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At least 127 records · Page 7

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NASA NTRS2002

Failure Mode Identification Through Clustering Analysis

Research has shown that nearly 80% of the costs and problems are created in product development and that cost and quality are essentially designed into products in the conceptual stage. Currently, failure identification procedures (such as FMEA (Failure Modes and Effects Analysis), FMECA (Failure Modes, Effects and Criticality Analysis) and FTA (Fault Tree Analysis)) and design of experiments are being used for quality control and for the detection of potential failure modes during the detail design stage or post-product launch. Though all of these methods have their own advantages, they do not give information as to what are the predominant failures that a designer should focus on while designing a product. This work uses a functional approach to identify failure modes, which hypothesizes that similarities exist between different failure modes based on the functionality of the product/component. In this paper, a statistical clustering procedure is proposed to retrieve information on the set of predominant failures that a function experiences. The various stages of the methodology are illustrated using a hypothetical design example.

Arunajadai, Srikesh G.↗

NASA NTRS2001

Analytical Method to Evaluate Failure Potential During High-Risk Component Development

Communicating failure mode information during design and manufacturing is a crucial task for failure prevention. Most processes use Failure Modes and Effects types of analyses, as well as prior knowledge and experience, to determine the potential modes of failures a product might encounter during its lifetime. When new products are being considered and designed, this knowledge and information is expanded upon to help designers extrapolate based on their similarity with existing products and the potential design tradeoffs. This paper makes use of similarities and tradeoffs that exist between different failure modes based on the functionality of each component/product. In this light, a function-failure method is developed to help the design of new products with solutions for functions that eliminate or reduce the potential of a failure mode. The method is applied to a simplified rotating machinery example in this paper, and is proposed as a means to account for helicopter failure modes during design and production, addressing stringent safety and performance requirements for NASA applications.

Tumer, Irem Y.↗

NASA NTRS2006

Progressive Failure Analysis of Composite Stiffened Panels

A new progressive failure analysis capability for stiffened composite panels has been developed based on the combination of the HyperSizer stiffened panel design/analysis/optimization software with the Micromechanics Analysis Code with Generalized Method of Cells (MAC/GMC). MAC/GMC discretizes a composite material s microstructure into a number of subvolumes and solves for the stress and strain state in each while providing the homogenized composite properties as well. As a result, local failure criteria may be employed to predict local subvolume failure and the effects of these local failures on the overall composite response. When combined with HyperSizer, MAC/GMC is employed to represent the ply level composite material response within the laminates that constitute a stiffened panel. The effects of local subvolume failures can then be tracked as loading on the stiffened panel progresses. Sample progressive failure results are presented at both the composite laminate and the composite stiffened panel levels. Deformation and failure model predictions are compared with experimental data from the World Wide Failure Exercise for AS4/3501-6 graphite/epoxy laminates.

Bednarcyk, Brett A.↗

NASA NTRS2018

An Abrupt Transition to an Intergranular Failure Mode in the Near-Threshold FCG Regime in Ni-Based Superalloys

Cyclic near-threshold FCG behavior of two disk superalloys was evaluated, and was shown to exhibit an unexpected sudden failure mode transition from a mostly transgranular failure mode at higher stress intensities to an almost completely intergranular failure mode in the threshold regime. The change in failure modes was associated with a crossover effect in which the conditions that produced higher FCG rates in the Paris regime resulted in lower FCG rates and increased ΔKth values in the threshold region. High resolution scanning and transmission electron microscopy was used to carefully characterize the crack tips at these near-threshold conditions. Formation of stable Al-oxide followed by Cr and Ti oxides was found to occur at the crack tip prior to formation of unstable oxides. To contrast with the threshold failure mode regime, a quantitative assessment of the role that the intergranular failure mode has on cyclic FCG behavior in the Paris regime was also performed. It was demonstrated that the even a very limited intergranular failure content dominates the FCG response under mixed mode failure conditions.

fatigue crack growth↗

NASA NTRS2018

A Prognostic Launch Vehicle Probability of Failure Assessment Methodology for Conceptual Systems Predicated on Human Causal Factors

