Results for “root cause analysis” — Page 18

NASA NTRS1992

Intelligent alarming

This talk discusses the importance of providing a process operator with concise information about a process fault including a root cause diagnosis of the problem, a suggested best action for correcting the fault, and prioritization of the problem set. A decision tree approach is used to illustrate one type of approach for determining the root cause of a problem. Fault detection in several different types of scenarios is addressed, including pump malfunctions and pipeline leaks. The talk stresses the need for a good data rectification strategy and good process models along with a method for presenting the findings to the process operator in a focused and understandable way. A real time expert system is discussed as an effective tool to help provide operators with this type of information. The use of expert systems in the analysis of actual versus predicted results from neural networks and other types of process models is discussed.

Braden, W. B.↗

NASA NTRS2016

Failure Analysis and Recovery of a 50mm Highly Elastic Intermetallic NiTi Ball Bearing for an ISS Application

The ISS Distillation Assembly centrifuge is the pathfinder application for 50mm bore, deep-groove ball bearings made from the highly elastic intermetallic material 60NiTi. Superior corrosion and shock resistance are required to withstand the acidic wastewater exposure and heavy spacecraft launch related loads that challenge conventional steel bearings. During early ground testing one bearing unexpectedly and catastrophically failed after operating for only 200 hours of run time. A second bearing running on the same shaft was completely unaffected. A thorough investigation into the root cause of the failure determined that an excessively tight press-fit of the bearing outer race coupled with NiTis relatively low elastic modulus were key contributing factors. The proposed failure mode was successfully duplicated by experiment. To further corroborate the root cause theory, a successful bearing life test using improved installation practices (selective fitting) was conducted. The results show that NiTi bearings are suitable for space applications provided that care is taken to accommodate their unique material characteristics.

intermetallics↗

NASA NTRS2016

Failure Analysis and Recovery of a 50 MM Highly Elastic Intermetallic NiTi Ball Bearing for an ISS Application

The ISS Distillation Assembly centrifuge is the pathfinder application for 50mm bore, deep-groove ball bearings made from the highly elastic intermetallic material 60NiTi. Superior corrosion and shock resistance are required to withstand the acidic wastewater exposure and heavy spacecraft launch related loads that challenge conventional steel bearings. During early ground testing one bearing unexpectedly and catastrophically failed after operating for only 200 hours of run time. A second bearing running on the same shaft was completely unaffected. A thorough investigation into the root cause of the failure determined that an excessively tight press-fit of the bearing outer race coupled with NiTis relatively low elastic modulus were key contributing factors. The proposed failure mode was successfully duplicated by experiment. To further corroborate the root cause theory, a successful bearing life test using improved installation practices (selective fitting) was conducted. The results show that NiTi bearings are suitable for space applications provided that care is taken to accommodate their unique material characteristics.

failure analyses↗

DOE OSTI2022

Tomato deploys defence and growth simultaneously to resist bacterial wilt disease

Abstract Plant disease limits crop production, and host genetic resistance is a major means of control. Plant pathogenic Ralstonia causes bacterial wilt disease and is best controlled with resistant varieties. Tomato wilt resistance is multigenic, yet the mechanisms of resistance remain largely unknown. We combined metaRNAseq analysis and functional experiments to identify core Ralstonia ‐responsive genes and the corresponding biological mechanisms in wilt‐resistant and wilt‐susceptible tomatoes. While trade‐offs between growth and defence are common in plants, wilt‐resistant plants activated both defence responses and growth processes. Measurements of innate immunity and growth, including reactive oxygen species production and root system growth, respectively, validated that resistant plants executed defence‐related processes at the same time they increased root growth. In contrast, in wilt‐susceptible plants roots senesced and root surface area declined following Ralstonia inoculation. Wilt‐resistant plants repressed genes predicted to negatively regulate water stress tolerance, while susceptible plants repressed genes predicted to promote water stress tolerance. Our results suggest that wilt‐resistant plants can simultaneously promote growth and defence by investing in resources that act in both processes. Infected susceptible plants activate defences, but fail to grow and so succumb to Ralstonia , likely because they cannot tolerate the water stress induced by vascular wilt.

