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All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Feedstock-Conversion Interface Consortium: Failure Mode and Effects Analysis Summary Report (FY2022)

This report provides an overview of the development of failure modes and effects analysis (FMEA) and its implementation as a systematic criticality and risk assessment tool supporting a quality by design (QbD) approach for FCIC research. This report also provides a high-level overview of the results for the FMEA evaluation of two feedstock preprocessing system configurations: (1) generation of pine residue materials for high-temperature pyrolysis conversion and (2) generation of corn stover materials for low-temperature conversion using deacetylation and disc mechanical refining pretreatment for fermentation to hydrocarbons. For the results presented in this report, our FMEA interviews included two approaches. The first approach was to perform FMEA interviews for the entire system of unit operations giving a wholistic system level view. The second approach consisted of detailed interviews for each individual unit operation within the system allowing for a “deep dive” into the specific failures for the individual components within the configuration. These two approaches provide different resolutions of information. The FMEA results of this report were focused on failures associated with meeting critical quality attributes (CQAs) identified for the target conversion processes for each processed feedstock type. The information gathered through the FMEA interviews include estimations of risk scores for meeting each given CQA specification, identification of the impacts for not meeting a CQA specification, capturing causes associated with material attributes and process parameters for each failure, identification of current detection methods, and speculation of potential mitigation strategies for decreasing a failure’s risk score. The complete results of all FMEA interviews are provided in the Appendices of this report.

09 BIOMASS FUELS↗
NASA NTRS2002

Analysis of Composite Skin-Stiffener Debond Specimens Using Volume Elements and a Shell/3D Modeling Technique

The debonding of a skin/stringer specimen subjected to tension was studied using three-dimensional volume element modeling and computational fracture mechanics. Mixed mode strain energy release rates were calculated from finite element results using the virtual crack closure technique. The simulations revealed an increase in total energy release rate in the immediate vicinity of the free edges of the specimen. Correlation of the computed mixed-mode strain energy release rates along the delamination front contour with a two-dimensional mixed-mode interlaminar fracture criterion suggested that in spite of peak total energy release rates at the free edge the delamination would not advance at the edges first. The qualitative prediction of the shape of the delamination front was confirmed by X-ray photographs of a specimen taken during testing. The good correlation between prediction based on analysis and experiment demonstrated the efficiency of a mixed-mode failure analysis for the investigation of skin/stiffener separation due to delamination in the adherents. The application of a shell/3D modeling technique for the simulation of skin/stringer debond in a specimen subjected to three-point bending is also demonstrated. The global structure was modeled with shell elements. A local three-dimensional model, extending to about three specimen thicknesses on either side of the delamination front was used to capture the details of the damaged section. Computed total strain energy release rates and mixed-mode ratios obtained from shell/3D simulations were in good agreement with results obtained from full solid models. The good correlations of the results demonstrated the effectiveness of the shell/3D modeling technique for the investigation of skin/stiffener separation due to delamination in the adherents.

Krueger, Ronald↗
DOE OSTI2025

Toward Drilling the Perfect Geothermal Well: An International Research Coordination Network for Geothermal Drilling Optimization Supported by Deep Machine Learning and Cloud Based Data Aggregation

The EDGE project, supported by the U.S. Department of Energy Geothermal Technologies Office under award DE-EE0008793, established a data-driven framework for improving the efficiency, cost-effectiveness, and reliability of geothermal well drilling. The project focused on developing scalable data infrastructure, advanced machine learning and probabilistic models, and integrated analytics tools to support continuous drilling optimization. A central objective was to reduce geothermal drilling costs by up to seventy percent while minimizing the risk of well failure through predictive diagnostics and adaptive planning. Over the project period, a comprehensive data repository was designed and deployed, incorporating records from over one hundred geothermal wells across varied geological settings. This repository supported both structured and unstructured data and adhered to FAIR data principles, enabling provenance tracking, quality control, and standardized metadata. The project introduced automated ingestion pipelines and a cloud-hosted platform that facilitated access to raw, processed, and derived datasets. This infrastructure served as the foundation for model development and analysis. Machine learning workflows were developed to predict key drilling metrics including rate of penetration, non-productive time, and total drilling costs. Self-organizing maps and dimensionality reduction methods were used to uncover operational patterns and outliers, while supervised learning algorithms such as random forests and deep neural networks were applied to forecast performance outcomes. The models were validated on heterogeneous datasets from both U.S. and Icelandic fields, demonstrating variable but significant predictive accuracy. The results indicated that finer temporal resolution, inclusion of lithological data, and consistency in operational annotations could substantially improve model performance. The project also implemented process mining techniques to reconstruct state-transition models from drilling event logs. These models enabled the identification of deviations from optimal workflows and provided insights into recurring failure modes. Analysis of non-productive time highlighted the impact of equipment failures, geological challenges, and human factors, offering opportunities for targeted mitigation strategies. The EDGE Dashboard was developed as a web-based expert system integrating data visualization, model outputs, and user-driven queries. It provided an accessible interface for operators to explore historical data, evaluate predicted outcomes, and compare drilling scenarios. Initial feedback from project partners suggested that the dashboard could serve as a foundation for more advanced advisory and optimization tools. Overall, the EDGE project demonstrated the feasibility and value of applying modern data science techniques to geothermal drilling. It delivered a set of interoperable tools and models that can support more efficient, lower-risk well development. The findings point toward a viable path for transitioning from advisory analytics to semi-autonomous drilling systems, contingent on continued collaboration, expanded datasets, and field validation. The project results have immediate relevance for drilling operations, data management practices, and future geothermal R&D efforts aimed at achieving reliable, cost-competitive geothermal energy at scale.

