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DOE OSTI2020

Enhanced Component Performance Study: Emergency Diesel Generators 1998–2018

This report presents an enhanced performance evaluation of emergency diesel generators (EDGs) at U.S. commercial nuclear power plants. This report evaluates component performance over time using (1) Institute of Nuclear Power Operations (INPO) Consolidated Events Database (ICES) data from 1998 through 2018 and (2) maintenance unavailability (UA) performance data from Mitigating Systems Performance Index (MSPI) Basis Document data from 2002 through 2018. The objective is to show estimates of current failure probabilities and rates related to EDGs, trend these data on an annual basis, determine if the current data are consistent with the probability distributions currently recommended for use in NRC probabilistic risk assessments, show how the reliability data differ for different EDG manufacturers and for EDGs with different ratings; and summarize the subcomponents, causes, detection methods, and recovery associated with each EDG failure mode. Engineering analyses were performed with respect to time period and failure mode without regard to the actual number of EDGs at each plant. The factors analyzed are: sub-component, failure cause, detection method, recovery, manufacturer, and EDG rating. A statistically significant increasing trend was identified in the frequency of FTLR demands for emergency power system (EPS) and high pressure core spray (HPCS) EDGs and a statistically significant decreasing trend was identified in the frequency of run > 1H hours for EPS and HPCS EDGs.

99 GENERAL AND MISCELLANEOUS↗

NASA NTRS1997

Fatigue Life Methodology for Tapered Composite Flexbeam Laminates

The viability of a method for determining the fatigue life of composite rotor hub flexbeam laminates using delamination fatigue characterization data and a geometric non-linear finite element (FE) analysis was studied. Combined tension and bending loading was applied to non-linear tapered flexbeam laminates with internal ply drops. These laminates, consisting of coupon specimens cut from a full-size S2/E7T1 glass-epoxy flexbeam were tested in a hydraulic load frame under combined axial-tension and transverse cyclic bending. The magnitude of the axial load remained constant and the direction of the load rotated with the specimen as the cyclic bending load was applied. The first delamination damage observed in the specimens occurred at the area around the tip of the outermost ply-drop group. Subsequently, unstable delamination occurred by complete delamination along the length of the specimen. Continued cycling resulted in multiple delaminations. A 2D finite element model of the flexbeam was developed and a geometrically non-linear analysis was performed. The global responses of the model and test specimens agreed very well in terms of the transverse displacement. The FE model was used to calculate strain energy release rates (G) for delaminations initiating at the tip of the outer ply-drop area and growing toward the thick or thin regions of the flexbeam, as was observed in the specimens. The delamination growth toward the thick region was primarily mode 2, whereas delamination growth toward the thin region was almost completely mode 1. Material characterization data from cyclic double-cantilevered beam tests was used with the peak calculated G values to generate a curve predicting fatigue failure by unstable delamination as a function of the number of loading cycles. The calculated fatigue lives compared well with the test data.

Murri, Gretchen B.↗

NASA NTRS2008

Aeroservoelastic Stability Analysis of the X-43A Stack

The first air launch attempt of an X-43A stack, consisting of the booster, adapter and Hyper-X research vehicle, ended in failure shortly after the successful drop from the National Aeronautics and Space Administration Dryden Flight Research Center (Edwards, California) B-52B airplane and ignition of the booster. The stack was observed to begin rolling and yawing violently upon reaching transonic speeds, and the grossly oscillating fins of the booster separated shortly thereafter. The flight then had to be terminated with the stack out of control. Very careful linear flutter and aeroservoelastic analyses were subsequently performed as reported herein to numerically duplicate the observed instability. These analyses properly identified the instability mechanism and demonstrated the importance of including the flight control laws, rigid-body modes, structural flexible modes and control surface flexible modes. In spite of these efforts, however, the predicted instability speed remained more than 25 percent higher than that observed in flight. It is concluded that transonic shock phenomena, which linear analyses cannot take into account, are also important for accurate prediction of this mishap instability.

Pak, Chan-gi↗

DOE OSTI2026

Scaling open-weight large language models for hydropower regulatory information extraction: A systematic analysis

Information extraction from regulatory and technical documents using large language models (LLMs) involves practical trade-offs between extraction quality and computational cost. We evaluate eight open-weight LLMs spanning 0.6B–70B parameters on hydropower licensing documents and report deployment-oriented evidence under a unified extraction schema and evaluation protocol. Across the model set, we observe clear scale-dependent trends in both baseline extraction quality and the effectiveness of reflective reasoning (self-checking) under our fixed-prompt, no-augmentation setting. Mid-scale models often provide a favorable balance of accuracy and efficiency, whereas the smallest models show limited or inconsistent gains from the reasoning variants tested. Larger models achieve the highest overall F1 scores but incur substantially greater compute and infrastructure requirements. We further find that reliability failure modes can distort conventional metrics in this domain: in particular, high recall can coincide with systematic extraction errors when models fabricate values for fields that are absent from the source text, underscoring the importance of conservative null handling and evidence-grounded evaluation. Overall, our study provides a reproducible resource–performance comparison for open-weight LLM-based extraction in hydropower regulatory documentation and offers practical guidance for model selection under different deployment constraints.