Meline, Valerian↗

DOE OSTI2023

Wounding rapidly alters transcription factor expression, hormonal signaling, and phenolic compound metabolism in harvested sugarbeet roots

Injuries sustained by sugarbeet (Beta vulgaris L.) roots during harvest and postharvest operations seriously reduce the yield of white sugar produced from stored roots. Although wound healing is critically important to reduce losses, knowledge of these processes is limited for this crop as well as for roots in other species. To better understand the metabolic signals and changes that occur in wounded roots, dynamic changes in gene expression were determined by RNA sequencing and the activity of products from key genes identified in this analysis were determined in the 0.25 to 24 h following injury. Nearly five thousand differentially expressed genes that contribute to a wide range of cellular and molecular functions were identified in wounded roots. Highly upregulated genes included transcription factor genes, as well as genes involved in ethylene and jasmonic acid (JA) biosynthesis and signaling and phenolic compound biosynthesis and polymerization. Enzyme activities for key genes in ethylene and phenolic compound biosynthesis and polymerization also increased due to wounding. Results indicate that wounding causes a major reallocation of metabolism in sugarbeet taproots. Although both ethylene and JA are likely involved in triggering wound responses, the greater and more sustained upregulation of ethylene biosynthesis and signaling genes relative to those of JA, suggest a preeminence of ethylene signaling in wounded sugarbeet roots. Changes in gene expression and enzymes involved in phenolic compound metabolism additionally indicate that barriers synthesized to seal off wounds, such as suberin or lignin, are initiated within the first 24 h after injury.

59 BASIC BIOLOGICAL SCIENCES↗

DOE OSTI2022

Application of Orthogonal Defect Classification for Software Reliability Analysis

The modernization of existing and new nuclear power plants with digital instrumentation and control systems (DI&C) is a recent and highly trending topic. However, there lacks strong consensus on best-estimate reliability methodologies by both the United States (U.S.) Nuclear Regulatory Commission (NRC) and the industry. This has resulted in hesitation for further modernization projects until a more unified methodology is realized. In this work, we develop an approach called Orthogonal-defect Classification for Assessing Software Reliability (ORCAS) to quantify probabilities of various software failure modes in a DI&C system. The method utilizes accepted industry methodologies for software quality assurance that are also verified by experimental or mathematical formulations. In essence, the approach combines a semantic failure classification model with a reliability growth model to predict (and quantify) the potential failure modes of a DI&C software system. The semantic classification model is used to address the question: How do latent defects in software contribute to different software failure root causes? The use of reliability growth models is then used to address the question: Given the connection between latent defects and software failure root causes, how can we quantify the reliability of the software? A case study was conducted on a representative I&C platform (ChibiOS) running a smart sensor acquisition software developed by Virginia Commonwealth University (VCU). The testing and evidence collection guidance in ORCAS was applied, and defects were uncovered in the software. Qualitative evidence, such as condition coverage, was used to gauge the completeness and trustworthiness of the assessment while quantitative evidence was used to determine the software failure probabilities. The reliability of the software was then estimated and compared to existing operational data of the sensor device. It is demonstrated that by using ORCAS, a semantic reasoning framework can be developed to justify software reliability (or unreliability) while still leveraging the strength of the existing methods.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2016

Assessment of potential greenhouse gas mitigation from changes to crop root mass and architecture