15 GEOTHERMAL ENERGY↗
NASA NTRS2002

Preliminary Thermal-Mechanical Sizing of Metallic TPS: Process Development and Sensitivity Studies

The purpose of this research was to perform sensitivity studies and develop a process to perform thermal and structural analysis and sizing of the latest Metallic Thermal Protection System (TPS) developed at NASA LaRC (Langley Research Center). Metallic TPS is a key technology for reducing the cost of reusable launch vehicles (RLV), offering the combination of increased durability and competitive weights when compared to other systems. Accurate sizing of metallic TPS requires combined thermal and structural analysis. Initial sensitivity studies were conducted using transient one-dimensional finite element thermal analysis to determine the influence of various TPS and analysis parameters on TPS weight. The thermal analysis model was then used in combination with static deflection and failure mode analysis of the sandwich panel outer surface of the TPS to obtain minimum weight TPS configurations at three vehicle stations on the windward centerline of a representative RLV. The coupled nature of the analysis requires an iterative analysis process, which will be described herein. Findings from the sensitivity analysis are reported, along with TPS designs at the three RLV vehicle stations considered.

Poteet, Carl C.↗
NASA NTRS2013

Failure Modes and Effects Analysis (FMEA) Assistant Tool Feasibility Study

An effort to determine the feasibility of a software tool to assist in Failure Modes and Effects Analysis (FMEA) has been completed. This new and unique approach to FMEA uses model based systems engineering concepts to recommend failure modes, causes, and effects to the user after they have made several selections from pick lists about a component s functions and inputs/outputs. Recommendations are made based on a library using common failure modes identified over the course of several major human spaceflight programs. However, the tool could be adapted for use in a wide range of applications from NASA to the energy industry.

Flores, Melissa↗
NASA NTRS1987

Fatigue damage accumulation in various metal matrix composites

The purpose of this paper is to review some of the latest understanding of the fatigue behavior of continuous fiber reinforced metal matrix composites. The emphasis is on the development of an understanding of different fatigue damage mechanisms and why and how they occur. The fatigue failure modes in continuous fiber reinforced metal matrix composites are controlled by the three constituents of the system: fiber, matrix, and fiber/matrix interface. The relative strains to fatigue failure of the fiber and matrix will determine the failure mode. Several examples of matrix, fiber, and self-similar damage growth dominated fatigue damage are given for several metal matrix composite systems. Composite analysis, failure modes, and damage modeling are discussed. Boron/aluminum, silicon-carbide/aluminum, FP/aluminum, and borsic/titanium metal matrix composites are discussed.

Johnson, W. S.↗
NASA NTRS2011

Human factors process failure modes and effects analysis (HF PFMEA) software tool

Methods, computer-readable media, and systems for automatically performing Human Factors Process Failure Modes and Effects Analysis for a process are provided. At least one task involved in a process is identified, where the task includes at least one human activity. The human activity is described using at least one verb. A human error potentially resulting from the human activity is automatically identified, the human error is related to the verb used in describing the task. A likelihood of occurrence, detection, and correction of the human error is identified. The severity of the effect of the human error is identified. The likelihood of occurrence, and the severity of the risk of potential harm is identified. The risk of potential harm is compared with a risk threshold to identify the appropriateness of corrective measures.

Chandler, Faith T.↗
NASA NTRS1975

Underground storage systems for high-pressure air and gases

This paper is a discussion of the safety and cost of underground high-pressure air and gas storage systems based on recent experience with a high-pressure air system installed at Moffett Field, California. The system described used threaded and coupled oil well casings installed vertically to a depth of 1200 ft. Maximum pressure was 3000 psi and capacity was 500,000 lb of air. A failure mode analysis is presented, and it is shown that underground storage offers advantages in avoiding catastrophic consequences from pressure vessel failure. Certain problems such as corrosion, fatigue, and electrolysis are discussed in terms of the economic life of such vessels. A cost analysis shows that where favorable drilling conditions exist, the cost of underground high-pressure storage is approximately one-quarter that of equivalent aboveground storage.

