified as sources of failures in the reported cases. In previous work, data from these reports were processed and placed in matrix form for all the system components and failure modes encountered, and then manipulated using matrix methods to determine similarities between the different components and failure modes. In this paper, these matrices are represented in the form of a linear combination of failures modes, mathematically formed using Principal Components Analysis (PCA) decomposition. The PCA decomposition results in a low-dimensionality representation of all failure modes and components of interest, represented in a transformed coordinate system. Such a representation opens the way for efficient pattern analysis and prediction of failure modes with highest potential risks on the final product, rather than making decisions based on the large space of component and failure mode data. The mathematics of the proposed method are explained first using a simple example problem. The method is then applied to component failure data gathered from helicopter, accident reports to demonstrate its potential.

Tumer, Irem Y.↗
NASA NTRS2003

Task Analysis Technologies at KSC

Project objective: (1) Form an integrated team of NASA. USA, Boeing, and Dynacs researches. (2) Create a user friendly software prototype that assists an analyst in performing a human factors process failure modes and effects analysis (HF-PFMEA). (3)Perform four task analyses on center: cargo late access task analysis (NASA/Boeing team); payload test and verification system task analysis (NASA/Boeing team); slammer cover installation operations task analysis (NASA/USA team); ATDC LOX pump acceptance test procedure task analysis (NASA/Dynacs team).

Carstens, Deborah S.↗
DOE OSTI2023

Automated Controller Hardware-In-The-Loop Testbed for EV Charger Resilience Analysis

This paper focuses on the development of a tool that includes an automated testbed with controls, protection, and communications integrated into a real-time system to provide a platform to generate data sets for failure modes and effects analysis. This tool establishes a value for automation of data generation for different scenarios and addresses the gap of nonexistent field data for different applications and use cases. The features of this tool can further be expanded to include multiple power electronics models, communication protocols, and scaled system architectures. This general framework was evaluated for a DC fast charger system use case to provide quantitative solution for resiliency.

Starke, Michael↗
NASA NTRS2002

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.↗
NASA NTRS2022

Natural Language Processing Techniques for Intelligent Knowledge Management of Safety Reports

Safety, failure, and incident reports are common artifacts across various domains, including aviation and wildfire response. These reports are often mandatory to submit, resulting in the culmination of large repositories of text-based documents. Simultaneously, these reports and corresponding repositories are often only manually analyzed and queried by users via out-of-date search engines. As a consequence, we have been developing the Manager for Intelligent Knowledge Access (MIKA) toolkit, which uses natural language processing to improve information access and reuse. In this presentation, we discuss natural language processing techniques for knowledge discovery and apply these methods to a repository of aerial wildfire mishap reports. Two methods are used for knowledge discovery: topic modeling and named-entity recognition. We use topic modeling to identify hazards and perform a trend analysis to produce a data-driven risk matrix. A custom named-entity recognition model, build from fine tuning a pre-trained language model, is used to identify failure modes, failure causes, failure effects, control processes, and recommendations to aid in failure modes and effects analysis (FMEA). Throughout the presentation, we discuss and apply natural language processing techniques to better leverage the vast amount of information contained in report repositories.

Machine learning↗
NASA NTRS1993

Failure detection and recovery in the assembly/contingency subsystem

The Assembly/Contingency Subsystem (ACS) is the primary communications link on board the Space Station. Any failure in a component of this system or in the external devices through which it communicates with ground-based systems will isolate the Station. The ACS software design includes a failure management capability (ACFM) that provides protocols for failure detection, isolation, and recovery (FDIR). The the ACFM design requirements as outlined in the current ACS software requirements specification document are reviewed. The activities carried out in this review include: (1) an informal, but thorough, end-to-end failure mode and effects analysis of the proposed software architecture for the ACFM; and (2) a prototype of the ACFM software, implemented as a C program under the UNIX operating system. The purpose of this review is to evaluate the FDIR protocols specified in the ACS design and the specifications themselves in light of their use in implementing the ACFM. The basis of failure detection in the ACFM is the loss of signal between the ground and the Station, which (under the appropriate circumstances) will initiate recovery to restore communications. This recovery involves the reconfiguration of the ACS to either a backup set of components or to a degraded communications mode. The initiation of recovery depends largely on the criticality of the failure mode, which is defined by tables in the ACFM and can be modified to provide a measure of flexibility in recovery procedures.