Reducing (and eventually reversing) the increase in greenhouse gases (GHGs) in the atmosphere due to human activities, and thus reducing the extent and severity of anthropogenic climate change, is one of the great challenges facing humanity. While most of the man-caused increase in GHGs has been due to fossil fuel use, land use (including agriculture) currently accounts for about 25% of total GHG emissions and thus there is a need to include emission reductions from the land use sector as part of an effective climate change mitigation strategy. In addition, analyses included in the recent IPCC 5th Climate Change Assessment report suggests that it may not be possible to achieve large enough emissions reductions in the energy, transport and industrial sectors alone to stabilize GHG concentrations at a level commensurate with a less than 2°C global average temperature increase, without the help of a substantial CO 2 sink (i.e., atmospheric CO 2 removal) from the land use sector. One of the potential carbon sinks that could contribute to this goal is increasing C storage in soil organic matter on managed lands. This report details a preliminary scoping analysis, to assess the potential agricultural area in the US – where appropriate soil, climate and land use conditions exist – to determine the land area on which ‘improved root phenotype’ crops could be deployed and to evaluate the potential long-term soil C storage, given a set of ‘bounding scenarios’ of increased crop root input and/or rooting depth for major crop species (e.g., row crops (corn, sorghum, soybeans), small grains (wheat, barley, oats), and hay and pasture perennial forages). The enhanced root phenotype scenarios assumed 25, 50 and 100% increase in total root C inputs, in combination with five levels of modifying crop root distributions (i.e., no change and four scenarios with increasing downward shift in root distributions). We also analyzed impacts of greater root production on the soil-crop nitrogen balance, from the standpoint of increased need for additional N inputs and consequences for increased N 2 O flux, as well as potential impacts if more and deeper roots contributed to reduced N leaching. In the enhanced root phenotype scenarios, the implicit assumption was that increases in overall plant production could be achieved (e.g., through increased CO 2 assimilation, greater growth efficiency) without reducing the harvested yield – that is, we did not include potential leakage and land substitution effects from potential decreased crop yield in the analysis.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2018

Analysis of Performance Instabilities of Hafnia-Based Ferroelectrics Using Modulus Spectroscopy and Thermally Stimulated Depolarization Currents

The discovery of the ferroelectric orthorhombic phase in doped hafnia films has sparked immense research efforts. Presently, a major obstacle for hafnia's use in high-endurance memory applications like nonvolatile random-access memories is its unstable ferroelectric response during field cycling. Different mechanisms are proposed to explain this instability including field-induced phase change, electron trapping, and oxygen vacancy diffusion. However, none of these is able to fully explain the complete behavior and interdependencies of these phenomena. Up to now, no complete root cause for fatigue, wake-up, and imprint effects is presented. In this study, the first evidence for the presence of singly and doubly positively charged oxygen vacancies in hafnia–zirconia films using thermally stimulated currents and impedance spectroscopy is presented. Moreover, it is shown that interaction of these defects with electrons at the interfaces to the electrodes may cause the observed instability of the ferroelectric performance.

36 MATERIALS SCIENCE↗

DOE OSTI2018

Modeling of Powder Bed Manufacturing Defects

Powder bed additive manufacturing offers unmatched capabilities. The deposition resolution achieved is extremely high enabling the production of innovative functional products and materials. Achieving the desired final quality is, however, hampered by many potential defects that have to be managed in due course of the manufacturing process. Defects observed in products manufactured via powder bed fusion have been studied experimentally. In this effort we have relied on experiments reported in the literature and—when experimental data were not sufficient—we have performed additional experiments providing an extended foundation for defect analysis. There is large interest in reducing the effort and cost of additive manufacturing process qualification and certification using integrated computational material engineering. A prerequisite is, however, that numerical methods can indeed capture defects. A multiscale multiphysics platform is developed and applied to predict and explain the origin of several defects that have been observed experimentally during laser-based powder bed fusion processes. The models utilized are briefly introduced. The ability of the models to capture the observed defects is verified. The root cause of the defects is explained by analyzing the numerical results thus confirming the ability of numerical methods to provide a foundation for rapid process qualification.

36 MATERIALS SCIENCE↗

NASA NTRS2000

Software Fault Tolerance: A Tutorial

Because of our present inability to produce error-free software, software fault tolerance is and will continue to be an important consideration in software systems. The root cause of software design errors is the complexity of the systems. Compounding the problems in building correct software is the difficulty in assessing the correctness of software for highly complex systems. After a brief overview of the software development processes, we note how hard-to-detect design faults are likely to be introduced during development and how software faults tend to be state-dependent and activated by particular input sequences. Although component reliability is an important quality measure for system level analysis, software reliability is hard to characterize and the use of post-verification reliability estimates remains a controversial issue. For some applications software safety is more important than reliability, and fault tolerance techniques used in those applications are aimed at preventing catastrophes. Single version software fault tolerance techniques discussed include system structuring and closure, atomic actions, inline fault detection, exception handling, and others. Multiversion techniques are based on the assumption that software built differently should fail differently and thus, if one of the redundant versions fails, it is expected that at least one of the other versions will provide an acceptable output. Recovery blocks, N-version programming, and other multiversion techniques are reviewed.