Evaluation protocol↗

NASA NTRS1994

Design for dependability: A simulation-based approach

This research addresses issues in simulation-based system level dependability analysis of fault-tolerant computer systems. The issues and difficulties of providing a general simulation-based approach for system level analysis are discussed and a methodology that address and tackle these issues is presented. The proposed methodology is designed to permit the study of a wide variety of architectures under various fault conditions. It permits detailed functional modeling of architectural features such as sparing policies, repair schemes, routing algorithms as well as other fault-tolerant mechanisms, and it allows the execution of actual application software. One key benefit of this approach is that the behavior of a system under faults does not have to be pre-defined as it is normally done. Instead, a system can be simulated in detail and injected with faults to determine its failure modes. The thesis describes how object-oriented design is used to incorporate this methodology into a general purpose design and fault injection package called DEPEND. A software model is presented that uses abstractions of application programs to study the behavior and effect of software on hardware faults in the early design stage when actual code is not available. Finally, an acceleration technique that combines hierarchical simulation, time acceleration algorithms and hybrid simulation to reduce simulation time is introduced.

Goswami, Kumar K.↗

NASA NTRS1987

Non-linear shipboard shock analysis of the Tomahawk missile shock isolation system

The identification, quantification, computer modeling and verification of the Tomahawk nonlinear liquid spring shock isolation system in a surface ship Vertical Launch System (VLS) are discussed. The isolation system hardware and mode of operation is detailed in an effort to understand the nonlinearities. These nonlinearities are then quantified and modeled using the MSC/NASTRAN finite element code. The model was verified using experimental data from the Navel Ordnance Systems Center MIL-S-901 medium weight shock tests of August 1986. The model was then used to predict the Tomahawk response to the CG-53 USS Mobile Bay shock trials of May-June 1987. Results indicate that the model is an accurate mathematical representation of the physical system either functioning as designed or in an impaired condition due to spring failure.

Leifer, Joel↗

NASA NTRS1994

Derivation and experimental verification of clock synchronization theory

The objective of this work is to validate mathematically derived clock synchronization theories and their associated algorithms through experiment. Two theories are considered, the Interactive Convergence Clock Synchronization Algorithm and the Mid-Point Algorithm. Special clock circuitry was designed and built so that several operating conditions and failure modes (including malicious failures) could be tested. Both theories are shown to predict conservative upper bounds (i.e., measured values of clock skew were always less than the theory prediction). Insight gained during experimentation led to alternative derivations of the theories. These new theories accurately predict the clock system's behavior. It is found that a 100% penalty is paid to tolerate worst case failures. It is also shown that under optimal conditions (with minimum error and no failures) the clock skew can be as much as 3 clock ticks. Clock skew grows to 6 clock ticks when failures are present. Finally, it is concluded that one cannot rely solely on test procedures or theoretical analysis to predict worst case conditions. conditions.

INTERACTIVE CONVERGENCE CLOCK↗

NASA NTRS1998

An Example of Concurrent Engineering

The Collaborative Engineering Design and Analysis Room (CEDAR) facility allows on-the- spot design review capability for any project during all phases of development. The required disciplines assemble in this facility to work on any problems (analysis, manufacturing, inspection, etc.) associated with a particular design. A small highly focused team of specialists can meet in this room to better expedite the process of developing a solution to an engineering task within the framework of the constraints that are unique to each discipline. This facility provides the engineering tools and translators to develop a concept within the confines of the room or with remote team members that could access the team's data from other locations. The CEDAR area is envisioned as excellent for failure investigation meetings to be conducted where the computer capabilities can be utilized in conjunction with the Smart Board display to develop failure trees, brainstorm failure modes, and evaluate possible solutions.

Rowe, Sidney↗

NASA NTRS1974

Operations analysis (study 2.1): Payload designs for space servicing

Potential modes of operating in space in the space shuttle era are documented. The October 1973 NASA Mission Model provides a definition of various NASA and non-DOD automated payload configurations when employed in an expendable mode. The model also specifies a launch schedule for initial deployment of payloads as well as for subsequent replacements at periodic cycles. This model and its associated payload definitions serve as a foundation for the data presented in this report. The reference model has been revised to reflect automated space servicing of payloads as an operational concept instead of the existing expendable approach. The indication is that the bulk of a payload's subsystems and mission equipment require no support over the lifetime of the program. However, failure of a single unit could result in loss of the mission objectives. When space servicing is employed, the approach is to replace only that unit causing the anomaly. This concept affords an opportunity to standardize space replacable units, as well as to reduce the expense of logistics support, by allowing multiple servicing on any single upper stage/shuttle flight.