Create an improved method to calculate reliability of a conceptual launch vehicle system prior to fabrication by using historic data of actual root causes of failures. While failures have unique "proximate causes", there are typically a finite amount of common "root causes". Heretofore launch vehicle reliability evaluation typically hardware-centric statistical analyses, while most root causes of failures are been shown to be human-centric. A method based on human-centric root causes can be used to quantify reliability assessments and focus proposed actions to mitigate problems. Existing methods have been optimistic in their projections of launch vehicle reliability compared to actuals. Hypothesis: reliability of a conceptual launch vehicle can be more accurately evaluated based on a rational, probabilistic approach using past failure assessment teams' findings predicated on human-centric causes."Human Reliability Analysis Methods Selection Guidance for NASA"Chandler F.T., et al., NASA HQ/OSMA study group, July 2006. Outside HRA experts from academia, other federal labs, and the private sector. 50 system reliability methods considered, fourteen selected for further study, four finally selected as best suited for human spaceflight. Probabilistic Risk Analysis (PRA) + Human Reliability Analysis (HRA) enabled incorporating effects and probabilities of human errors. While four down-selected methods deemed appropriate for failure assessment, it did not appear that these methods could be concisely applied to perform major system-wide assessment of probability of failure of a conceptual design without becoming unwieldy."Engineering a Safer World", Detailed, comprehensive study external to NASA Leveson N. G., MIT, 2011.Systems-Theoretic Accident Model and Processes (STAMP). All-encompassing accident model based on systems theory analyzed accidents after they occurred and created approaches to prevent occurrence in developing systems not focused on failure prevention per se, but rather reducing hazards by influencing human behavior through use of constraints, hierarchical control structures, and process models to improve system safetySystem Theoretic Process Analysis (STPA) addresses predictive part of problem (a "hazard analysis"). Includes all causal factors identified in STAMP: "...design errors, software flaws, component interaction accidents, cognitively complex human decision-making errors, and social organizational and management factors contributing to accidents" can guide design process rather than require it to exist before-hand did not appear capable of concise application for system-wide assessment of probability of failure of a conceptual design without becoming unwieldy.

Williams, Craig H.↗

NASA NTRS2018

An Abrupt Transition to an Intergranular Failure Mode in the Near-Threshold Fatigue Crack Growth Regime in Ni-Based Superalloys

Cyclic near-threshold fatigue crack growth (FCG) behavior of two disk superalloys was evaluated and was shown to exhibit an unexpected sudden failure mode transition from a mostly transgranular failure mode at higher stress intensity factor ranges to an almost completely intergranular failure mode in the threshold regime. The change in failure modes was associated with a crossover of FCG resistance curves in which the conditions that produced higher FCG rates in the Paris regime resulted in lower FCG rates and increased Kth values in the threshold region. High-resolution scanning and transmission electron microscopy were used to carefully characterize the crack tips at these near-threshold conditions. Formation of stable Al-oxide followed by Cr-oxide and Ti-oxides was found to occur at the crack tip prior to formation of unstable oxides. To contrast with the threshold failure mode regime, a quantitative assessment of the role that the intergranular failure mode has on cyclic FCG behavior in the Paris regime was also performed. It was demonstrated that even a very limited intergranular failure content dominates the FCG response under mixed mode failure conditions.

Telesman, J.↗

NASA NTRSDate not supplied

More Data Needed for Failure Rate Estimation, Validation, and Uncertainty Reduction

The currently planned schedule for advanced Environmental Control and Life Support System (ECLSS) development and test activities to support human exploration missions is unlikely to generate sufficient data to enable statistically-supportable, precise Orbital Replacement Unit (ORU) failure rate estimates to meet existing crew safety expectations. Accurate and precise failure rate estimates are critical for missions beyond Low Earth Orbit (LEO) because current risk mitigation approaches –namely regular resupply and rapid abort capabilities –will not be available. Safe operations will depend on mission planners’ ability to accurately forecast spares demand and efficiently provide the necessary resources. However, even after more than a decade of International Space Station (ISS) ECLSS operations, a significant amount of uncertainty remains in failure rate estimates. Uncertain or inaccurate failure rates result in increased risk and spares mass. A Bayesian estimation approach, such as the one currently implemented by the ISS Program, can reduce uncertainty by incorporating engineering judgement into failure rate estimates. However, experience on the ISS and with other complex systems shows that these prior failure rate estimates are often inaccurate. In addition, prior estimates are typically point values; some level of uncertainty must be added to convert these into probability distributions for Bayesian updating, and there are several potential methods for doing so. Due to the low rate of data collection, any inaccuracy in theseprior estimates currently hasa strong influence on the end result. This paper examines the challenges associated with failure rate estimation, validation, and uncertainty reduction in the context of ECLSS development for beyond-LEO missions. A variety of techniques for generating and updating Bayesian priors are discussed and evaluated using both real-world and simulated data. Potential solutions for improving failure rate estimation, including testing additional units, are analyzed and discussed, and a set of recommendations are provided for next-generation system development activities.