Torres-Pomales, Wilfredo↗

NASA NTRS2022

Remote Diagnosis and Operational Response to an In-Flight Failure of the Drill Feed Mechanism Onboard the Mars Science Laboratory Rover

On November 30th, 2016 (Sol 1536 of the mission), the Mars Science Laboratory (MSL) flight operations team commanded the Curiosity rover to drill into a Martian rock to acquire the mission’s 16th rock powder sample. The drilling operation was halted when the drill feed mechanism unexpectedly stalled shortly after disengaging its magnetically-actuated friction brake at the start of a long move to extend the drill bit into contact with the target rock. The drilling campaign was put on hold and later abandoned as diagnostic experimentation revealed a tendency for the actuator to transition in and out of a high-drag state in which the mechanism could not actuate. In the subsequent months, the team conducted a variety of in-flight and ground-based investigations to determine root cause and identify mitigation strategies for continued operation. Mechanism reliability continued to degrade and by June 2017, it became clear that the mechanism could not be relied upon to support drilling operations. The team succeeded in fully extending the feed, enabling the development of new sampling techniques that would not rely on the feed mechanism. The first feed-extended drilling sample was successfully collected on Sol 2057, 521 sols after the initial feed stall. This paper discusses the anomaly investigation process, failure analysis, and feed mechanism operation mitigation strategies. It concludes with key lessons learned about mechanism design, mission architecture, and operational best practices.

Lin, Megan Richardson↗

DOE OSTI2024

Process–Property–Performance Mapping of Additively Manufactured 316H Stainless Steel Components

The Advanced Materials and Manufacturing Technologies Program is focused on accelerating the development of advanced materials and components fabricated via additive manufacturing, and is using laser powder bed fusion (LPBF) of 316H stainless steel as an initial case study. In the previous fiscal year, miniature high-throughput specimens were printed on multiple LPBF systems to provide initial processing windows to minimize porosity and limit epitaxial grain growth during prints. This fiscal year, scaled builds were completed on three different LPBF systems at ORNL: a GE Concept Laser M2, a Renishaw AM400, and an EOS M290. Builds on the Concept Laser were conducted on multiple powder lots and processing parameter ranges to provide microstructure effects on time-independent and time-dependent mechanical properties. Builds on the Renishaw were produced using Oak Ridge National Laboratory (ORNL)-optimized printing parameters and Argonne National Laboratory (ANL)-optimized printing parameters to compare outcomes of parallel process optimization efforts at different national laboratories on the same LPBF system. Similarly, the build completed on the EOS M290 replicated the processing parameters of builds completed at Los Alamos National Laboratory (LANL). Optical microscopy and electron backscatter diffraction characterization was completed on all builds. In addition to the general round robin characterization, this work-package generated time-independent data, including tensile and fracture toughness test data on scaled Concept Laser builds as a function of processing parameters and post-build heat treatment. This analysis is complimentary to work in parallel work packages aiming to establish heat treatment and processing effects on time-dependent properties. It was found that although the stress-relief heat treatment provides the highest strength at lower-temperatures, tensile strength begins to converge at higher temperatures regardless of heat treatment condition. In addition, the more rigorous solution annealing and hot-isostatic pressing post-build heat treatments result in higher fracture toughness than the stress-relieved condition. The root-causes of the lower fracture toughness of the stress-relieved LPBF 316H material was informed via a stress-relief optimization study on a scaled concept laser print, where it was found that although dislocation recovery was largely complete after only a couple hours at 650°C, the extended hold of the current 24h heat treatment employed on scaled builds likely caused increased carbide volume fractions along the LPBF 316H grain boundaries, thereby deteriorating crack propagation resistance. This trend was seen to become more deleterious with additional increases of stress-relief temperature to 750°C or 850°C. These results have helped inform a new optimal stress-relief annealing condition for LPBF 316H for future campaign testing (650°C for 2h).