Wolfe, R. R.↗

NASA NTRS2016

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

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

intermetallics↗

NASA NTRS1988

Computational simulation methods for composite fracture mechanics

Structural integrity, durability, and damage tolerance of advanced composites are assessed by studying damage initiation at various scales (micro, macro, and global) and accumulation and growth leading to global failure, quantitatively and qualitatively. In addition, various fracture toughness parameters associated with a typical damage and its growth must be determined. Computational structural analysis codes to aid the composite design engineer in performing these tasks were developed. CODSTRAN (COmposite Durability STRuctural ANalysis) is used to qualitatively and quantitatively assess the progressive damage occurring in composite structures due to mechanical and environmental loads. Next, methods are covered that are currently being developed and used at Lewis to predict interlaminar fracture toughness and related parameters of fiber composites given a prescribed damage. The general purpose finite element code MSC/NASTRAN was used to simulate the interlaminar fracture and the associated individual as well as mixed-mode strain energy release rates in fiber composites.

Murthy, Pappu L. N.↗

NASA NTRS1991

Control system failure monitoring using generalized parity relations

Many applications require that a control system must be tolerant to the failure of its components. This is especially true for large space-based systems that must work unattended and with long periods between maintenance. Fault tolerance can be obtained by detecting the failure of the control system component, determining which component has failed, and reconfiguring the system so that the failed component is isolated from the controller. Component failure detection experiments that were conducted on an experimental space structure, the NASA Langley Mini-Mast are presented. Two methodologies for failure detection and isolation (FDI) exist that do not require the specification of failure modes and are applicable to both actuators and sensors. These methods are known as the Failure Detection Filter and the method of Generalized Parity Relations. The latter method was applied to three different sensor types on the Mini-Mast. Failures were simulated in input-output data that were recorded during operation of the Mini-Mast. Both single and double sensor parity relations were tested and the effect of several design parameters on the performance of these relations is discussed. The detection of actuator failures is also treated. It is shown that in all the cases it is possible to identify the parity relations directly from input-output data. Frequency domain analysis is used to explain the behavior of the parity relations.

Vanschalkwyk, Christiaan Mauritz↗

NASA NTRS2013

Demonstrating the Effect of Particle Impact Dampers on the Random Vibration Response and Fatigue Life of Printed Wiring Assemblies

In a recent experimental study, small Particle Impact Dampers (PID) were bonded directly to the surface of printed circuit board (PCB) or printed wiring assemblies (PWA), reducing the random vibration response and increasing the fatigue life. This study provides data verifying practicality of this approach. The measured peak strain and acceleration response of the fundamental out of plane bending mode was significantly attenuated by adding a PID device. Attenuation of this mode is most relevant to the fatigue life of a PWA because the local relative displacements between the board and the supported components, which ultimately cause fatigue failures of the electrical leads of the board-mounted components are dominated by this mode. Applying PID damping at the board-level of assembly provides mitigation with a very small mass impact, especially as compared to isolation at an avionics box or shelf level of assembly. When compared with other mitigation techniques at the PWA level (board thickness, stiffeners, constrained layer damping), a compact PID device has the additional advantage of not needing to be an integral part of the design. A PID can simply be bonded to heritage or commercial off the shelf (COTS) hardware to facilitate its use in environments beyond which it was originally qualified. Finite element analysis and test results show that the beneficial effect is not localized and that the attenuation is not due to the simple addition of mass. No significant, detrimental reduction in frequency was observed. Side-by-side life testing of damped and un-damped boards at two different thicknesses (0.070" and 0.090") has shown that the addition of a PID was much more significant to the fatigue life than increasing the thickness. High speed video, accelerometer, and strain measurements have been collected to correlate with analytical results.

Knight, Brent↗

NASA NTRS2016

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

failure analyses↗

DOE OSTI2024

Understanding GPU Memory Corruption at Extreme Scale: The Summit Case Study

GPU memory corruption and in particular double-bit errors (DBEs) remain one of the least understood aspects of HPC system reliability. Albeit rare, their occurrences always lead to job termination and can potentially cost thousands of node-hours, either from wasted computations or as the overhead from regular checkpointing needed to minimize the losses. As supercomputers and their components simultaneously grow in scale, density, failure rates, and environmental footprint, the efficiency of HPC operations becomes both an imperative and a challenge. We examine DBEs using system telemetry data and logs collected from the Summit supercomputer, equipped with 27,648 Tesla V100 GPUs with 2nd-generation high-bandwidth memory (HBM2). Using exploratory data analysis and statistical learning, we extract several insights about memory reliability in such GPUs. We find that GPUs with prior DBE occurrences are prone to experience them again due to otherwise harmless factors, correlate this phenomenon with GPU placement, and suggest manufacturing variability as a factor. On the general population of GPUs, we link DBEs to short- and long-term high power consumption modes while finding no significant correlation with higher temperatures. We also show that the workload type can be a factor in memory’s propensity to corruption.