Reliability↗

NASA NTRSDate not supplied

More Data Needed for Failure Rate Estimation, Validation, and Uncertainty Reduction

Reliability↗

NASA NTRS2020

Continued Discussion of Failure Mode Modeling and Overall Component Reliability: Are the Data Missing or Censored?

This paper is the continuation of a paper presented at the 13th Probabilistic Safety Assessment and Management Conference, in which a methodology of modeling failure modes of complex components was presented; see Paulos and Smith (2016). This methodology is not particularly helpful in the space industry where there is a lack of failure data, but is more helpful in industries that see a lot of component repairs and improvements, such as in the aircraft or automotive industries. The previous paper demonstrated how the typical approach of treating failure modes as being exponential in nature may yield optimistic predictions when estimating how improvements to components will perform in the future. It is more accurate to model the failure modes as a race in time; unfortunately, this does not give a closed-form solution. This paper uses simulation to solve for the model of the world, and the results compared to the standard methodology of treating the failure modes as being exponential random failures. The standard method is shown to have optimistic predictions, which will lead to prediction errors when failure modes are removed or “fixed.” The failure mode methodology presented in the first paper treated the data as being censored when the test stopped. In this paper, we will compare the results from treating the data as both censored and missing.

Smith, Curtis↗

NASA NTRS2024

Coronado National Memorial Disasters: Investigating Geohazards & Slope Failure Susceptibility Utilizing NASA Earth Observations

The Coronado National Memorial (CORO), located in Hereford, Arizona, is situated along the United States' southern border, featuring recently established but still incomplete border barrier roads. This landscape is inherently prone to geohazards, and debris flow due to the steep mountainous topography, complex terrain, monsoonal rains, and freeze/thaw action - and the new infrastructure has exhibited these processes in the form of rockfall, embankment failure, and debris flow. NASA DEVELOP partnered with CORO to conduct a feasibility assessment of Earth observations for identification of geohazards and slope failure susceptibility. Leveraging Earth observations (United States Geological Survey 3D Elevation Program Digital Elevation Model and a locally obtained Light Detection And Ranging-derived Digital Elevation Model) from 2019 to 2023, and geospatial datasets starting from 2008, the study was able to provide tools to determine the focus for damage mitigation, identify areas most susceptible to slope failures, and prioritize at risk assets through three products: change detection maps, slope failure susceptibility maps, and a slope failure prioritization model. With an emphasis on monitoring high-risk areas and prioritizing mitigation efforts, the project addresses a critical gap in remediation strategies and aims to enhance preservation and safety of the region. Results of this study found that (i) the most identifiable areas of change were the road cuts and debris directly adjacent to the roads created for border construction, (ii) areas of highest slope failure susceptibility are located in mountainous areas with erosive geology, and (iii) roads resulting from border construction have approximately twice the risk of slope failure as roads created by the national park service.