36 MATERIALS SCIENCE↗

DOE OSTI2024

Process–Property–Performance Mapping of Additively Manufactured 316H Stainless Steel Components

The Advanced Materials and Manufacturing Technologies Program is focused on accelerating the development of advanced materials and components fabricated via additive manufacturing, and is using laser powder bed fusion (LPBF) of 316H stainless steel as an initial case study. In the previous fiscal year, miniature high-throughput specimens were printed on multiple LPBF systems to provide initial processing windows to minimize porosity and limit epitaxial grain growth during prints. This fiscal year, scaled builds were completed on three different LPBF systems at ORNL: a GE Concept Laser M2, a Renishaw AM400, and an EOS M290. Builds on the Concept Laser were conducted on multiple powder lots and processing parameter ranges to provide microstructure effects on time-independent and time-dependent mechanical properties. Builds on the Renishaw were produced using Oak Ridge National Laboratory (ORNL)-optimized printing parameters and Argonne National Laboratory (ANL)-optimized printing parameters to compare outcomes of parallel process optimization efforts at different national laboratories on the same LPBF system. Similarly, the build completed on the EOS M290 replicated the processing parameters of builds completed at Los Alamos National Laboratory (LANL). Optical microscopy and electron backscatter diffraction characterization was completed on all builds. In addition to the general round robin characterization, this work-package generated time-independent data, including tensile and fracture toughness test data on scaled Concept Laser builds as a function of processing parameters and post-build heat treatment. This analysis is complimentary to work in parallel work packages aiming to establish heat treatment and processing effects on time-dependent properties. It was found that although the stress-relief heat treatment provides the highest strength at lower-temperatures, tensile strength begins to converge at higher temperatures regardless of heat treatment condition. In addition, the more rigorous solution annealing and hot-isostatic pressing post-build heat treatments result in higher fracture toughness than the stress-relieved condition. The root-causes of the lower fracture toughness of the stress-relieved LPBF 316H material was informed via a stress-relief optimization study on a scaled concept laser print, where it was found that although dislocation recovery was largely complete after only a couple hours at 650°C, the extended hold of the current 24h heat treatment employed on scaled builds likely caused increased carbide volume fractions along the LPBF 316H grain boundaries, thereby deteriorating crack propagation resistance. This trend was seen to become more deleterious with additional increases of stress-relief temperature to 750°C or 850°C. These results have helped inform a new optimal stress-relief annealing condition for LPBF 316H for future campaign testing (650°C for 2h).

36 MATERIALS SCIENCE↗

NASA NTRS1995

Multiparameter linear least-squares fitting to Poisson data one count at a time

A standard problem in gamma-ray astronomy data analysis is the decomposition of a set of observed counts, described by Poisson statistics, according to a given multicomponent linear model, with underlying physical count rates or fluxes which are to be estimated from the data. Despite its conceptual simplicity, the linear least-squares (LLSQ) method for solving this problem has generally been limited to situations in which the number n(sub i) of counts in each bin i is not too small, conventionally more than 5-30. It seems to be widely believed that the failure of the LLSQ method for small counts is due to the failure of the Poisson distribution to be even approximately normal for small numbers. The cause is more accurately the strong anticorrelation between the data and the wieghts w(sub i) in the weighted LLSQ method when square root of n(sub i) instead of square root of bar-n(sub i) is used to approximate the uncertainties, sigma(sub i), in the data, where bar-n(sub i) = E(n(sub i)), the expected value of N(sub i). We show in an appendix that, avoiding this approximation, the correct equations for the Poisson LLSQ (PLLSQ) problems are actually identical to those for the maximum likelihood estimate using the exact Poisson distribution. We apply the method to solve a problem in high-resolution gamma-ray spectroscopy for the JPL High-Resolution Gamma-Ray Spectrometer flown on HEAO 3. Systematic error in subtracting the strong, highly variable background encountered in the low-energy gamma-ray region can be significantly reduced by closely pairing source and background data in short segments. Significant results can be built up by weighted averaging of the net fluxes obtained from the subtraction of many individual source/background pairs. Extension of the approach to complex situations, with multiple cosmic sources and realistic background parameterizations, requires a means of efficiently fitting to data from single scans in the narrow (approximately = 1.2 keV, HEAO 3) energy channels of a Ge spectrometer, where the expected number of counts obtained per scan may be very low. Such an analysis system is discussed and compared to the method previously used.

