Results for “failure” — Page 23

NASA NTRS1994

Increased walking variability in elderly persons with congestive heart failure

OBJECTIVES: To determine the effects of congestive heart failure on a person's ability to walk at a steady pace while ambulating at a self-determined rate. SETTING: Beth Israel Hospital, Boston, a primary and tertiary teaching hospital, and a social activity center for elderly adults living in the community. PARTICIPANTS: Eleven elderly subjects (aged 70-93 years) with well compensated congestive heart failure (NY Heart Association class I or II), seven elderly subjects (aged 70-79 years) without congestive heart failure, and 10 healthy young adult subjects (aged 20-30 years). MEASUREMENTS: Subjects walked for 8 minutes on level ground at their own selected walking rate. Footswitches were used to measure the time between steps. Step rate (steps/minute) and step rate variability were calculated for the entire walking period, for 30 seconds during the first minute of the walk, for 30 seconds during the last minute of the walk, and for the 30-second period when each subject's step rate variability was minimal. Group means and 5% and 95% confidence intervals were computed. MAIN RESULTS: All measures of walking variability were significantly increased in the elderly subjects with congestive heart failure, intermediate in the elderly controls, and lowest in the young subjects. There was no overlap between the three groups using the minimal 30-second variability (elderly CHF vs elderly controls: P < 0.001, elderly controls vs young: P < 0.001), and no overlap between elderly subjects with and without congestive heart failure when using the overall variability. For all four measures, there was no overlap in any of the confidence intervals, and all group means were significantly different (P < 0.05).

NASA Discipline Cardiopulmonary↗

NASA NTRS2015

Space Shuttle Stiffener Ring Foam Failure Analysis, a Non-Conventional Approach

The Space Shuttle Program made use of the excellent properties of rigid polyurethane foam for cryogenic tank insulation and as structural protection on the solid rocket boosters. When foam applications de-bond, classical methods of failure analysis did not provide root cause of the failure of the foam. Realizing that foam is the ideal media to document and preserve its own mode of failure, thin sectioning was seen as a logical approach for foam failure analysis to observe the three dimensional morphology of the foam cells. The cell foam morphology provided a much greater understanding of the failure modes than previously achieved.

cryogenic tank insulation↗

NASA NTRS2018

Space Shuttle Stiffener Ring Foam Failure Analysis, a Non-Conventional Approach.

The Space Shuttle Program made use of the excellent properties of rigid polyurethane foam for cryogenic tank insulation and as structural protection on the solid rocket boosters. When foam applications de-bond, classical methods of failure analysis did not provide root cause of the failure of the foam. Realizing that foam is the ideal media to document and preserve its own mode of failure, thin sectioning was seen as a logical approach for foam failure analysis to observe the three dimensional morphology of the foam cells. The cell foam morphology provided a much greater understanding of the failure modes than previously achieved.

Foam↗

NASA NTRSDate not supplied

Tribology Induced Water Pump Bearing Failure

NASA’s In-Space Propulsion facility experienced two infant mortality water pump bearing failures during a recent refurbishment campaign, the cause or causes of which were unclear. A forensic failure study was undertaken that included site visits, collection and examination of physical evidence and a bearing and pump design review. The pumps are large (2000 hp) vertical turbine design machines that utilize metallic sleeve bearings cooled and lubricated by the pumped fluid (water). Though initial possible root cause for the failures were attributed to improper fabrication and debris contamination, detailed examination of failure surfaces combined with bearing design revealed that the failure mode was thermal seizure brought on by inadequate cooling flow. An unusual contributing factor was that the use of grease as an assembly lubricant, as opposed to a fluid like oil, appears to have exacerbated the rather than alleviated the thermal runaway by blocking water flow. Resolution of the problem was achieved through the design and installation of dedicated bearing lubrication water feed system.

bearings↗

NASA NTRSDate not supplied

Having a Come-Apart: Lessons Learned from Additively Manufactured Hardware Failures