Oles, Vlad↗

NASA NTRS1992

Experimental validation of clock synchronization algorithms

The objective of this work is to validate mathematically derived clock synchronization theories and their associated algorithms through experiment. Two theories are considered, the Interactive Convergence Clock Synchronization Algorithm and the Midpoint Algorithm. Special clock circuitry was designed and built so that several operating conditions and failure modes (including malicious failures) could be tested. Both theories are shown to predict conservative upper bounds (i.e., measured values of clock skew were always less than the theory prediction). Insight gained during experimentation led to alternative derivations of the theories. These new theories accurately predict the behavior of the clock system. It is found that a 100 percent penalty is paid to tolerate worst-case failures. It is also shown that under optimal conditions (with minimum error and no failures) the clock skew can be as much as three clock ticks. Clock skew grows to six clock ticks when failures are present. Finally, it is concluded that one cannot rely solely on test procedures or theoretical analysis to predict worst-case conditions.

Palumbo, Daniel L.↗

NASA NTRS1997

Response of Composite Panels with Stiffness Gradients Due to Stiffener Terminations and Cutouts

The results of an analytical and experimental study of stiffened graphite-epoxy compression panels with terminated stiffeners are presented. The local stress gradients at the stiffener termination location are determined by finite element analysis. Three stiffener termination concepts are evaluated by analysis to determine the stiffener and skin laminate parameters that affect the panel response and failure. The effects of changing local skin laminate definitions, skin reinforcement details, and stiffener termination details on local stress gradients and load-path eccentricities are discussed. Analytical and test results are presented for panels with one terminated stiffener and for panels with one terminated stiffener and two unterminated stiffeners. The effects of a cutout in the skin of a panel with a terminated stiffener is also evaluated to determine the interaction between the stress gradients in the panel due to the cutout and those due to the terminated stiffener. The results of the study indicate that the critical failure modes of the panels initiate at the skin-stiffener interface near the end of the terminated stiffener.

Ambur, Damodar R.↗

DOE OSTI2025

UV + Damp Heat Induced Power Losses in Fielded Utility N-Type Si PV Modules

A recent trend in commercial PV modules is a transition to n-type silicon cells, including passivated emitter rear totally diffused (n-PERT), tunnel oxide passivated contact (TOPCon), and silicon heterojunction (SHJ). There is evidence via lab studies that some of these cells are more susceptible to UV induced degradation (UVID), yet there is a lack of confirmation that such degradation occurs in the field. Current IEC standards designed to screen for early module failures require only minimal UV exposure (15 kWh/m2 280-400 nm, ~2-3 months equivalent outdoor exposure). Here, we investigate fielded n-PERT silicon (Si) modules from a commercial utility that show power losses of ~2%/year. We present a comprehensive picture of the physics and chemistry of degradation supported by both module and cell electronic characterization (EL, PL, IV, EQE, and DLIT) and materials-level morphological and chemical analysis (SEM, EDS, XPS, FTIR, and HPLC). All sampled site modules show short circuit current (Isc) and open circuit voltage (Voc) losses when compared to unfielded spares, with the most severely degraded also having losses in fill factor (FF). We identify two different degradation modes contributing to overall power loss: (1) external quantum efficiency (EQE) measurements show losses in the blue range of the spectra, indicative of cell surface recombination losses, and (2) variations in high series resistance (Rs) at the cell level that are correlated with compositional differences in cell metallization. Using unfielded spares, we were able to reproduce Voc, Isc, and EQE losses via a minimum UV stress of 67.5 kWh/m2 (280-400 nm), 4.5x the exposure currently required in IEC 61215-2 (MQT 10). Degradation continued with additional UV dosage equivalent to the fielded modules (405 kWh/m2 total), with power loss leveling out at an average of 6.1%. Subsequent 1000 h of 85% RH/85degrees C damp heat testing showed that cells exposed to UV underwent additional severe series resistance degradation, even those without the susceptible paste composition seen in the field, whereas non-UV exposed cells saw little change. We attribute this to higher concentrations of acetic acid generated on the UV exposed area of the module, leading to degradation of the gridline/cell interface and high Rs. This study is unique in that it reproduces field observed utility scale UVID with an accelerated test and supports the need for standards development for longer UV exposure combined with other stress factors to catch materials interplay within a module package.

14 SOLAR ENERGY↗