Wheaton, Wm. A.↗

NASA NTRS2018

Analysis of Performance Degradation of Silica Gels After Extended Use Onboard the ISS

The teardown of two flight desiccant beds from the Carbon Dioxide Removal Assembly (CDRA) revealed significant discoloration of the silica gel near the bed inlet as well as a coincidental performance loss. This material was analyzed for the presence of chemical contaminants, physical porosity changes, and adsorption performance. The material characteristics are compared against the location in the bed from which they were sampled in order to develop profiles through the bed. Additional testing of the beds prior to teardown provided more data points. Possible mechanisms for the loss of capacity are provided though no root cause has been found. Extrapolation of the performance loss is used to estimate the required oversizing of the silica gel layer for long-term operation.

Cmarik, Gregory E.↗

NASA NTRS2018

Analysis of Performance Degradation of Silica Gels After Extended Use Onboard the ISS

The disassembly of two flight desiccant beds from the Carbon Dioxide Removal Assembly (CDRA) revealed significant discoloration of the silica gel near the bed inlet as well as a coincidental performance loss. This material was analyzed for the presence of chemical contaminants, physical porosity changes, and adsorption performance. The material characteristics are compared against the location in the bed from which they were sampled in order to develop profiles through the bed. Additional testing of the beds prior to disassembly provided more data points. Possible mechanisms for the loss of capacity are provided though no root cause has been confirmed. Extrapolation of the performance loss is used to estimate the required oversizing of the silica gel layer for long-term operation.

Cmarik, Gregory E.↗

NASA NTRS2016

Failure Analysis and Recovery of a 50-mm Highly Elastic Intermetallic NiTi Ball Bearing for an ISS Application

Ball bearings used inside the ISS Distillation Assembly centrifuge require superior corrosion and shock resistance to withstand acidic wastewater exposure and heavy spacecraft launch related loads. These requirements challenge conventional steel bearings and provide an ideal pathfinder application for 50-mm bore, deep-groove ball bearings made from the corrosion immune and highly elastic intermetallic material 60NiTi. During early ground testing in 2014 one 60NiTi bearing unexpectedly and catastrophically failed after operating for only 200 hr. A second bearing running on the same shaft was completely unaffected. An investigation into the root cause of the failure determined that an excessively tight press fit of the bearing outer race coupled with NiTi's relatively low elastic modulus were key contributing factors. The proposed failure mode was successfully replicated by experiment. To further corroborate the root cause theory, a successful bearing life test using improved installation practices (selective fitting) was conducted. The results show that NiTi bearings are suitable for space applications provided that care is taken to accommodate their unique material characteristics.

DellaCorte, Christopher↗

DOE OSTI2017

Beyond the classical kinetic model for chronic graphite oxidation by moisture in high temperature gas-cooled reactors

Four grades of nuclear graphite with various microstructures were subjected to accelerated oxidation tests in helium with traces of moisture and hydrogen in order to evaluate the effects of chronic oxidation on graphite components in high temperature gas cooled reactors. Kinetic analysis showed that the Langmuir-Hinshelwood (LH) model cannot consistently reproduce all results. In particular, at high temperatures and water partial pressures oxidation was always faster than the LH model predicts, with stronger deviations for superfine grain graphite than for medium grain grades. It was also found empirically that the apparent reaction order for water has a sigmoid-type variation with temperature which follows the integral Boltzmann distribution function. This suggests that the apparent activation with temperature of graphite reactive sites that causes deviations from the LH model is rooted in specific structural and electronic properties of surface sites on graphite. A semi-global kinetic model was proposed, whereby the classical LH model was modified with a temperature-dependent reaction order for water. The new Boltzmann-enhanced model (BLH) was shown to consistently predict experimental oxidation rates over large ranges of temperature (800-1100 oC) and partial pressures of water (3-1200 Pa) and hydrogen (0-300 Pa), not only for the four grades of graphite but also for the historic grade H-451. The BLH model offers as more reliable input for modeling the chemical environment effects during the life-time operation of new grades of graphite in advanced nuclear reactors operating at high and very high temperatures.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