NASA has been engaged with additively manufactured (AM) process and component development since the 2000’s. AM offers various technical advantages, such as enhanced hardware design complexity, part consolidation, and processing of novel alloys in addition to programmatic advantages for reduction in processing time and cost. The focus of much of the AM development at NASA has been to mature the various processes, characterize material properties, develop standards, produce demonstrator parts, and integrate AM hardware in liquid rocket engines. These aspects have been demonstrated through process and design iterations using a methodical characterization, test-fail-fix cycles, as well as application and dissemination of lessons learned. In addition to these fundamental demonstrations of the AM process and hardware development, alloys that provide performance advantages in the high temperature and high-pressure environments have been matured for use in rocket engines. These environments are challenging for any alloy and any design, and the AM process is required to fully meet the intended design requirements. The importance of proper AM process was made evident in the failure of a Laser Powder Bed Fusion (L-PBF) copper-alloy combustion chamber during a hot-fire test due to a degraded material quality resulted from an AM process issue. The hot-fire test aimed to demonstrate high duty cycle under a risk-tolerant development project, where consequences of component failure would be minimal. However, the unintentional component failure emphasized the necessity of robust material characterization and rigorous process control procedures for the safe use of AM components in critical applications. In part, such concerns motivate the AM certification approach that NASA has recently adopted in NASA-STD-6030 “Additive Manufacturing Requirements for Spaceflight Systems”. This presentation provides an overview of the previously mentioned failure, a discussion on the evaluation of the failed chamber and supplemental chambers produced at the same time, a representative material samples that included intentional build witness lines, and a summary of the key results and recommendations from the evaluations. NASA continues to approach AM processes and designs with a level of risk and acceptance of failures that is appropriate for the project objectives, with the overall goal of safe implementation of AM technology and transferring AM technology into commercial space applications. The objective of this presentation is to provide awareness to the community working critical and non-critical AM components and the lessons learned on proper implementation of AM.

Additive Manufacturing↗

NASA NTRSDate not supplied

Metal Additive Manufacturing for Rocket Engines: Successes and Failures

NASA has been developing additive manufacturing (AM) for various technical and programmatic advantages for complex rocket engine and aerospace components. This maturation has focused on various AM processes, new alloys, characterizing material properties, developing standards, producing demonstrator parts, and integrating AM hardware in liquid rocket engines through test-fail-fix cycles, as well as application and dissemination of lessons learned of the AM lifecycle. The importance of proper AM processing was made evident in the failure of a Laser Powder Bed Fusion (L-PBF) copper-alloy combustion chamber during a hot-fire test due to a degraded material quality. The hot-fire test aimed to demonstrate high duty cycle under a risk-tolerant development project, where consequences of component failure would be minimal. However, the unintentional component failure emphasized the necessity of robust material characterization and rigorous process control procedures for the safe use of AM components in critical applications. This presentation provides an overview of the development failure, a discussion on the evaluation of the failed chamber and supplemental chambers produced at the same time, a representative material samples that included intentional build witness lines, and a summary of the key results and recommendations from the evaluations. NASA continues to approach AM processes and designs with a level of risk and acceptance of failures that is appropriate for the project objectives, with the overall goal of safe implementation of AM technology and transferring AM technology into commercial space applications. This presentation with provide critical awareness to the community lessons learned on proper implementation of AM.

L-PBF↗

NASA NTRSDate not supplied

From BERTopic to SysML: Informing Model-Based Failure Analysis With Natural Language Processing for Complex Aerospace Systems

The development of emerging complex aerospace systems will require new approaches for capturing safety incident scenarios as early as possible in the design phase. However, for novel systems, relevant data available is limited. In this work, we propose a framework informing model-based mission assurance activities with historical incident reports, lessons learned, or other relevant engineering documents using natural language processing. In doing so, we investigate whether there is useful information in data sets that are relevant, if not identical, to the system under design and whether, through rigorous systems engineering practice, this information can be effectively leveraged through model-based failure analysis. In a worked case study, we apply state-of-the-art topic modeling techniques to two data sets, a mission relevant data set and a system relevant data set. The sets of topics are merged and interpreted to form a preliminary list of failure topics that can be used to inform the identification of off-nominal modes in the model-based failure modes and effects analysis development. Once data from the system in operation is available, it can be used to update the topics identified. By extracting information about likely failures from relevant historical data sets and utilizing model-based mission assurance to ensure relevance and rigor, unanticipated failures can be reduced, and projects can more effectively learn from past missions.

Failure Analysis↗

NASA NTRSDate not supplied

From BERTopic to SysML: Informing Model-Based Failure Analysis With Natural Language Processing for Complex Aerospace Systems

The development of emerging complex aerospace systems will require new approaches for capturing safety incident scenarios as early as possible in the design phase. However, for novel systems, relevant data available is limited. In this work, we propose a framework informing model-based mission assurance activities with historical incident reports, lessons learned, or other relevant engineering documents using natural language processing. In doing so, we investigate whether there is useful information in data sets that are relevant, if not identical, to the system under design and whether, through rigorous systems engineering practice, this information can be effectively leveraged through model-based failure analysis. In a worked case study, we apply state-of-the-art topic modeling techniques to two data sets, a mission relevant data set and a system relevant data set. The sets of topics are merged and interpreted to form a preliminary list of failure topics that can be used to inform the identification of off-nominal modes in the model-based failure modes and effects analysis development. Once data from the system in operation is available, it can be used to update the topics identified. By extracting information about likely failures from relevant historical data sets and utilizing model-based mission assurance to ensure relevance and rigor, unanticipated failures can be reduced, and projects can more effectively learn from past missions.

