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DOE OSTI2020

Characterization and identification of HPC applications at leadership computing facility

High Performance Computing (HPC) is an important method for scientific discovery via large-scale simulation, data analysis, or artificial intelligence. Leadership-class supercomputers are expensive, but essential to run large HPC applications. The Petascale era of supercomputers began in 2008, with the first machines achieving performance in excess of one petaflops, and with the advent of new supercomputers in 2021 (e.g., Aurora, Frontier), the Exascale era will soon begin. However, the high theoretical computing capability (i.e., peak FLOPS) of a machine is not the only meaningful target when designing a supercomputer, as the resources demand of applications varies. A deep understanding of the characterization of applications that run on a leadership supercomputer is one of the most important ways for planning its design, development and operation. In order to improve our understanding of HPC applications, user demands and resource usage characteristics, we perform correlative analysis of various logs for different subsystems of a leadership supercomputer. This analysis reveals surprising, sometimes counter-intuitive patterns, which, in some cases, conflicts with existing assumptions, and have important implications for future system designs as well as supercomputer operations. For example, our analysis shows that while the applications spend significant time on MPI, most applications spend very little time on file I/O. Combined analysis of hardware event logs and task failure logs show that the probability of a hardware FATAL event causing task failure is low. Combined analysis of control system logs and file I/O logs reveals that pure POSIX I/O is used more widely than higher level parallel I/O. Based on holistic insights of the application gained through combined and co-analysis of multiple logs from different perspectives and general intuition, we engineer features to "fingerprint" HPC applications. We use t-SNE (a machine learning technique for dimensionality reduction) to validate the explainability of our features and finally train machine learning models to identify HPC applications or group those with similar characteristic. To the best of our knowledge, this is the first work that combines logs on file I/O, computing, and inter-node communication for insightful analysis of HPC applications in production.

Liu, Zhengchun↗

NASA NTRS2001

Assessment of Stirling Technology Has Provided Critical Data Leading Toward Flight Readiness of the Stirling Converter

The NASA Glenn Research Center is supporting the development of a Stirling converter with the Department of Energy (DOE, Germantown, Maryland) for an advanced Stirling Radioisotope Power System (SRPS) to provide spacecraft onboard electric power for NASA space science missions. A key technology assessment completed by Glenn and DOE has led to the SRPS being identified as a high-efficiency power source for such deep space missions as the Europa Orbiter and the Solar Probe. In addition, the Stirling system is now being considered for unmanned Mars rovers, especially where mission profiles may exclude the use of photovoltaic power systems, such as exploration at high Martian latitudes or for missions of long duration. The SRPS efficiency of over 20 percent will reduce the required amount of radioisotope by more than a factor of 3 in comparison to current radioisotope thermoelectric generators. This significantly reduces radioisotope cost, radiological inventory, and system cost, and it provides efficient use of scarce radioisotope resources. In support of this technology assessment, Glenn conducted a series of independent evaluations and tests to determine the technology readiness of a 55-We Stirling converter developed by Stirling Technology Company (Kennewick, Washington) and DOE. Key areas evaluated by Glenn included: 1) Radiation tolerance of materials; 2) Random vibration testing of the Stirling converter in Glenn's Structural Dynamics Lab to simulate operation in the launch environment; 3) Electromagnetic interference and compatibility (EMI/EMC) of the converter operating in Glenn's EMI lab; Independent failure modes, effects, and criticality analysis, and life and reliability 4. Independent failure modes, effects, and criticality analysis, and life and reliability assessment; and 5) SRPS cost estimate. The data from these evaluations were presented to NASA Headquarters and the Jet Propulsion Laboratory mission office by a joint industry/Government team consisting of DOE, Glenn, and Lockheed Martin Astronautics. This team concluded that there are no technical reasons that would rule out using the Stirling converter for deep space missions. As a direct result of the successful testing at Glenn, the DOE/Stirling Technology Company 55-We Stirling converter has been baselined for the SRPS. Glenn is now continuing an in-house project to assist in developing the Stirling converter for readiness for space qualification and mission implementation. As part of this effort, the Stirling converter will be further characterized under launch environment random vibration testing, methods to reduce converter EMI will be developed, and an independent performance verification will be completed. Converter life assessment and permanent magnet aging characterization tasks are also underway. Substitute organic materials for the linear alternator and piston bearing coatings for use in a high-radiation environment have been identified and have now been incorporated in Stirling converters built by Stirling Technology Company for Glenn. Electromagnetic and thermal finite element analyses for the alternator are also being conducted.

