Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “failure”

Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 1,621 records · Page 90
All sourcesNASA NTRSDOE OSTI
DOE OSTI2016

Buckling failure of square ice-nanotube arrays constrained in graphene nanocapillaries

Graphene confinement provides a new physical and mechanical environment with ultrahigh van der Waals pressure, resulting in new quasi-two-dimensional phases of few-layer ice. Polymorphic transition can occur in bilayer constrained water/ice system. Here, we perform a comprehensive study of the phase transition of AA-stacked bilayer water constrained within a graphene nanocapillary. The compression-limit and superheating-limit (phase) diagrams are obtained, based on the extensive molecular-dynamics simulations at numerous thermodynamic states. Liquid-to-solid, solid-to-solid, and solid-to-liquid-to-solid phase transitions are observed in the compression and superheating of bilayer water. Interestingly, there is a temperature threshold (∼275 K) in the compression-limit diagram, which indicates that the first-order and continuous-like phase transitions of bilayer water depend on the temperature. Two obviously different physical processes, compression and superheating, display similar structural evolution; that is, square ice-nanotube arrays (BL-VHDI) will bend first and then transform into bilayer triangular AA stacking ice (BL-AAI). The superheating limit of BL-VHDI exhibits local maxima, while that of BL-AAI increases monotonically. More importantly, from a mechanics point of view, we propose a novel mechanism of the transformation from BL-VHDI to BL-AAI, both for the compression and superheating limits. This structural transformation can be regarded as the “buckling failure” of the square-ice-nanotube columns, which is dominated by the lateral pressure.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2023

Effect of surface defects on damage and failure of dynamically driven cylindrical shells

Here, in this work, expanding cylinder experiments are performed using a gas gun on the aluminum 6061 alloy to understand the dynamic deformation and failure behavior of this material in the presence of surface defects in the form of scratches. The experiments are then modeled with the modified Tepla (for tensile plasticity) model, which is equipped with the damage yield function of Gurson [“Continuum theory of ductile rupture by void nucleation and growth: Part I—Yield criteria and flow rules for porous ductile media,” (1977)] and Tvergaard and Needleman [Acta Metall. 32(1), 157–169 (1984)], over-stress viscosity [F. Addessio and J. Johnson, J. Appl. Phys. 74(3), 1640–1648 (1993)], and the underlying viscoplastic model of Preston et al. [J. Appl. Phys. 93(1), 211–220 (2003)] (Preston–Tonks–Wallace model) for the dense material. The Tepla model parameters were calibrated using the Bayesian approach against experimentally measured free-surface velocity data obtained from plate impact experiments on the aluminum 6061 alloy. The evolution of radial expansion and shapes of the deformed cylinder from the simulations on a pristine cylinder wall and a cylinder wall with a longitudinal surface defect shows excellent agreement with the corresponding experimental results. Finally, the role of surface defect size and cylinder wall geometry on the dynamic strength of the cylinder wall was also investigated through a series of simulations.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2020

Dark Lock-in Thermography Identifies Solder Bond Failure as the Root Cause of Series Resistance Increase in Fielded Solar Modules

Correlating the electrical performance of photovoltaic modules to the spatially resolved photoluminescence, electroluminescence, and dark lock-in thermography (DLIT) images is an important long-term goal for developing solar cell technology. These images offer highly sophisticated and detailed information about the spatial distribution and (if imaged at successive time intervals) temporal degradation of local series and shunt resistances. There have been extensive studies to correlate these imaging techniques to local characteristics at the cell level. However, it has been difficult to extract and quantify module-level information from the techniques. In this study, we interpret module current-voltage (I-V) measurements along with corresponding DLIT images within a module-scale simulation framework, demonstrating that series resistance degradation of the module I-V characteristics, in this case, can be attributed to solder bond failures. Our simulations highlight how current crowding associated with a failed solder joint (or a section of the solder pad) translates to the characteristic point-like (asymmetric doublet) heating pattern in neighboring solder joints (or the neighboring regions of the solder pad). Overall, the correlation between series resistance and solder joint degradation could inform expedited diagnosis of field degradation of solar modules.

