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Development of failure sensing switching circuitry for electrical power system reliability during extended space missions
The cooperative agreement partly supported research leading to the open-literature publication cited. Additional efforts under the agreement included research into fault modeling of semiconductor devices. Results of this research are presented in this report which is summarized in the following paragraphs. As a result of the cited research, it appears that semiconductor failure mechanism data is abundant but of little use in developing pin-level device models. Failure mode data on the other hand does exist but is too sparse to be of any statistical use in developing fault models. What is significant in the failure mode data is that, unlike classical logic, MSI and LSI devices do exhibit more than 'stuck-at' and open/short failure modes. Specifically they are dominated by parametric failures and functional anomalies that can include intermittent faults and multiple-pin failures. The report discusses methods of developing composite pin-level models based on extrapolation of semiconductor device failure mechanisms, failure modes, results of temperature stress testing and functional modeling. Limitations of this model particularly with regard to determination of fault detection coverage and latency time measurement are discussed. Indicated research directions are presented.
To demonstrate the advanced composite materials technology under development within the Ultra-Efficient Engine Technology (UEET) Program, it was planned to fabricate, test, and analyze a turbine vane made entirely of silicon carbide-fiber-reinforced silicon carbide matrix composite (SiC/SiC CMC) material. The objective was to utilize a five-harness satin weave melt-infiltrated (MI) SiC/SiC composite material developed under this program to design and fabricate a stator vane that can endure 1000 hours of engine service conditions. The vane was designed such that the expected maximum stresses were kept within the proportional limit strength of the material. Any violation of this design requirement was considered as the failure. This report presents results of a probabilistic analysis and reliability assessment of the vane. Probability of failure to meet the design requirements was computed. In the analysis, material properties, strength, and pressure loading were considered as random variables. The pressure loads were considered normally distributed with a nominal variation. A temperature profile on the vane was obtained by performing a computational fluid dynamics (CFD) analysis and was assumed to be deterministic. The results suggest that for the current vane design, the chance of not meeting design requirements is about 1.6 percent.
The reliability program consists of: parts stress analysis, failure mode, effect and criticality analysis, standardization of design practices, and a design review program. Malfunction reporting, and failure analysis is delineated, as well as identification of inputs and outputs.
The failure of wing panels on a number of TBF-1 and TBM-1 airplanes in flight has prompted several investigations of the possible causes of failure. This report describes tests in the Langley 16-foot high-speed tunnel to determine whether these failures could be attributed to changes in the aerodynamic characteristics of the ailerons at high speeds. The tests were made of a 12-foot-span section including the tip and aileron of the right wing of a TBF-1 airplane. Hinge moments, control-link stresses due to aerodynamic buffeting, and fabric-deflection photographs were obtained at true airspeeds ranging from 110 to 365 miles per hour. The aileron hinge-moment coefficients were found to vary only slightly with airspeed in spite of the large fabric deflections that developed as the speed was increased. An analysis of these results indicated that the resultant hinge moment of the ailerons as installed in the airplane would tend to restore the ailerons to their neutral position for all the high-speed flight conditions covered in the tests. Serious aerodynamic buffeting occurred at up aileron angles of -10 degrees or greater because of stalling of the sharp projecting lip of the Frise aileron. The peak stresses set up in the aileron control linkages in the buffeting condition were as high as three times the mean stress. During the hinge-moment investigation, flutter of the test installation occurred at airspeeds of about 150 miles per hour. This flutter condition was investigated in some detail and slow-motion pictures were made of the motion of the wing tip and aileron. The flutter was found to involve simultaneous normal bending and chordwise oscillation of the wing and flapping of the aileron. The aileron motion appeared to be coupled with this flutter condition and was investigated in some detail and slow-motion pictures were made of the motion of the wing tip and aileron. The flutter was found to involve simultaneous normal bending and chordwise oscillation of the wing and flapping of the aileron. The aileron motion appeared to be coupled with the motion of the wing through the mass unbalance of the aileron in the normal-to-chord plane due to location of the hinge line 2.17 inches below the center of gravity of the aileron. Flutter did not occur when the installation was stiffened to prevent chordwise motion or when the bending frequency of the aileron system was appreciably higher than that of the wing as in the complete airplane installation.
Structural failure criteria for viscoelastic materials
Report describes effects of power and temperature overstress on National Semiconductor and Raytheon transistors. Good junction quality was maintained. Gain losses predominated. Other failures are reported.