Failure Analysis↗

DOE OSTI2015

Analyzing the Interplay of Failures and Workload on a Leadership-Class Supercomputer

The unprecedented computational power of cur- rent supercomputers now makes possible the exploration of complex problems in many scientific fields, from genomic analysis to computational fluid dynamics. Modern machines are powerful because they are massive: they assemble millions of cores and a huge quantity of disks, cards, routers, and other components. But it is precisely the size of these machines that glooms the future of supercomputing. A system that comprises many components has a high chance to fail, and fail often. In order to make the next generation of supercomputers usable, it is imperative to use some type of fault tolerance platform to run applications on large machines. Most fault tolerance strategies can be optimized for the peculiarities of each system and boost efficacy by keeping the system productive. In this paper, we aim to understand how failure characterization can improve resilience in several layers of the software stack: applications, runtime systems, and job schedulers. We examine the Titan supercomputer, one of the fastest systems in the world. We analyze a full year of Titan in production and distill the failure patterns of the machine. By looking into Titan s log files and using the criteria of experts, we provide a detailed description of the types of failures. In addition, we inspect the job submission files and describe how the system is used. Using those two sources, we cross correlate failures in the machine to executing jobs and provide a picture of how failures affect the user experience. We believe such characterization is fundamental in developing appropriate fault tolerance solutions for Cray systems similar to Titan.

Cray↗

DOE OSTI2017

Estimating a Service-Life Distribution Based on Production Counts and a Failure Database

A manufacturer wanted to compare the service-life distributions of two similar products. These concern product lifetimes after installation (not manufacture). For each product, there were available production counts and an imperfect database providing information on failing units. In the real case, these units were expensive repairable units warrantied against repairs. Failure (of interest here) was relatively rare and driven by a different mode/mechanism than ordinary repair events (not of interest here). Approach: Data models for the service life based on a standard parametric lifetime distribution and a related limited failure population were developed. These models were used to develop expressions for the likelihood of the available data that properly accounts for information missing in the failure database. Results: A Bayesian approach was employed to obtain estimates of model parameters (with associated uncertainty) in order to investigate characteristics of the service-life distribution. Custom software was developed and is included as Supplemental Material to this case study. One part of a responsible approach to the original case was a simulation experiment used to validate the correctness of the software and the behavior of the statistical methodology before using its results in the application, and an example of such an experiment is included here. Because of confidentiality issues that prevent use of the original data, simulated data with characteristics like the manufacturer’s proprietary data are used to illustrate some aspects of our real analyses. Lastly, we also note that, although this case focuses on rare and complete product failure, the statistical methodology provided is directly applicable to more standard warranty data problems involving typically much larger warranty databases where entries are warranty claims (often for repairs) rather than reports of complete failures.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2016

Siting Radioactive Waste Management Facilities: Successes and Failures - 16392

Our assessment in 2015 of 39 attempts to site nuclear waste facilities in democratic countries over the past 40 years identified common inherent threads of both success and failure. In the successes, including those efforts still ongoing, the common threads include a) providing the host communities the opportunity to withdraw at any point, b) the physical presence of a significant project team in the host community, and c) the establishment of credibility and trust in the project team, the regulator and, where possible, a neutral commenting party. In the failures, two dominant causes are present. The first is the failure to properly address the legitimate concerns of indigenous people. This has caused failures in the US and Australia. The second and more common cause is lack of political consensus amongst the host community. In nearly every case when the facility proponent selects the site and attempts to gain host approval, the effort has failed. Within the failed cases, two topics appear to be common. The first is that the definition of 'host community' is initially too narrow by the proponents. In many situations, the very local community is supportive of radioactive waste projects but the larger community is not. The second factor is a failure on the part of the proponent to accurately communicate the risks associated with the project, driven significantly by differences in the manner in which the general public and experts process risk communications. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2024

Root Cause Correlation Analysis of Software Failures via Orthogonal Defect Classification and Natural Language Processing