Geohazard↗

NASA NTRS2005

Failure Assessment

Three questions to which software developers want accurate, precise answers are "How can the software system fail?", "mat bad things will happen if the software fails?t', and "How many failures will the software experience?". Numerous techniques have been devised to answer these questions; three of the best known are: 1) Software Fault Tree Analysis (SFTA) 2) Software Failure Modes, Effects, and Criticality Analysis (SFMECA 3) Software Fault/Failure Modeling. SFTA and SFMECA have been successfully used to analyze the flight software for a number of robotic planetary exploration missions, including Galileo, Cassini, and Deep Space 1. Given the increasing interest in reusing software components from mission to mission, one of us has developed techniques for reusing the corresponding portions of the SFTA and SFMECA, reducing the effort required to conduct these analyses. SFTA has also been shown to be effective in analyzing the security aspects of software systems; intrusion mechanisms and effects can easily be modeled using these techniques. The Bi- Directional Safety Analysis (BDSA) method combines a forward search (similar to SFMECA) from potential failure modes to their effects, with a backward search (similar to SFTA) from feasible hazards to the contributing causes of each hazard. BDSA offers an efficient way to identify latent failures. Recent work has extended BDSA to product-line applications such as flight-instrumentation displays and developed tool support for the reuse of the failure-analysis artifacts within a product line. BDSA has also been streamlined to support those projects having tight cost and/or schedule constraints for their failure analysis efforts. We discuss lessons learned from practice, describe available tools, and identi@ some future directions for the topic. A substantial amount of research has been devoted to estimating the number of failures that a software system will experience during test and operations, as well as the number of faults that have been inserted into that system during its development. One of us has found that the amount of structural change to a system during its development is strongly related to the number of faults inserted into it. Using techniques requiring no additional effort on the part of the development organization, the required measurements of structural evolution can be easily obtained from a development effort's configuration management system and readily transformed into an estimate of fault content. So far, structure-fault relationships have been identified for source code; current work seeks to examine artifacts available earlier in the lifecycle to determine if similar relationships between structure and fault content can be found. In particular, relationships between requirements change requests and the number of faults inserted into the implemented system would provide a significant improvement in our ability to control software quality during the early development phases.

fault tree↗

DOE OSTI2026

Testing Recommendations for Thermal Failure Analysis

Minimizing ranges of uncertainty in failure QOIs is vital for making informed engineering decisions. To improve our decision-making ability, it is necessary to have a QOI representation that captures more complex failure modes. Capturing the physics of complex time-dependent temperature failure in explicit detail can be computationally and experimentally expensive. To avoid this blooming of complication and costs, an empirical QOI component-level failure/damage model may be sufficient to help identify component-level failure. In this context, failure and damage are abstractions of more complicated processes that lead to the cessation of normal operating behavior, not a representation of mechanical damage, such as void formation. Such a model requires minimal increases in computational cost and experimental burden. The proposed QOI serves as an indicator that something has likely failed, similar to the previous critical failure temperatures or pressures. This QOI will not replace any existing failure QOIs. It will be calculated alongside them, allowing for preservation of legacy style QOI measurements with new context from the new QOI.

36 MATERIALS SCIENCE↗

NASA NTRS1988

An Investigation of the Ability to Recover from Transients Following Failures for Single-Pilot Rotorcraft

A moving-base simulation was conducted to investigate a pilot's ability to recover from transients following single-axis hard-over failures of the flight-control system. The investigation was performed in conjunction with a host simulation that examined the influence of control modes on a single pilot's ability to perform various mission elements under high-workload conditions. The NASA Ames large-amplitude-motion Vertical Motion Simulator (VMS) was utilized, and the experimental variables were the failure axis, the severity of the failure, and the airspeed at which the failure occurred. Other factors, such as pilot workload and terrain and obstacle proximity at the time of failure, were kept as constant as possible within the framework of the host simulation task scenarios. No explicit failure warnings were presented to the pilot. Data from the experiment are shown, and pilot ratings are compared with the proposed handling-qualities requirements for military rotorcraft. Results indicate that the current proposed failure transient requirements may need revision.

Mansur, M. Hossein↗

NASA NTRS1991

Intelligent failure-tolerant control

An overview of failure-tolerant control is presented, beginning with robust control, progressing through parallel and analytical redundancy, and ending with rule-based systems and artificial neural networks. By design or implementation, failure-tolerant control systems are 'intelligent' systems. All failure-tolerant systems require some degrees of robustness to protect against catastrophic failure; failure tolerance often can be improved by adaptivity in decision-making and control, as well as by redundancy in measurement and actuation. Reliability, maintainability, and survivability can be enhanced by failure tolerance, although each objective poses different goals for control system design. Artificial intelligence concepts are helpful for integrating and codifying failure-tolerant control systems, not as alternatives but as adjuncts to conventional design methods.