42 ENGINEERING↗
DOE OSTI2018

A Comprehensive Review toward the State-of-the-Art in Failure and Lifetime Predictions of Power Electronic Devices

This paper discusses various types of failure mechanisms, precursor parameters, and accelerated aging- based procedures to estimate the remaining life of power electronic devices. Special attention has been given to summarize the different techniques typically used for measuring the junction temperature, because it plays a vital role during accelerated aging and condition monitoring. We reviewed more than 250 papers, and the references list 139 of them in order to explain and address the advantages and disadvantages of various techniques towards the reliability prognosis. Thus, this paper can be considered as an expedient reference to conduct future research on lifetime prediction of existing power electronic devices.

42 ENGINEERING↗
DOE OSTI2013

Evaluating IMRT and VMAT dose accuracy: Practical examples of failure to detect systematic errors when applying a commonly used metric and action levels

Purpose: This study (1) examines a variety of real-world cases where systematic errors were not detected by widely accepted methods for IMRT/VMAT dosimetric accuracy evaluation, and (2) drills-down to identify failure modes and their corresponding means for detection, diagnosis, and mitigation. The primary goal of detailing these case studies is to explore different, more sensitive methods and metrics that could be used more effectively for evaluating accuracy of dose algorithms, delivery systems, and QA devices.Methods: The authors present seven real-world case studies representing a variety of combinations of the treatment planning system (TPS), linac, delivery modality, and systematic error type. These case studies are typical to what might be used as part of an IMRT or VMAT commissioning test suite, varying in complexity. Each case study is analyzed according to TG-119 instructions for gamma passing rates and action levels for per-beam and/or composite plan dosimetric QA. Then, each case study is analyzed in-depth with advanced diagnostic methods (dose profile examination, EPID-based measurements, dose difference pattern analysis, 3D measurement-guided dose reconstruction, and dose grid inspection) and more sensitive metrics (2% local normalization/2 mm DTA and estimated DVH comparisons).Results: For these case studies, the conventional 3%/3 mm gamma passing rates exceeded 99% for IMRT per-beam analyses and ranged from 93.9% to 100% for composite plan dose analysis, well above the TG-119 action levels of 90% and 88%, respectively. However, all cases had systematic errors that were detected only by using advanced diagnostic techniques and more sensitive metrics. The systematic errors caused variable but noteworthy impact, including estimated target dose coverage loss of up to 5.5% and local dose deviations up to 31.5%. Types of errors included TPS model settings, algorithm limitations, and modeling and alignment of QA phantoms in the TPS. Most of the errors were correctable after detection and diagnosis, and the uncorrectable errors provided useful information about system limitations, which is another key element of system commissioning.Conclusions: Many forms of relevant systematic errors can go undetected when the currently prevalent metrics for IMRT/VMAT commissioning are used. If alternative methods and metrics are used instead of (or in addition to) the conventional metrics, these errors are more likely to be detected, and only once they are detected can they be properly diagnosed and rooted out of the system. Removing systematic errors should be a goal not only of commissioning by the end users but also product validation by the manufacturers. For any systematic errors that cannot be removed, detecting and quantifying them is important as it will help the physicist understand the limits of the system and work with the manufacturer on improvements. In summary, IMRT and VMAT commissioning, along with product validation, would benefit from the retirement of the 3%/3 mm passing rates as a primary metric of performance, and the adoption instead of tighter tolerances, more diligent diagnostics, and more thorough analysis.

61 RADIATION PROTECTION AND DOSIMETRY↗
DOE OSTI2014

SU-E-T-458: Determining Threshold-Of-Failure for Dead Pixel Rows in EPID-Based Dosimetry

Purpose: A pixel correction map is applied to all EPID-based applications on the TrueBeam (Varian Medical Systems, Palo Alto, CA). When dead pixels are detected, an interpolative smoothing algorithm is applied using neighboring-pixel information to supplement missing-pixel information. The vendor suggests that when the number of dead pixels exceeds 70,000, the panel should be replaced. It is common for entire detector rows to be dead, as well as their neighboring rows. Approximately 70 rows can be dead before the panel reaches this threshold. This study determines the number of neighboring dead-pixel rows that would create a large enough deviation in measured fluence to cause failures in portal dosimetry (PD). Methods: Four clinical two-arc VMAT plans were generated using Eclipse's AXB algorithm and PD plans were created using the PDIP algorithm. These plans were chosen to represent those commonly encountered in the clinic: prostate, lung, abdomen, and neck treatments. During each iteration of this study, an increasing number of dead-pixel rows are artificially applied to the correction map and a fluence QA is performed using the EPID (corrected with this map). To provide a worst-case-scenario, the dead-pixel rows are chosen so that they present artifacts in the highfluence region of the field. Results: For all eight arc-fields deemed acceptable via a 3%/3mm gamma analysis (pass rate greater than 99%), VMAT QA yielded identical results with a 5 pixel-width dead zone. When 10 dead lines were present, half of the fields had pass rates below the 99% pass rate. With increasing dead rows, the pass rates were reduced substantially. Conclusion: While the vendor still suggests to request service at the point where 70,000 dead rows are measured (as recommended by the vendor), the authors suggest that service should be requested when there are greater than 5 consecutive dead rows.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2015