Gantenbein, Rex E.↗
NASA NTRS1984

Recertification analysis and inspection planning for environmental test facilities

Program development and implementation for recertification of pressure vessels used at NASA facilities are outlined, together with inspection procedures. The recertification is carried out in three phases: analysis, inspection planning, and long term inspection plans and management. A data base was developed for each piece of equipment and the associated performance parameters. Either documentation was obtained or NDT was performed on the vessels to confirm design and Code compliance. A Failure Modes and Effects Analysis technique was used to target recurring inspection items and guidelines were drawn up for inspections of parts and systems and intervals between inspections. The steps taken in establishing the program are considered applicable in both research and industrial situations.

Rebeck, K. J.↗
DOE OSTI2022

Liquid Hydrogen Heavy-Duty Vehicle Safety Review and Refueling Facility Design

Liquid hydrogen (LH 2 ) used as a fuel onboard a heavy-duty vehicle can result in increased storage capacity and faster refueling relative to compressed gas. However, there are concerns about hydrogen losses from boil-off, potential safety issues, gaps in codes and standards for cryogenic hydrogen fuel, and technical challenges with LH 2 systems for widespread transportation applications. A failure modes and effects analysis (FMEA), a safety codes and standards review, and a design review of the onboard liquid hydrogen system for a heavy-duty vehicle identified some of these potential safety issues and gaps in the codes and standards. The FMEA identified some medium and low risk failure points of the conceptual design, and the design review identified how carefully pressure relief needs to be considered for LH 2 systems. In addition, a conceptual design for a LH 2 refueling station was developed. Rough capital costs for the refueling station design were $\$1 million$ and the layout occupied approximately 13,000 ft 2 . These results can be used to inform future designs and analyses for LH 2 heavy-duty vehicles.

08 HYDROGEN↗
DOE OSTI2024

Highly accelerated life testing (HALT): A review from a statistical perspective

Despite its use in one form or another for at least four decades, HALT and related techniques [e.g., highly accelerated-stress screening (HASS) and stress audits (HASA)] are not well understood within the statistical community and remain controversial. This largely reflects a conflict in motivation between engineers, testing under harsh conditions to discover and eliminate failure modes, and statisticians, taking a more cautious approach to develop quantitative estimates of parameters such as mean time between failures (MTBF). Here, this review article will clarify HALT concepts and methods and explain where it fits within the universe of methods that involve the application of accelerating factors to compress the time required to evaluate or enhance product reliability. A major distinction is between methods such as HALT, a high-stress test-analyze-fix-test iterative process directed at improving reliability by discovering and fixing weak points in a design, and quantitative accelerated life testing (QALT), whose goal is the estimation of product life for a fixed design. We discuss methods such as physics of failure that offer some hope of bridging the gap between the qualitative nature of HALT, and purely quantitative statistical methods. We present a variety of engineering applications of HALT including metal fatigue, piping and pressure vessels, structural damage, radiation damage, and rotating machinery. We also discuss potential synergies between HALT and QALT, such as rapid identification, through HALT, of failure modes requiring quantitative analysis. For further study, extensive references to the applicable literature are provided as well as an appendix that describes related methods.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2024

Analyzing Potential Failures and Effects in a Pilot-Scale Biomass Preprocessing Facility for Improved Reliability

This study demonstrates a failure identification methodology applied to a preprocessing facility generating conversion-ready feedstocks from biomass meeting conversion process critical quality attribute (CQA) specifications. Failure Modes and Effects Analysis (FMEA) was used as an industrially relevant risk analysis approach to evaluate a logging residue preprocessing system to prepare feedstock for pyrolysis conversion. Risk evaluations considered both system-level and operation unit-level assessments considering process efficiency, product quality, cost, sustainability, and safety. Key outputs included estimations of semi-quantitative risk scores for each failure, identification of the failure impacts, identification of failure causes associated with material attributes and process parameters, ranking success rates of failure detection methods, and speculation of potential mitigation strategies for decreasing failure risk scores. Results showed that deviations from moisture specifications had cascading consequences for other CQAs along with process safety implications. Failures linked to fixed carbon specifications carried the highest risk scores for product quality and process efficiency impacts. As increased throughput can be inversely related to meeting product quality specifications; achieving throughput and other material-based CQAs simultaneously will likely require system optimization or prioritization based on system economics. Ultimately, this work successfully demonstrates FMEA as a risk analysis approach for other bioenergy process systems.