Systems theoretic process analysis (STPA) is becoming an increasingly popular technique to assess how complex digital software systems can fail. Rather than defining failures by their observable failure events, which may be sparse especially for safety rated nuclear digital instrumentation and control systems (DI&C), failures are defined as postulated unsafe actions under specific contextual conditions. This permits a top-down analysis of system hazards and identifies whether imposed constraints and requirements can sufficiently address undesirable hazards. However, STPA is a qualitative approach at identifying inadequacies in the development process and cannot currently be used to quantify unsafe action likelihoods for probabilistic risk assessment. Therefore, in this work, we examine the root causes of software failure and explore whether a consistent correlation can be linked to specific unsafe action classes. We implement Lbl2Vec, an unsupervised document classification and retrieval algorithm, on a database of 4,096 software defect reports acquired from various open-source software systems. By analyzing sentence structure, embedded labels, and word vectors, we show that certain defect types positively correlate to specific unsafe action classes over others. The correlations developed can be used to estimate the failure probability of safety intended DI&C systems which provides a licensing basis for nuclear plant modernization efforts.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2024

Root Cause Correlation Analysis of Software Failures via Orthogonal Defect Classification and Natural Language Processing

Systems theoretic process analysis (STPA) is becoming an increasingly popular technique to assess how complex digital software systems can fail. Rather than defining failures by their observable failure events, which may be sparse especially for safety rated nuclear digital instrumentation and control systems (DI&C), failures are defined as postulated unsafe actions under specific contextual conditions. This permits a top-down analysis of system hazards and identifies whether imposed constraints and requirements can sufficiently address undesirable hazards. However, STPA is a qualitative approach at identifying inadequacies in the development process and cannot currently be used to quantify unsafe action likelihoods for probabilistic risk assessment. Therefore, in this work, we examine the root causes of software failure and explore whether a consistent correlation can be linked to specific unsafe action classes. We implement Lbl2Vec, an unsupervised document classification and retrieval algorithm, on a database of 4,096 software defect reports acquired from various open-source software systems. By analyzing sentence structure, embedded labels, and word vectors, we show that certain defect types positively correlate to specific unsafe action classes over others. The correlations developed can be used to estimate the failure probability of safety intended DI&C systems which provides a licensing basis for nuclear plant modernization efforts.

22 - GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2019

Node failure resiliency for Uintah without checkpointing

The frequency of failures in upcoming exascale supercomputers may well be greater than at present due to many-core architectures if component failure rates remain unchanged. This potential increase in failure frequency coupled with I/O challenges at exascale may prove problematic for current resiliency approaches such as checkpoint restarting, although the use of fast intermediate memory may help. Algorithm-Based Fault Tolerance (ABFT) using Adaptive Mesh Refinement (AMR) is one resiliency approach used to address these challenges. For adaptive mesh codes, a coarse mesh version of the solu- tion may be used to restore the fine mesh solution. This paper addresses the implementation of the ABFT approach within the Uintah software framework: both at a software level within Uintah and in the data reconstruction method used for the recovery of lost data. This method has two problems: inaccuracies introduced during the reconstruction propagate forward in time, and the physical consistency of variables such as positivity or boundedness may be violated during interpolation. These challenges can be addressed by the combination of two techniques: 1. a fault-tolerant MPI implementation to recover from runtime node failures, and 2. high-order interpolation schemes to preserve the physical solution and reconstruct lost data. Here, the approach considered here uses a "Limited Essentially Non-Oscillatory" (LENO) scheme along with AMR to rebuild the lost data without checkpointing using Uintah. Experiments were carried out using a fault-tolerant MPI - ULFM to recover from runtime failure, and LENO to recover data on patches belonging to failed ranks, while the simulation was continued to the end. Results show that this ABFT approach is up to 10x faster than the traditional checkpointing method. The new interpolation approach is more accurate than linear interpolation and not subject to the overshoots found in other interpolation methods.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2018

On the Applicability of Nadai and Mogi Failure Criteria to Porous Sandstones

Following the ISRM Suggested Method on Failure Criteria, ‘A failure criterion for rocks based on true triaxial testing’ by Chang and Haimson (2012), we attempted to obtain experiment-based Nadai (1950) and Mogi (1971) failure criteria for the aforementioned four sandstones: TCDP (Oku et al. 2007), Coconino, Bentheim (Ma and Haimson 2016; Ma et al. 2017a), and Castlegate (Ingraham et al. 2013). Here, the current work extends beyond the scope of Chang and Haimson (2012), to compare σ1 at failure (i.e., σ 1,peak ) from test data with predictions based on the experimentally generated Nadai and Mogi criteria. The applicability of Nadai and Mogi criteria to porous sandstones is then evaluated and discussed, considering failure mode evolution in these rocks.