SU-E-T-119: Analysis the Efficacy of Different Radiotherapy Methods and Failure Mode in No-Metastasis Esophageal Squamous Cell Carcinoma

Purpose: To evaluate the curative effect of radio (chemo) therapy and mode of treatment failure in no-metastasis and lesion length ≤ 5.0cm esophageal squamous cell carcinoma (ESCC). Methods: There were 158 eligible patients were retrospectively analyzed, to analysis the curative effect of radio (chemo) therapy, prognosis factors, toxicity and prognostic index model. Results: To all patients the 1, 3, 5 overall survival rate were 83.54%, 52.53%, 32.58%, the local recurrence rate were 15.08%, 33.60% and 38.14%; distant metastasis rate were 10.64%, 25.21% and 36.06%; tumor specific survival rate were 76.64%, 54.07% and 44.51%. Multivariate analysis showed that patients with ECOG grade (χ2=13.945, P=0.000), short-term effect (χ2=19.360, P=0.000) and different radiotherapy methods (χ2=9.866, P=0.002) as the independent prognostic factors. Prognostic index model showed that the survival rate was significantly higher in the lower value of PI group than in the larger value of PI group (χ2=49.19, P=0.0000). In our whole group, there were simple locoregional recurrence (LR) 40 cases (25.3%), simple Distant metastasis (DM) 31 cases (19.6%), LR and DM in 14 cases (8.9%) after treatment. The chi-square test showed that there were no significant difference in the incidence of Elective Nodal Irradiation (ENI )and Involved Field Irradiation (IFI) patients with LR and DM ( χ2=2.363, 2.950, P=0.124, 0.085). Conclusion: Radio (chemo) therapy has a good curative effect in no-metastasis and lesion length ≤ 5.0cm ESCC patients.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2015

SU-E-T-128: Applying Failure Modes and Effects Analysis to a Risk-Based Quality Management for Stereotactic Radiosurgery in Brazil

Purpose: The goal of the present work was to evaluate the process maps for stereotactic radiosurgery (SRS) treatment at three radiotherapy centers in Brazil and apply the FMEA technique to evaluate similarities and differences, if any, of the hazards and risks associated with these processes. Methods: A team, consisting of professionals from different disciplines and involved in the SRS treatment, was formed at each center. Each team was responsible for the development of the process map, and performance of FMEA and FTA. A facilitator knowledgeable in these techniques led the work at each center. The TG100 recommended scales were used for the evaluation of hazard and severity for each step for the major process “treatment planning”. Results: Hazard index given by the Risk Priority Number (RPN) is found to range from 4–270 for various processes and the severity (S) index is found to range from 1–10. The RPN values > 100 and severity value ≥ 7 were chosen to flag safety improvement interventions. Number of steps with RPN ≥100 were found to be 6, 59 and 45 for the three centers. The corresponding values for S ≥ 7 are 24, 21 and 25 respectively. The range of RPN and S values for each center belong to different process steps and failure modes. Conclusion: These results show that interventions to improve safety is different for each center and it is associated with the skill level of the professional team as well as the technology used to provide radiosurgery treatment. The present study will very likely be a model for implementation of risk-based prospective quality management program for SRS treatment in Brazil where currently there are 28 radiotherapy centers performing SRS. A complete FMEA for SRS for these three radiotherapy centers is currently under development.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2020

Accumulation of collagen molecular unfolding is the mechanism of cyclic fatigue damage and failure in collagenous tissues