Thieme, Lanny G.↗

DOE OSTI2026

Reliability Assessment of Cooling Fans for PV Inverters: Testing, Modeling, and Case Studies

The reliability of photovoltaic (PV) inverters is critical for long-term solar system performance, with cooling fan failures frequently leading to costly downtime. While much research exists on general cooling fan reliability, little attention has been given to fans operating within PV inverters and their unique environmental challenges. Here, this article proposes a comprehensive methodology to address this gap. First, a failure mode and effects analysis is performed on fans to identify the key failure mechanisms in PV applications, their corresponding stressors, and the models necessary for lifetime prediction. Second, an accelerated life test is designed and conducted to collect valuable experimental data for PV inverter fans in a reasonable amount of time. Third, a mathematical conversion of dynamic mission profiles into effective constant stress levels is derived. Fourth, case studies are given, showcasing lifetime estimates that account for geographic variations in mission profile data. The results demonstrate that this integrated approach leads to an accurate reliability assessment for PV inverter cooling fans.

accelerated life testing (ALT)↗

NASA NTRS1993

Structural design and analysis of a Mach zero to five turbo-ramjet system

The paper discusses the structural design and analysis of a Mach zero to five turbo-ramjet propulsion system for a Mach five waverider-derived cruise vehicle. The level of analysis detail necessary for a credible conceptual design is shown. The results of a finite-element failure mode sizing analysis for the engine primary structure is presented. The importance of engine/airframe integration is also discussed.

Spoth, Kevin A.↗

NASA NTRS1996

Progressive Damage Analysis of Laminated Composite (PDALC)-A Computational Model Implemented in the NASA COMET Finite Element Code

A method for analysis of progressive failure in the Computational Structural Mechanics Testbed is presented in this report. The relationship employed in this analysis describes the matrix crack damage and fiber fracture via kinematics-based volume-averaged variables. Damage accumulation during monotonic and cyclic loads is predicted by damage evolution laws for tensile load conditions. The implementation of this damage model required the development of two testbed processors. While this report concentrates on the theory and usage of these processors, a complete list of all testbed processors and inputs that are required for this analysis are included. Sample calculations for laminates subjected to monotonic and cyclic loads were performed to illustrate the damage accumulation, stress redistribution, and changes to the global response that occur during the load history. Residual strength predictions made with this information compared favorably with experimental measurements.

Lo, David C.↗

NASA NTRS1998

Progressive Damage Analysis of Laminated Composite (PDALC) (A Computational Model Implemented in the NASA COMET Finite Element Code)

A method for analysis of progressive failure in the Computational Structural Mechanics Testbed is presented in this report. The relationship employed in this analysis describes the matrix crack damage and fiber fracture via kinematics-based volume-averaged damage variables. Damage accumulation during monotonic and cyclic loads is predicted by damage evolution laws for tensile load conditions. The implementation of this damage model required the development of two testbed processors. While this report concentrates on the theory and usage of these processors, a complete listing of all testbed processors and inputs that are required for this analysis are included. Sample calculations for laminates subjected to monotonic and cyclic loads were performed to illustrate the damage accumulation, stress redistribution, and changes to the global response that occurs during the loading history. Residual strength predictions made with this information compared favorably with experimental measurements.

Coats, Timothy W.↗

NASA NTRS1988

Local buckling and crippling of composite stiffener sections

Local buckling, postbuckling, and crippling (failure) of channel, zee, and I- and J-section stiffeners made of AS4/3502 graphite-epoxy unidirectional tape are studied by experiment and analysis. Thirty-six stiffener specimens were tested statically to failure in axial compression as intermediate length columns. Web width is 1.25 inches for all specimens, and the flange width-to-thickness ratio ranges from 7 to 28 for the specimens tested. The radius of the stiffener corners is either 0.125 or 0.250 inches. A sixteen-ply orthotropic layup, an eight-ply quasi-isotropic layup, and a sixteen-ply quasi-isotropic layup are examined. Geometrically nonlinear analyses of five specimens were performed with the STAGS finite element code. Analytical results are compared to experimental data. Inplane stresses from STAGS are used to conduct a plane stress failure analysis of these specimens. Also, the development of interlaminar stress equations from equilibrium for classical laminated plate theory is presented. An algorithm to compute high order displacement derivatives required by these equations based on the Discrete Fourier Transform (DFT) is discussed.