58 GEOSCIENCES↗

DOE OSTI2019

Evolution of damage and failure in an additively manufactured 316L SS structure: experimental reinvestigation of the third Sandia fracture challenge

The third Sandia Fracture Challenge (SFC3) was a benchmark problem for comparing experimental and simulated ductile deformation and failure in an additively manufactured (AM) 316L stainless steel structure. One surprising observation from the SFC3 was the Challenge-geometry specimens had low variability in global load versus displacement behavior, attributed to the large stress-concentrating geometric features dominating the global behavior, rather than the AM voids that tend to significantly influence geometries with uniform cross-sections. This current study reinvestigates the damage and failure evolution of the Challenge-geometry specimens, utilizing interrupted tensile testing with micro-computed tomography (micro-CT) scans to monitor AM void and crack growth from a virgin state through complete failure. This study did not find a correlation between global load versus displacement behavior and AM void attributes, such as void volume, location, quantity, and relative size, which incidentally corroborates the observation from the SFC3. However, this study does show that the voids affect the local behavior of damage and failure. Surface defects (i.e. large voids located on the surface, far exceeding the nominal surface roughness) that were near the primary stress concentration affected the location of crack initiation in some cases, but they did not noticeably affect the global response. The fracture surfaces were a combination of classic ductile dimples and crack deviation from a more direct path favoring intersection with AM voids. Even though the AM voids promoted crack deviation, pre-test micro-CT scan statistics of the voids did not allow for conclusive predictions of preferred crack paths. This study is a first step towards investigating the importance of voids on the ductile failure of AM structures with stress concentrations.

36 MATERIALS SCIENCE↗

DOE OSTI2019

Characterization of Static Performance and Failure of Resistance Spot Welds of High-Strength and Press-Hardened Steels

The static performances and failure characteristics of resistance spot welds (RSW) of steel sheets were studied in this work. Both similar and dissimilar joints of press-hardened steel grade 22MnB5 and as-rolled high-strength steel grade 1000 were examined. From metallographic analyses and micro-hardness measurements, it was shown that the microstructures of base metal (BM), heat affected zone (HAZ) and fusion zone of steel joints were noticeably different. In particular, the HAZ close to BM or subcritical HAZ (SCHAZ) of 22MnB5 steel exhibited greatly decreased hardness due to occurring tempered martensite, in which carbide precipitation was clearly observed. Furthermore, tensile shear test and cross-tension test of the welded steel sheets were carried out. The determined maximum loads, energy absorbability and corresponding failure mechanisms were analyzed and compared. The RSW samples of similar steel grade 1000 provided the highest load-carrying capacity and absorbed energy in both tests. Due to the large hardness difference and soft zone in weldment of dissimilar steel specimen, failure loads and static absorbed energies were deteriorated up to 17 and 68%, respectively. The observed fracture occurrences of all investigated joints were pullout failure mode, in which BM and HAZ were the crack initiation sites of grades 1000 steel and 22MnB5 steel, respectively. The SCHAZ of welded boron steel considerably caused the failure onset in tension shear test, but seemed to have negligible effect on cross-tension test.

36 MATERIALS SCIENCE↗

DOE OSTI2019

The role of elastic and plastic anisotropy in intergranular spall failure

Recent mesoscale experimental observations of dynamic ductile failure have demonstrated a strong relationship between grain boundary (GB) misorientation and the likelihood of failure initiation along said GB. This correlation has been attributed to inherent GB weakness of particular misorientation. Here we discuss the role played by mechanics, i.e. elastic and plastic anisotropy, on the experimental observation. We make use of a recently developed framework for modeling dislocation-based crystal plasticity and ductile failure of single crystals under dynamic loading (CPD-FE). Polycrystals are studied at the mesoscale level through the explicit resolution of individual grains, i.e. resolving each individual grain's size, shape, and orientation. In our simulations, failure naturally localizes along the GBs with no necessity for ad hoc rules governing damage nucleation. We carry out a few thousand mesoscale calculations, systematically varying the misorientation angles of the GB in the computational microstructure. Despite the fact that we neglect the possibility of variations in inherent GB weakness, our simulations agree favorably with the experimental observations, implying that stress concentration generated by elastic and plastic anisotropies across GBs is a dominant governing factor in this phenomenon. Lastly, we find that misorientation angle is an insufficient GB descriptor to predict the likelihood of intergranular spall failure, which is better understood through the consideration of additional GB degrees of freedom.

36 MATERIALS SCIENCE↗