Status of life testing, stress testing, and failure analysis and corrective action
Service life/stress testing, failure analysis and corrective action from technical and cost positions
Bland, W. M., Jr.↗
SEARCH · Engineering Papers
Results for “stress test”
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.
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Contact integrity testing of stress-tested silicon terrestrial solar cells
A test procedure was developed and applied to terrestrial silicon solar cells in order to determine the effect of accelerated environmental and time-temperature aging on metal contact integrity. Quantities of cells of four different manufacturers were given the contact integrity test after being subjected to accelerated stress tests that included forward bias-temperature, thermal cycle and thermal shock, power cycle, and bias-temperature humidity tests at two temperature-humidity levels. Significant effects due to certain stress tests were found for some cell types. It is concluded that cells fabricated using plated nickel/solder metallization showed significantly more serious contact integrity degradation than silver-metallized cells.
Prince, J. L.↗
Cerium migration during PEM fuel cell accelerated stress testing
Cerium is a radical scavenger which improves polymer electrolyte membrane (PEM) fuel cell durability. During operation, however, cerium rapidly migrates in the PEM and into the catalyst layers (CLs). In this work, membrane electrode assemblies (MEAs) were subjected to accelerated stress tests (ASTs) under different humidity conditions. Cerium migration was characterized in the MEAs after ASTs using X-ray fluorescence. During fully humidified operation, water flux from cell inlet to outlet generated in-plane cerium gradients. Conversely, cerium profiles were flat during low humidity operation, where in-plane water flux was negligible, however, migration from the PEM into the CLs was enhanced. Humidity cycling resulted in both in-plane cerium gradients due to water flux during the hydration component of the cycle, and significant migration into the CLs. Fluoride and cerium emissions into effluent cell waters were measured during ASTs and correlated, which signifies that ionomer degradation products serve as possible counter-ions for cerium emissions. Fluoride emission rates were also correlated to final PEM cerium contents, which indicates that PEM degradation and cerium migration are coupled. Lastly, it is proposed that cerium migrates from the PEM due to humidification conditions and degradation, and is subsequently stabilized in the CLs by carbon catalyst supports.
30 DIRECT ENERGY CONVERSION↗
Extended Accelerated Stress Testing (EAST) of Glass/Glass, Glass/Backsheet and Glass/Transparent Backsheet PV Modules: Influence of EVA and POE Encapsulants: Preprint
This paper presents the indoor extended accelerated stress testing (EAST) results of glass/glass (GG), glass/backsheet (GB) and glass/transparent backsheet (GT) modules having identical cells and two different encapsulant types, ethyl-vinyl-acetate (EVA) and polyolefin-elastomer (POE). Six 4-cell modules having the above-mentioned construction combinations were subjected to extended ultraviolet (UV; 600 kWh/m2), damp-heat (DH; 2000 hours) and thermal-cycling (TC; 600 cycles) tests. The post-stress UV fluorescent imaging, electroluminescent imaging, reflectance spectrophotometry and colorimetry results indicated that the grid finger degradation and encapsulant browning are slightly higher in the GG modules compared to the GB modules. The post-stress IV test results indicated, in general, that the GG/EVA modules tend to perform inferior to the GG/POE modules with the EAST evaluation.
EVA↗
Stress-testing of the throat of a rocket's nozzle
Test motor in which high initial pressure can be reduced suddenly provides a method of testing stress effects in the throat of a rockets nozzle. Motors operating pressure is increased to aggravate tensile stresses in a submerged throat. Opposing compression stresses are limited by control of the operating pressure.
Estes, E. G.↗
A robust protonic ceramic fuel cell with a triple conducting oxygen electrode under accelerated stress tests
Accelerated stress test of protonic ceramic fuel cells for evaluating the durability of materials and interfaces.
Zheng, Shuanglin↗
Photovoltaic cable jackets A comparison of representative products using combined-accelerated stress testing
Not Available
Miller, David C. (ORCID:0000000246985277)↗
Overview of Durability Testing and Accelerated Stress Tests [Slides]
Abstract not provided.
Energy Sciences↗
Temperature-Dependency Analysis and Correction Methods of in situ Power-Loss Estimation for Crystalline Silicon Modules Undergoing Potential-Induced Degradation Stress Testing
Explore the source record for details and available documents.
14 SOLAR ENERGY↗
Exercise stress testing
Positive maximum stress tests in the management of coronary patients are discussed. It is believed that coronary angiography would be the ultimate test to predict the future of patients with coronary heart disease. Progression of angina, myocardial infarction, and death due to heart disease were analyzed.