Bonanni, David L.↗

NASA NTRS1986

Independent Orbiter Assessment (IOA): Analysis of the ascent thrust vector control actuator subsystem

The results of the Independent Orbiter Assessment (IOA) of the Failure Modes and Effects Analysis (FMEA) and Critical Items List (CIL) are presented. The IOA approach features a top-down analysis of the hardware to determine failure modes, criticality, and potential critical items. To preserve independence, this analysis was accomplished without reliance upon the results contained within the NASA FMEA/CIL documentation. The independent analysis results for the Ascent Thrust Vector Control (ATVC) Actuator hardware are documented. The function of the Ascent Thrust Vector Control Actuators (ATVC) is to gimbal the main engines to provide for attitude and flight path control during ascent. During first stage flight, the SRB nozzles provide nearly all the steering. After SRB separation, the Orbiter is steered by gimbaling of its main engines. There are six electrohydraulic servoactuators, one pitch and one yaw for each of the three main engines. Each servoactuator is composed of four electrohydraulic servovalve assemblies, one second stage power spool valve assembly, one primary piston assembly and a switching valve. Each level of hardware was evaluated and analyzed for possible failure modes and effects. Criticality was assigned based upon the severity of the effect for each failure mode. Critical failures resulting in loss of ATVC were mainly due to loss of hydraulic fluid, fluid contamination and mechanical failures.

Wilson, R. E.↗

NASA NTRS1992

Weathering processes implied from analysis of small Martian avalanche chutes

It has been proposed that the smaller features of martian spur and gully slope morphology, located along the upper walls of Valles Marineris, are avalanche chutes. A three-dimensional stability back-analysis technique was developed and applied to these small avalanche chutes, yielding average values of cohesion and angle of internal friction for the mobile layer materials on these slopes at the time of each slope failure. Generally, the analysis showed that at the time of each slope failure material strengths had been reduced to those of moderately cohesive debris down through depths of tens of meters. These results have implications and possible constraints for the nature and rate of martian weathering processes.

Sullivan, R.↗

NASA NTRS1999

Rate Dependent Deformation and Strength Analysis of Polymer Matrix Composites

A research program is being undertaken to develop rate dependent deformation and failure models for the analysis of polymer matrix composite materials. In previous work in this program, strain-rate dependent inelastic constitutive equations used to analyze polymers have been implemented into a mechanics of materials based composite micromechanics method. In the current work, modifications to the micromechanics model have been implemented to improve the calculation of the effective inelastic strain. Additionally, modifications to the polymer constitutive model are discussed in which pressure dependence is incorporated into the equations in order to improve the calculation of constituent and composite shear stresses. The Hashin failure criterion is implemented into the analysis method to allow for the calculation of ply level failure stresses. The deformation response and failure stresses for two representative uniaxial polymer matrix composites, IM7/977-2 and AS4-PEEK, are predicted for varying strain rates and fiber orientations. The predicted results compare favorably to experimentally obtained values.

Goldberg, Robert K.↗

NASA NTRS2017

Accounting for Epistemic Uncertainty in Mission Supportability Assessment: A Necessary Step in Understanding Risk and Logistics Requirements

Future crewed missions to Mars present a maintenance logistics challenge that is unprecedented in human spaceflight. Mission endurance – defined as the time between resupply opportunities – will be significantly longer than previous missions, and therefore logistics planning horizons are longer and the impact of uncertainty is magnified. Maintenance logistics forecasting typically assumes that component failure rates are deterministically known and uses them to represent aleatory uncertainty, or uncertainty that is inherent to the process being examined. However, failure rates cannot be directly measured; rather, they are estimated based on similarity to other components or statistical analysis of observed failures. As a result, epistemic uncertainty – that is, uncertainty in knowledge of the process – exists in failure rate estimates that must be accounted for. Analyses that neglect epistemic uncertainty tend to significantly underestimate risk. Epistemic uncertainty can be reduced via operational experience; for example, the International Space Station (ISS) failure rate estimates are refined using a Bayesian update process. However, design changes may re-introduce epistemic uncertainty. Thus, there is a tradeoff between changing a design to reduce failure rates and operating a fixed design to reduce uncertainty. This paper examines the impact of epistemic uncertainty on maintenance logistics requirements for future Mars missions, using data from the ISS Environmental Control and Life Support System (ECLS) as a baseline for a case study. Sensitivity analyses are performed to investigate the impact of variations in failure rate estimates and epistemic uncertainty on spares mass. The results of these analyses and their implications for future system design and mission planning are discussed.