Beam, B. H.↗
NASA NTRSDate not supplied

Enhancing Fault Isolation for Health Monitoring of Electric Aircraft Propulsion by Embedding Failure Mode and Effect Analysis into Bayesian Networks

This paper describes a fault isolation approach for electric powertrains of unmanned aerial vehicles. The approach leverages the combination of failure mode and effect analysis (FMEA) and Bayesian networks, thus introducing depend-ability structures into a diagnostic framework. Faults and failure events from the FMEA are mapped within a Bayesian network, where network edges replicate the links embedded within FMEAs. This framework helps the fault isolation process by identifying the probability of occurrence of specific faults or root causes given evidence observed through sensor signals. The framework is applied to an electric power-train system of a small, rotary-wing unmanned aerial vehicle, demonstrating how a Bayesian network enhanced by FMEA helps disambiguate between root causes of incipient failures, which would otherwise be considered as equally probable.

Fault Isolation↗
NASA NTRS1989

Fatigue analysis of mini-mast space truss

The functional, structural adequacy of a 20 meter long generic space truss (Mini-Mast), subjected to fatigue loading, was examined with respect to the failure modes which are most likely to occur during services. The space truss is made of thin-walled tubes having unidirectional, zero degree layups of Celanese G50 graphite fibers/Narmco 5217 epoxy composites. The approach used to investigate the most probable failure mode of the truss under fatigue loading is to determine the stress level, including the types of stress, in the member first, then followed by failure mode analysis based on the stress level just determined. To begin, an approximate beam-parameter truss (BPT) model is analyzed first, followed by a detailed analysis of the truss using a finite element model (FEM) run with NASTRAN code. The response results of the BPT model are used to compare FEM results and to check any major deviation of trend derived from the FEM. The purpose of the work was to search available fatigue data of the tube material, to conduct approximate dynamical stress analysis of the BPT model, to run detailed dynamical stress analysis of the FEM model using NASTRAN code, and to predict the fatigue life of the truss member based on limited fatigue data.

Hwang, Shoi Y.↗
DOE OSTI2026

Nanometer Scale Imaging to Develop Quantitative Descriptors of Bipolar Membrane Junction Structure

Swings in pH can be achieved by electrically polarizing a bipolar membrane (BPM) to drive water dissociation at the BPM junction for electrochemical conversion and separation processes. BPM junction design is critical to tailor performance for specific applications; however, characterization techniques capable of resolving the nanometer scale physical structure of the junction are limited. We present sample preparation, imaging, and analysis workflows that are adaptable to a variety of BPM junction architectures. Atomic force microscopy produces BPM junction images with nanometer scale lateral resolution for samples with and without a graphene oxide water dissociation catalyst in the junction. Subsequent image segmentation and analysis quantify line edge roughness and catalyst layer thickness as descriptors of junction structure. Comparison of pre- and post-electrodialysis junctions suggests electric field-induced alignment of catalyst particles during electrodialysis. This characterization workflow can inform manufacturing protocols, computational modeling, and failure mode analysis for next-generation BPMs.

97 MATHEMATICS AND COMPUTING↗
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 NTRS1991

A three-dimensional finite-element thermal/mechanical analytical technique for high-performance traveling wave tubes

Current research in high-efficiency, high-performance traveling wave tubes (TWT's) has led to the development of novel thermal/ mechanical computer models for use with helical slow-wave structures. A three-dimensional, finite element computer model and analytical technique used to study the structural integrity and thermal operation of a high-efficiency, diamond-rod, K-band TWT designed for use in advanced space communications systems. This analysis focused on the slow-wave circuit in the radiofrequency section of the TWT, where an inherent localized heating problem existed and where failures were observed during earlier cold compression, or 'coining' fabrication technique that shows great potential for future TWT development efforts. For this analysis, a three-dimensional, finite element model was used along with MARC, a commercially available finite element code, to simulate the fabrication of a diamond-rod TWT. This analysis was conducted by using component and material specifications consistent with actual TWT fabrication and was verified against empirical data. The analysis is nonlinear owing to material plasticity introduced by the forming process and also to geometric nonlinearities presented by the component assembly configuration. The computer model was developed by using the high efficiency, K-band TWT design but is general enough to permit similar analyses to be performed on a wide variety of TWT designs and styles. The results of the TWT operating condition and structural failure mode analysis, as well as a comparison of analytical results to test data are presented.