The development of DEPEND, an integrated simulation environment for the design and dependability analysis of fault-tolerant systems, is described. DEPEND models both hardware and software components at a functional level, and allows automatic failure injection to assess system performance and reliability. It relieves the user of the work needed to inject failures, maintain statistics, and output reports. The automatic failure injection scheme is geared toward evaluating a system under high stress (workload) conditions. The failures that are injected can affect both hardware and software components. To illustrate the capability of the simulator, a distributed system which employs a prediction-based, dynamic load-balancing heuristic is evaluated. Experiments were conducted to determine the impact of failures on system performance and to identify the failures to which the system is especially susceptible.
Operations of the P78-2 spacecraft and its 12 payloads, which attempt to measure the buildup and breakdown of charge on various spacecraft components and to characterize the natural environment at synchronous altitudes, are summarized. Launch procedures, orbit alignment, and eclipse seasons are reviewed. The spacecraft configuration and subsystems are described. Catastrophic payload failures are reported: the SC6 (AFGL Thermal Plasma Analyzer) failed due to an excessive power draw in the electron step generator. The SC7 (NASA/MSFC Light Ion Mass Spectrometer) internal power supply failed. Lesser payload failures, including SC2 probe biasing, SC4-1 pulsed mode, and SC4-2 neutralizer are discussed.
Signal Corps wind equipment AN/GMQ-1 consisting of a 3-cup anemometer and wind vane was calibrated for wind velocities from 1 to 200 miles per hour. Cup-shaft failure prevented calibration at higher wind velocities. The action of the wind vane was checked and found to have very poor directional accuracy below a velocity of 8 miles per hour. After shaft failure was reported to the Signal Corps, the cup rotors were redesigned by strengthening the shafts for better operation at high velocities. The anemometer with the redesigned cup rotors was recalibrated, but cup-shaft failure occurred again at a wind velocity of approximately 220 miles per hour. In the course of this calibration two standard generators were checked for signal output variation, and a wind-speed meter was calibrated for use with each of the redesigned cup rotors. The variation of pressure coefficient with air-flow direction at four orifices on a disk-shaped pitot head was obtained for wind velocities of 37.79 53.6, and 98.9 miles per hour. A pitot-static tube mounted in the nose of a vane was calibrated up to a dynamic pressure of 155 pounds per square foot, or approximately 256 miles per hour,
Two test incidents involving instability of large scale commercially built structures are described. Two classes of structure are discussed; the first, a fuselage with skin designed to buckle at low stress, and the second, a wing whose surface remains unbuckled to failure. The structure in the region of failure is defined and the failures described and illustrated. Insofar as possible, the stresses in the critical area at the time of failure are reported and compared to strength determined by analysis. Both fuselage and wing surfaces were observed to fail in the mode of a medium range column when adequate support was provided by ribs and frames. Initial failure in the wing example was premature due to a design deficiency in rib strength. A clear illustration is given of the effect of rib stiffness on wing surface stability. Adding stiffness to wing ribs increases the limit of surface stability to the theoretical flat panel value.
Since 1963, solid-propellant apogee motors have been placing satellites into geosynchronous orbits. Major technological breakthroughs are not required to satisfy future mission requirements; however, there is a need to improve reliability to enhance cost effectiveness. A summary of results and conclusions derived from a review of missions, where failure of a solid motor was inferred, and from a correlation of system factors with failures are reported. Highlights of a solid motor diagnostic instrumentation study are presented. Finally, recommendations are provided for areas of future apogee motor upgrade, which will increase project cost effectiveness by reducing the potential for future flight failures.
Since 1963, solid propellant apogee motors have been placing satellites into geosynchronous orbits. Major technological breakthroughs are not required to satisfy future mission requirements; however, there is a need to improve reliability to enhance cost effectiveness. Several management test options are discussed. A summary of results and conclusions derived from review of missions, where failure of a solid motor was inferred, and correlation of system factors with failures are reported. Highlights of a solid motor diagnostic instrumentation study are presented. Finally, recommendations are provided for areas of future apogee motor upgrade, which will increase project cost effectiveness by reducing the potential for future flight failures.