Owens, Andrew↗

NASA NTRS1986

Independent Orbiter Assessment (IOA): Analysis of the electrical power distribution and control/electrical power generation subsystem

The results of the Independent Orbiter Assessment (IOA) of the Failure Modes and Effects Analysis (FMEA) and Critical Items List (CIL) are presented. The IOA approach features a top-down analysis of the hardware to determine failure modes, criticality, and potential critical items. To preserve independence, this analysis was accomplished without reliance upon the results contained within the NASA FMEA/CIL documentation. This report documents the independent analysis results corresponding to the Orbiter Electrical Power Distribution and Control (EPD and C)/Electrical Power Generation (EPG) hardware. The EPD and C/EPG hardware is required for performing critical functions of cryogenic reactant storage, electrical power generation and product water distribution in the Orbiter. Specifically, the EPD and C/EPG hardware consists of the following components: Power Section Assembly (PSA); Reactant Control Subsystem (RCS); Thermal Control Subsystem (TCS); Water Removal Subsystem (WRS); and Power Reactant Storage and Distribution System (PRSDS). The IOA analysis process utilized available EPD and C/EPG hardware drawings and schematics for defining hardware assemblies, components, and hardware items. Each level of hardware was evaluated and analyzed for possible failure modes and effects. Criticality was assigned based upon the severity of the effect for each failure mode.

Patton, Jeff A.↗

NASA NTRS1987

Independent Orbiter Assessment (IOA): Assessment of the displays and controls subsystem

The results of the Independent Orbiter Assessment (IOA) of the Failure Modes and Effects Analysis (FMEA) and Critical Items Llist (CIL) are presented. The IOA effort first completed an analysis of the Displays and Control hardware, generating draft failure modes and potential critical items. To preserve independence, this analysis was accomplished without reliance upon the results contained within the NASA FMEA/CIL documentation. The IOA results were than compared to the NASA FMEA/CIL baseline with proposed Post 51-L updates included. A resolution of each discrepancy is provided through additional analysis as required. The results of that comparison for the Orbiter D and C hardware are documented.

Trahan, W. H.↗

NASA NTRS2002

Compression Buckling Behavior of Large-Scale Friction Stir Welded and Riveted 2090-T83 Al-Li Alloy Skin-Stiffener Panels

To evaluate the potential of friction stir welding (FSW) as a replacement for traditional rivet fastening for launch vehicle dry bay construction, a large-scale friction stir welded 2090-T83 aluminum-lithium (Al-Li) alloy skin-stiffener panel was designed and fabricated by Lockheed-Martin Space Systems Company - Michoud Operations (LMSS) as part of NASA Space Act Agreement (SAA) 446. The friction stir welded panel and a conventional riveted panel were tested to failure in compression at the NASA Langley Research Center (LaRC). The present paper describes the compression test results, stress analysis, and associated failure behavior of these panels. The test results provide useful data to support future optimization of FSW processes and structural design configurations for launch vehicle dry bay structures.

Hoffman, Eric K.↗

NASA NTRS1990

Scaling effects in the static and dynamic response of graphite-epoxy beam-columns

Scale model technology represents one method of investigating the behavior of advanced, weight-efficient composite structures under a variety of loading conditions. It is necessary, however, to understand the limitations involved in testing scale model structures before the technique can be fully utilized. These limitations, or scaling effects, are characterized. in the large deflection response and failure of composite beams. Scale model beams were loaded with an eccentric axial compressive load designed to produce large bending deflections and global failure. A dimensional analysis was performed on the composite beam-column loading configuration to determine a model law governing the system response. An experimental program was developed to validate the model law under both static and dynamic loading conditions. Laminate stacking sequences including unidirectional, angle ply, cross ply, and quasi-isotropic were tested to examine a diversity of composite response and failure modes. The model beams were loaded under scaled test conditions until catastrophic failure. A large deflection beam solution was developed to compare with the static experimental results and to analyze beam failure. Also, the finite element code DYCAST (DYnamic Crash Analysis of STructure) was used to model both the static and impulsive beam response. Static test results indicate that the unidirectional and cross ply beam responses scale as predicted by the model law, even under severe deformations. In general, failure modes were consistent between scale models within a laminate family; however, a significant scale effect was observed in strength. The scale effect in strength which was evident in the static tests was also observed in the dynamic tests. Scaling of load and strain time histories between the scale model beams and the prototypes was excellent for the unidirectional beams, but inconsistent results were obtained for the angle ply, cross ply, and quasi-isotropic beams. Results show that valuable information can be obtained from testing on scale model composite structures, especially in the linear elastic response region. However, due to scaling effects in the strength behavior of composite laminates, caution must be used in extrapolating data taken from a scale model test when that test involves failure of the structure.