Overuse injuries to dense collagenous tissues are common, but their etiology is poorly understood. The predominant hypothesis that micro-damage accumulation exceeds the rate of biological repair is missing a mechanistic explanation. Here, we used collagen hybridizing peptides to measure collagen molecular damage during tendon cyclic fatigue loading and computational simulations to identify potential explanations for our findings. Our results revealed that triple-helical collagen denaturation accumulates with increasing cycles of fatigue loading, and damage is correlated with creep strain independent of the cyclic strain rate. Finite-element simulations demonstrated that biphasic fluid flow is a possible fascicle-level mechanism to explain the rate dependence of the number of cycles and time to failure. Molecular dynamics simulations demonstrated that triple-helical unfolding is rate dependent, revealing rate-dependent mechanisms at multiple length scales in the tissue. The accumulation of collagen molecular denaturation during cyclic loading provides a long-sought “micro-damage” mechanism for the development of overuse injuries.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2025

Plasma proteomic biomarkers of physical frailty in heart failure: a propensity score matched discovery-based pilot study

Background: Physical frailty is highly prevalent in heart failure (HF), but we lack an understanding of the underlying pathophysiology. Proteomics evaluation of plasma samples may elucidate potential mechanisms and biomarkers of physical frailty in HF. We aimed to identify plasma proteomic biomarkers that are differentially expressed between physically frail and non physically frail adults with HF. Methods: This was a secondary analysis of a subset of data and plasma samples from a study of frailty among patients with New York Heart Association (NYHA) Functional Classification I-IV HF. Physical frailty was measured using the Frailty Phenotype Criteria. Propensity score matching was used to match pairs of physically frail (n = 20) vs. non-physically frail (n = 20) patients on clinical characteristics. Plasma samples were processed using a sensitive liquid chromatography mass spectrometry platform, utilizing a multiplexed tandem mass tag-labeled quantitative proteomics approach. Differentially expressed proteins were quantified individually using paired t tests with associated log fold change of 0.3 and Fisher’s combined p values. Results: The sample (n = 40) was 62.8±16.9 years old, 58% female, and 55% NYHA Class III/IV. Proteomics analysis revealed 7 proteins differentially expressed using full differential criteria: matrix metalloproteinase-14 was downregulated in frailty, and copine-1, low affinity immunoglobulin gamma Fc region receptor III-A and III-B, probable non-functional immunoglobulin kappa variable 2D-24, glutathione S-transferase Mu 1, and argininosuccinate lyase were upregulated in frailty. Conclusions: Proteomic biomarkers related to the immune system, stress response, and detoxification were differentially expressed between physically frail and non-physically frail adults with HF.

Biomarkers↗
DOE OSTI2013

In-Vessel Coil Material Failure Rate Estimates for ITER Design Use

The ITER international project design teams are working to produce an engineering design for construction of this large tokamak fusion experiment. One of the design issues is ensuring proper control of the fusion plasma. In-vessel magnet coils may be needed for plasma control, especially the control of edge localized modes (ELMs) and plasma vertical stabilization (VS). These coils will be lifetime components that reside inside the ITER vacuum vessel behind the blanket modules. As such, their reliability is an important design issue since access will be time consuming if any type of repair were necessary. The following chapters give the research results and estimates of failure rates for the coil conductor and jacket materials to be used for the in-vessel coils. Copper and CuCrZr conductors, and stainless steel and Inconel jackets are examined.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2018

Metallurgical Failure Analysis of A2 Tool Steel Die Set from High Explosive Pellet Pressing Event

On 2 April 2018, a high explosive violent reaction (HEVR) occurred during routine pressing of a 1-in -diameter cylindrical pellet of PBX 9501 high explosive. Fragments of the die set (die body and stemples) involved in the event were sent to Sigma Division for metallurgical analysis. A handheld x-ray fluorescence alloy tester confirmed the die set material to be A2 tool steel. Light optical microscopy revealed what appear to be pre-existing flaws on the inner diameter of the die body. Scanning Electron Microscopy could neither confirm nor exclude the presence of fatigue cracking in the vicinity of these potential flaws. Energy Dispersive Spectroscopy indicated the presence of a carbon-bearing residue on fracture surfaces; nitrogen-bearing residue was also found. Optical microscopy revealed that the microstructure of the stemple and inner diameter of the die body contained large stringers and non-uniform grain size; this was distinct from the relatively clean and uniform microstructure seen at the outer diameter of the die body, and also other A2 tool steel stock (pedigree unknown and with no known connection to any HE pressing hardware) that was examined for additional comparison. Rockwell hardness testing indicated the material was heat treated properly. Metallographic analysis alone could not positively identify the root cause of the event, but, coupled with accounts provided by the operator and the successful history with the particular lot of HE involved in the event, points to ward mechanical failure of the die set due to pre -existing flaw as the most likely precipitating event. Suggestions for additional analyses and future qualification techniques are discussed.