The Grid opens up opportunities for resource-starved scientists and engineers to harness highly distributed computing resources. A number of Grid middleware projects are currently available to support the simultaneous exploitation of heterogeneous resources distributed in different administrative domains. However, efficient job submission and management continue being far from accessible to ordinary scientists and engineers due to the dynamic and complex nature of the Grid. This report describes a new Globus framework that allows an easier and more efficient execution of jobs in a 'submit and forget' fashion. Adaptation to dynamic Grid conditions is achieved by supporting automatic application migration following performance degradation, 'better' resource discovery, requirement change, owner decision or remote resource failure. The report also includes experimental results of the behavior of our framework on the TRGP testbed.
This report presents a high-level overview of a general strategy to mitigate the risks from threats to safety-critical computer-based systems. In this context, a safety threat is a process or phenomenon that can cause operational safety hazards in the form of computational system failures. This report is intended to provide insight into the safety-risk mitigation problem and the characteristics of potential solutions. The limitations of the general risk mitigation strategy are discussed and some options to overcome these limitations are provided. This work is part of an ongoing effort to enable well-founded assurance of safety-related properties of complex safety-critical computer-based aircraft systems by developing an effective capability to model and reason about the safety implications of system requirements and design.
Crack propagation and failure mechanisms in viscoelastic materials
Failure modes of large multilevel silicon microcircuit arrays
Inverter reliability remains one of the most persistent challenges limiting the performance, availability, and economic viability of utility‑scale photovoltaic (PV) plants. Industry data consistently show that inverters account for the highest share of corrective maintenance events and unplanned outages across PV fleets. These failures result in energy losses, increased O&M costs, and reduced confidence in long‑term solar asset performance. Motivated by these challenges, this project—Extending Component Lifetime and Improving Inverter Reliability (ECLAIIR)—was undertaken to systematically investigate inverter degradation and failure mechanisms, develop predictive maintenance capabilities, and establish data‑driven pathways to improve service life and reduce the Levelized Cost of Energy (LCOE) for large‑scale PV systems. The primary goal of the project was to identify pre‑failure signatures in string inverters using both lab‑based accelerated lifetime testing and field‑based data and to develop predictive maintenance algorithms that can anticipate inverter faults before they occur. Through collaboration with inverter testing laboratory, solar PV plant owner, and failure‑analysis experts, the project advanced the technical understanding of inverter reliability. By instrumenting inverters with thermistors, humidity sensors, power‑quality meters, and acoustic sensors, the research established how multiple sensing modalities can reliably detect deviations from normal behavior hours to days before failure. These findings substantially enhance scientific understanding of inverter failure kinetics and provide the PV industry with the most comprehensive cross‑OEM characterization of early‑stage failure indicators reported to date. Technically, the project demonstrated the effectiveness of predictive maintenance by developing and validating the PreDICT (Predictive Diagnostics of PV Inverters Using Condition Monitoring and Trend Analysis) framework—a multi‑layer diagnostic architecture combining peer‑to‑peer analytics, historical trend modeling, and advanced machine‑learning techniques such as the Sequential Conditional Variational Autoencoder (SCVAE). This predictive model achieved more than 90% accuracy in detecting pre‑failure conditions and provided up to four days of lead time before inverter failure in field scenarios. Economically, the project’s LCOE analysis showed that predictive maintenance can reduce lifetime energy losses and minimize corrective maintenance interventions. Modeling indicated that, depending on inverter failure rates and replacement timelines, predictive maintenance can significantly reduce LCOE impacts associated with inverter downtime: from as high as 19.4% under conventional maintenance strategies to 0.1%–10.17% when predictive analytics are adopted. These results confirm that predictive maintenance is both technically feasible and economically advantageous for utilities and plant operators. The project’s findings also have broad public benefit. By improving inverter reliability and reducing downtime, predictive maintenance directly increases electricity generation from existing PV assets. Enhanced reliability lowers operational costs for utilities, which can translate over time into lower energy costs for consumers. Furthermore, the project’s technical publications, conference presentations, and industry workshops ensure that knowledge gained is shared broadly across the solar industry, supporting workforce development and enabling utilities of all sizes to adopt modern asset‑health monitoring practices. The retrofitting case study and service‑life prediction framework further support informed decision‑making for aging PV fleets, helping operators extend system life and reduce electronic waste. In summary, the ECLAIIR project significantly advanced the state of knowledge on inverter degradation, demonstrated the technical and economic value of predictive maintenance, and delivered actionable tools and insights that support more reliable, cost‑effective, and sustainable PV plant operation. The outcomes of this project will continue to inform utility practices, guide inverter design improvements, and strengthen the long‑term performance of solar assets nationwide.