Jackson, Karen E.↗

NASA NTRS1987

Independent Orbiter Assessment (IOA): Analysis of the electrical power distribution and control subsystem, volume 1

The results of the Independent Orbiter Assessment (IOA) of the Failure Modes and Effects Analysis (FMEA) and Critical Items List (CIL) are presented. The IOA approach features a top-down analysis of the hardware to determine failure modes, criticality, and potential critical items. To preserve independence, this analysis was accomplished without reliance upon the results contained within the NASA FMEA/CIL documentation. This report documents the independent analysis results corresponding to the Orbiter Electrical Power Distribution and Control (EPD and C) hardware. The EPD and C hardware performs the functions of distributing, sensing, and controlling 28 volt DC power and of inverting, distributing, sensing, and controlling 117 volt 400 Hz AC power to all Orbiter subsystems from the three fuel cells in the Electrical Power Generation (EPG) subsystem. Each level of hardware was evaluated and analyzed for possible failure modes and effects. Criticality was assigned based upon the severity of the effect for each failure mode. Of the 1671 failure modes analyzed, 9 single failures were determined to result in loss of crew or vehicle. Three single failures unique to intact abort were determined to result in possible loss of the crew or vehicle. A possible loss of mission could result if any of 136 single failures occurred. Six of the criticality 1/1 failures are in two rotary and two pushbutton switches that control External Tank and Solid Rocket Booster separation. The other 6 criticality 1/1 failures are fuses, one each per Aft Power Control Assembly (APCA) 4, 5, and 6 and one each per Forward Power Control Assembly (FPCA) 1, 2, and 3, that supply power to certain Main Propulsion System (MPS) valves and Forward Reaction Control System (RCS) circuits.

Schmeckpeper, K. R.↗

NASA NTRS1991

Probabilistic structural analysis methods for space transportation propulsion systems

Information on probabilistic structural analysis methods for space propulsion systems is given in viewgraph form. Information is given on deterministic certification methods, probability of failure, component response analysis, stress responses for 2nd stage turbine blades, Space Shuttle Main Engine (SSME) structural durability, and program plans. .

Chamis, C. C.↗

NASA NTRS1988

Independent Orbiter Assessment (IOA): FMEA/CIL assessment

The McDonnell Douglas Astronautics Company (MDAC) was selected to perform an Independent Orbiter Assessment (IOA) of the Failure Modes and Effects Analysis (FMEA) and Critical Items List (CIL). Direction was given by the Orbiter and GFE Projects Office to perform the hardware analysis and assessment using the instructions and ground rules defined in NSTS 22206. The IOA analysis featured a top-down approach to determine hardware failure modes, criticality, and potential critical items. To preserve independence, the analysis was accomplished without reliance upon the results contained within the NASA and Prime Contractor FMEA/CIL documentation. The assessment process compared the independently derived failure modes and criticality assignments to the proposed NASA post 51-L FMEA/CIL documentation. When possible, assessment issues were discussed and resolved with the NASA subsystem managers. Unresolved issues were elevated to the Orbiter and GFE Projects Office manager, Configuration Control Board (CCB), or Program Requirements Control Board (PRCB) for further resolution. The most important Orbiter assessment finding was the previously unknown stuck autopilot push-button criticality 1/1 failure mode. The worst case effect could cause loss of crew/vehicle when the microwave landing system is not active. It is concluded that NASA and Prime Contractor Post 51-L FMEA/CIL documentation assessed by IOA is believed to be technically accurate and complete. All CIL issues were resolved. No FMEA issues remain that have safety implications. Consideration should be given, however, to upgrading NSTS 22206 with definitive ground rules which more clearly spell out the limits of redundancy.

Hinsdale, L. W.↗