Bartos, Karen F.↗
NASA NTRS1992

A three-dimensional finite-element thermal/mechanical analytical technique for high-performance traveling wave tubes

Current research in high-efficiency, high-performance traveling wave tubes (TWT's) has led to the development of novel thermal/mechanical computer models for use with helical slow-wave structures. A three-dimensional, finite element computer model and analytical technique used to study the structural integrity and thermal operation of a high-efficiency, diamond-rod, K-band TWT designed for use in advanced space communications systems. This analysis focused on the slow-wave circuit in the radiofrequency section of the TWT, where an inherent localized heating problem existed and where failures were observed during earlier cold compression, or 'coining' fabrication technique that shows great potential for future TWT development efforts. For this analysis, a three-dimensional, finite element model was used along with MARC, a commercially available finite element code, to simulate the fabrication of a diamond-rod TWT. This analysis was conducted by using component and material specifications consistent with actual TWT fabrication and was verified against empirical data. The analysis is nonlinear owing to material plasticity introduced by the forming process and also to geometric nonlinearities presented by the component assembly configuration. The computer model was developed by using the high efficiency, K-band TWT design but is general enough to permit similar analyses to be performed on a wide variety of TWT designs and styles. The results of the TWT operating condition and structural failure mode analysis, as well as a comparison of analytical results to test data are presented.

Shalkhauser, Kurt A.↗
NASA NTRS1988

Failure mode and effects analysis (FMEA) for the Space Shuttle solid rocket motor

The recertification of the Space Shuttle Solid Rocket Booster (SRB) and Solid Rocket Motor (SRM) has included an extensive rewriting of the Failure Mode and Effects Analysis (FMEA) and Critical Items List (CIL). The evolution of the groundrules and methodology used in the analysis is discussed and compared to standard FMEA techniques. Especially highlighted are aspects of the FMEA/CIL which are unique to the analysis of an SRM. The criticality category definitions are presented and the rationale for assigning criticality is presented. The various data required by the CIL and contribution of this data to the retention rationale is also presented. As an example, the FMEA and CIL for the SRM nozzle assembly is discussed in detail. This highlights some of the difficulties associated with the analysis of a system with the unique mission requirements of the Space Shuttle.

Russell, D. L.↗
DOE OSTI2026

Failure Mode and Effects Analysis (FMEA) for Photovoltaic Inverter

Photovoltaic (PV) inverters are critical yet vulnerable components in modern energy systems, often acting as reliability bottlenecks that increase the levelized cost of energy (LCOE). To address this, this paper presents a comprehensive Failure Mode and Effects Analysis (FMEA) tailored for PV inverters. Leveraging field data and literature, we identify failure-prone components, such as capacitors,, and relays, and prioritize their risks based on quantitative Risk Priority Numbers (RPNs). The analysis reveals that surge-induced MOV short circuits, capacitor degradation, and environmental cooling fan failures dominate the risk profile. These findings provide a targeted framework for reliability improvement, guiding future efforts in predictive diagnostics, design optimization, and accelerated life testing strategies.

14 SOLAR ENERGY↗
DOE OSTI2024

An Operations and Maintenance Roadmap for U.S. Offshore Wind: Enabling a Cost-Effective and Sustainable U.S. Offshore Wind Energy Industry Through Innovative Operations and Maintenance

The United States is currently targeting 30GW of offshore wind to be installed by 2030, and 150GW by 2050. Even considering future turbine sizes, this represents thousands of new turbines installed in a diverse set of environments, each with their unique design, installation, and maintenance challenges. While much can be learned from European and Asian experience with offshore wind over the past two decades, it is important to understand the unique circumstances of the U.S. This document explores operations and maintenance of offshore wind energy, specific to the U.S. and attempts to lay out a roadmap for needed activities to ensure reliability of future installations. The roadmap was informed through dozens of interviews with a wide cross-section of the industry, including representatives from OEMs, owner/operators, service companies, certification agencies, service providers, and researchers. The roadmap first describes the problem by component - blades, drivetrain and nacelle, structures and foundations, and electrical systems - through a look at current practices and opportunities for improvement in the areas of Failure Mode Analysis and Mitigation; Monitoring, Sensing, and Inspection; and Maintenance Execution. Crosscutting areas of Digitalization, Robotics and Automation, Prognostics and Health Management and O&M Optimization, Experimentation and Demonstration, Standardization, and Design Optimization Considering Reliability and O&M are then discussed. Finally, the roadmap summarizes all of these topics with recommendations for short (1-3 years), medium (4-7 years), and long term (8-12 years) activities, with a description of needed public and private sector contributions.

17 WIND ENERGY↗