36 MATERIALS SCIENCE↗
DOE OSTI2019

PBX 9502 Failure Diameter: Addendum

In previous reports, the SURFplus reactive burn model was used to study a propagating detonation wave for PBX 9502 in an unconfined rate stick just above the failure diameter. Simulations showed that the sonic boundary condition at the HE interface leads to a boundary layer. Here we provide additional details on the steady-state flow with emphasis on the boundary layer. This confirms the previous conclusion that within the boundary layer the lead shock, which initiates the hot-spot reaction, is largely supported by transverse energy flow in the reaction zone from the interior towards the boundary. Consequently, the reactive wave along a boundary layer streamline does not correspond to a 1-D detonation wave in the sense of detonation shock dynamics; i.e. , the lead shock which initiates the reaction is not driven by the reaction energy along the streamline.

45 MILITARY TECHNOLOGY, WEAPONRY, AND NATIONAL DEF↗
DOE OSTI2016

Analysis of a Full Scale Blowdown Due to a Mechanical Failure of a Pressure Relief Device in a Natural Gas Vehicle Maintenance Facility

A computational fluid dynamics (CFD) analysis of a natural gas vehicle experiencing a mechanical failure of a pressure relief device on a full CNG cylinder was completed to determine the resulting amount and location of flammable gas. The resulting overpressure if it were to ignite was also calculated. This study completes what is discussed in Ekoto et al. which covers other related leak scenarios. We are not determining whether or not this is a credible release, rather just showing the result of a possible worst case scenario. The Sandia National Laboratories computational tool Netflow was used to calculate the leak velocity and temperature. The in - house CFD code Fuego was used to determine the flow of the leak into the maintenance garage. A maximum flammable mass of 35 kg collected along the roof of the garage. This would result in an overpressure that could do considerable damage if it were to ignite at the time of this maximum volume. It is up to the code committees to decide whet her this would be a credible leak, but if it were, there should be preventions to keep the flammable mass from igniting.

03 NATURAL GAS↗
DOE OSTI2021

Developing Generic Prior Distributions for Common Cause Failure Alpha Factors and Causal Alpha Factors

This report is a revision of the original report, INL/LTD-17-43723. Distribution of the original report was to the Nuclear Regulatory Commission (NRC) only, and the report was not made available to the public. The original report was revised as this report for public distribution. This report presents the latest update of generic prior distributions for common cause failure (CCF) alpha factors, as well as the development of new generic prior distributions for CCF causal alpha factors. The history of CCF treatment and parameter estimations is reviewed. The existing process for developing generic prior distributions is reviewed and used to develop new priors for CCF alpha factors and causal alpha factors. For causal alpha factors, different priors are developed for the five different CCF cause groups: Component (GC), Design (GD), Environment (GE), Human (GH), and Other (GO). These generic prior distributions could be used in the Standardized Plant Analysis Risk (SPAR) models for CCF parameter estimation. The issues and preliminary thoughts regarding prior distribution development are documented. Potential future work is then proposed for improving the process of developing priors.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2021

Feasibility Study of Developing Alternative Common-Cause Failure Model for Event Assessment

This report is a revision of the original report, INL/LTD-14-33376. The original report, which was a limited distribution to the Nuclear Regulatory Commission (NRC) only and not available to the public, was revised as this report for public distribution. The report presents the feasibility study of alternative common-cause failure (CCF) models that could be used for event assessment in the Standardized Plant Analysis Risk (SPAR) models. The current CCF model used by the SPAR models is the alpha factor model. The proposed alternative CCF models are the partial alpha factor model and general dependency model. These alternative CCF models are reviewed and compared to the current alpha factor model, with the partial alpha factor model being identified as the preferred CCF model that could be used for event assessment in the SPAR models.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2021

Prediction of Aluminum to Steel RSW Joint Failure (CRADA 405)

General Motors, LLC has developed a resistance spot welding process to join aluminum sheet to steel for body-in-white manufacturing. Efforts to develop the process for any one joint configuration (combination of alloy and thicknesses) is intensive. To aid in process understanding and eventual reduction in process development efforts, an initiative was created to develop an finite element model of the various destructive test configurations (lap shear, cross-tension, and coach peel) to help predict the failure mode and load displacement curves under tensile testing. This report describes the finite element modeling approach, the means by which local material properties were determined, as well as model validation and refinement efforts.

36 MATERIALS SCIENCE↗