09 BIOMASS FUELS↗
DOE OSTI2021

Reliability Prediction using FMEA, FTA, and Related Techniques [Slides]

Summary: We presented a reliability analysis framework. We made point estimates of reliability using reliability block diagrams, fault trees, success trees and estimates with uncertainty using expert elicitation, Monte Carlo simulation, Bayesian analysis. Expert elicitation of failure modes and probabilities is labor-intensive, but critical. Bayesian analysis updates information from expert elicitation with data from reliability and aging tests (aging/compatibility data are needed to estimate lower-bound reliabilities at end of life). Estimation by more than one method helps insure consistency and accuracy.

97 MATHEMATICS AND COMPUTING↗
NASA NTRS2002

Human Factors Process Task Analysis Liquid Oxygen Pump Acceptance Test Procedure for the Advanced Technology Development Center

A process task analysis effort was undertaken by Dynacs Inc. commencing in June 2002 under contract from NASA YA-D6. Funding was provided through NASA's Ames Research Center (ARC), Code M/HQ, and Industrial Engineering and Safety (IES). The John F. Kennedy Space Center (KSC) Engineering Development Contract (EDC) Task Order was 5SMA768. The scope of the effort was to conduct a Human Factors Process Failure Modes and Effects Analysis (HF PFMEA) of a hazardous activity and provide recommendations to eliminate or reduce the effects of errors caused by human factors. The Liquid Oxygen (LOX) Pump Acceptance Test Procedure (ATP) was selected for this analysis. The HF PFMEA table (see appendix A) provides an analysis of six major categories evaluated for this study. These categories include Personnel Certification, Test Procedure Format, Test Procedure Safety Controls, Test Article Data, Instrumentation, and Voice Communication. For each specific requirement listed in appendix A, the following topics were addressed: Requirement, Potential Human Error, Performance-Shaping Factors, Potential Effects of the Error, Barriers and Controls, Risk Priority Numbers, and Recommended Actions. This report summarizes findings and gives recommendations as determined by the data contained in appendix A. It also includes a discussion of technology barriers and challenges to performing task analyses, as well as lessons learned. The HF PFMEA table in appendix A recommends the use of accepted and required safety criteria in order to reduce the risk of human error. The items with the highest risk priority numbers should receive the greatest amount of consideration. Implementation of the recommendations will result in a safer operation for all personnel.

Diorio, Kimberly A.↗
NASA NTRS2009

Parts and Components Reliability Assessment: A Cost Effective Approach

System reliability assessment is a methodology which incorporates reliability analyses performed at parts and components level such as Reliability Prediction, Failure Modes and Effects Analysis (FMEA) and Fault Tree Analysis (FTA) to assess risks, perform design tradeoffs, and therefore, to ensure effective productivity and/or mission success. The system reliability is used to optimize the product design to accommodate today?s mandated budget, manpower, and schedule constraints. Stand ard based reliability assessment is an effective approach consisting of reliability predictions together with other reliability analyses for electronic, electrical, and electro-mechanical (EEE) complex parts and components of large systems based on failure rate estimates published by the United States (U.S.) military or commercial standards and handbooks. Many of these standards are globally accepted and recognized. The reliability assessment is especially useful during the initial stages when the system design is still in the development and hard failure data is not yet available or manufacturers are not contractually obliged by their customers to publish the reliability estimates/predictions for their parts and components. This paper presents a methodology to assess system reliability using parts and components reliability estimates to ensure effective productivity and/or mission success in an efficient manner, low cost, and tight schedule.

Lee, Lydia↗