Stengel, Robert F.↗

NASA NTRS1992

Postbuckling failure of composite plates with central holes

The postbuckling failure of square composite plates with central holes is analyzed numerically and experimentally. The particular plates studies have stacking sequences of: (+ and - 45/0/90)(sub 2S); (+ and - 45/0(sub 2))(sub 2S); (+ and - 45/0(sub 6))(sub S); and (+ and - 45)(sub 4S). A simple plate geometry, one with a hole diameter to plate width ratio of 0.3 is compared. Failure load, failure mode, and failure location are predicted numerically by using the finite element method. Predictions are compared with experimental results. In numerical failure analysis the interlaminar shear stresses, as well as the inplane stresses are taken into account. An issue addressed in this study is the possible mode shape change of the plate during loading. It is predicted that the first three laminates fail due to excessive stresses in the fiber direction, and more importantly, that the load level is independent of whether the laminate is deformed in a one-half or two-half wave configuration. It is predicted that the fourth laminate fails due to excessive inplane shear stress. Interlaminar shear failure is not predicted for any laminates. For the first two laminates the experimental observations correlated well with the predictions. Experimentally, the third laminate failed along the side support due to interlaminar shear strength S(sub 23). The fourth experimental laminate failed due to inplane shear in the location predicted, however material softening resulted in a different failure load from predictions.

Lee, H. H.↗

NASA NTRS1993

Failure environment analysis tool applications

Understanding risks and avoiding failure are daily concerns for the women and men of NASA. Although NASA's mission propels us to push the limits of technology, and though the risks are considerable, the NASA community has instilled within, the determination to preserve the integrity of the systems upon which our mission and, our employees lives and well-being depend. One of the ways this is being done is by expanding and improving the tools used to perform risk assessment. The Failure Environment Analysis Tool (FEAT) was developed to help engineers and analysts more thoroughly and reliably conduct risk assessment and failure analysis. FEAT accomplishes this by providing answers to questions regarding what might have caused a particular failure; or, conversely, what effect the occurrence of a failure might have on an entire system. Additionally, FEAT can determine what common causes could have resulted in other combinations of failures. FEAT will even help determine the vulnerability of a system to failures, in light of reduced capability. FEAT also is useful in training personnel who must develop an understanding of particular systems. FEAT facilitates training on system behavior, by providing an automated environment in which to conduct 'what-if' evaluation. These types of analyses make FEAT a valuable tool for engineers and operations personnel in the design, analysis, and operation of NASA space systems.

Pack, Ginger L.↗

NASA NTRS1994

Failure environment analysis tool applications

Understanding risks and avoiding failure are daily concerns for the women and men of NASA. Although NASA's mission propels us to push the limits of technology, and though the risks are considerable, the NASA community has instilled within it, the determination to preserve the integrity of the systems upon which our mission and, our employees lives and well-being depend. One of the ways this is being done is by expanding and improving the tools used to perform risk assessment. The Failure Environment Analysis Tool (FEAT) was developed to help engineers and analysts more thoroughly and reliably conduct risk assessment and failure analysis. FEAT accomplishes this by providing answers to questions regarding what might have caused a particular failure; or, conversely, what effect the occurrence of a failure might have on an entire system. Additionally, FEAT can determine what common causes could have resulted in other combinations of failures. FEAT will even help determine the vulnerability of a system to failures, in light of reduced capability. FEAT also is useful in training personnel who must develop an understanding of particular systems. FEAT facilitates training on system behavior, by providing an automated environment in which to conduct 'what-if' evaluation. These types of analyses make FEAT a valuable tool for engineers and operations personnel in the design, analysis, and operation of NASA space systems.

Pack, Ginger L.↗

NASA NTRS1999

Electrostatic Discharge (ESD) Failures in Thin Film Resistors

Field failures of nichrome thin film resistors have been investigated recently for several pieces of space flight hardware. These failures have involved resistance shifts ranging from a few percent to complete open circuits. Failure analysis and duplication of these failures have revealed that the failures were caused by electrostatic discharge. The failure characteristics and the circuit conditions necessary for failure have been studied for several types of thin film resistors including nichrome and tantalum nitride resistive elements. The effects of latent damage and resistive pattern design will also be discussed.

Hull, Scott M.↗