Schuster, B.↗
Development of Combined and Sequential Accelerated Stress Testing for Derisking Photovoltaic Modules
This talk reviews sequential and combined accelerated stress tests of the past decade that have been shown to better replicate degradation mechanisms seen in the field, that single-factor steady-state tests have failed to reproduce. When designing stress tests for PV modules, it is shown, with examples, how it is beneficial to consider representation of the shipping module, the stress factors applied, and how the stress factors are sequenced or combined in the natural environment. Finally, current and future efforts to realize accelerated stress tests based on these concepts are discussed.
14 SOLAR ENERGY↗
Adaptive Stress Testing of Trajectory Predictions in Flight Management Systems
To find failure events and their likelihoods in flight-critical systems, we investigate the use of an advanced black-box stress testing approach called adaptive stress testing. We analyze a trajectory predictor from a developmental commercial flight management system which takes as input a collection of lateral waypoints and en-route environmental conditions. Our aim is to search for failure events relating to inconsistencies in the predicted lateral trajectories. The intention of this work is to find likely failures and report them back to the developers so they can address and potentially resolve shortcomings of the system before deployment. To improve search performance, this work extends the adaptive stress testing formulation to be applied more generally to sequential decision-making problems with episodic reward by collecting the state transitions during the search and evaluating at the end of the simulated rollout. We use a modified Monte Carlo tree search algorithm with progressive widening as our adversarial reinforcement learner. The performance is compared to direct Monte Carlo simulations and to the cross-entropy method as an alternative importance sampling baseline. The goal is to find potential problems otherwise not found by traditional requirements-based testing. Results indicate that our adaptive stress testing approach finds more failures and finds failures with higher likelihood relative to the baseline approaches.
adaptive stress testing↗
Failure Analysis of a New Polyamide-Based Fluoropolymer-Free Backsheet After Combined-Accelerated Stress Testing
The viability of novel coextruded, fluoropolymer-free backsheets for photovoltaic (PV) modules has been questioned as a result of a large number of early-life backsheet failures in PV installations containing one of the earliest co-extruded polyamide (PA)-based backsheet to reach the market, “AAA.” New PV reliability testing protocols have been recently developed and applied to backsheets to reproduce failures observed in the field and evaluate the durability of novel backsheet materials and designs prior to commercialization. A new co-extruded PA-based backsheet was tested using combined-accelerated stress testing (C-AST) and demonstrated a greater lifetime than AAA, and some other fluoropolymer-based backsheets such as polyvinylidene fluoride. The improved PA-based backsheet also eventually failed by through-thickness cracking. Using surface and bulk material characterization techniques, we performed a comprehensive study of material properties before and after the stress testing. Aging of the backsheet resulted in an increase of surface roughness by erosion of the outer PA layer. However the failure is more likely related to an increase in crystallinity of the polyolefin core layer reducing the backsheet tearing energy. The analysis can ultimately inform on the specific weaknesses of the materials so that the manufacturer can improve the backsheet design to extend its lifetime.
14 SOLAR ENERGY↗
Membrane Accelerated Stress Test Development for Polymer Electrolyte Fuel Cell Durability Validated Using Field and Drive Cycle Testing
A combined chemical/mechanical accelerated stress test (AST) was developed for proton exchange membrane (PEM) fuel cells based on relative humidity cycling (RHC) between dry and saturated gases at open circuit voltage (OCV). Membrane degradation and failure were investigated using scanning electron microscopy and small- and wide-angle X-ray scattering. Changes to membrane thickness, hydrophilic domain spacing, and crystallinity were observed to be most similar between field-operated cells and OCV RHC ASTs, where local thinning and divot-type defects are the primary failure modes. While RHC in air also reproduces these failure modes, it is not aggressive enough to differentiate between different membrane types in >1,333 hours (55 days) of testing. Conversely, steady-state OCV tests result in significant ionomer morphology changes and global thinning, which do not replicate field degradation and failure modes. It is inferred that during the OCV RHC AST, the decay of the membrane's mechanical properties is accelerated such that materials can be evaluated in hundreds, instead of thousands, of hours, while replicating the degradation and failure modes of field operation; associated AST protocols are recommended as OCV RHC at 90°C for 500 hours with wet/dry cycle durations of 30s/45s and 2m/2m for automotive and bus operation, respectively.
25 ENERGY STORAGE↗
Certification Considerations for Adaptive Stress Testing of Airborne Software
eduAdaptive Stress Testing (AST) has shown promise in identifying errant corner cases in complex software used in aerospace applications including Flight Management Systems (FMS). The strength of AST is performing test-based verification of complex aerospace software intensive systems at scale in simulated operational environments.Simulating and capturing the realistic operational complexities in integrated verification environments may exposeflaws in the softwareprior to field deployment, whereas the software may perform just fine to traditional requirements-basedunit and component level testing.AST can be used to test the whole system.Individual components may behave safely, but together can result in complex interactions and emergent failures, so it is important to test at the integrated system level.Motivated by the observed benefitsat the prototype proof of concept scale, this paper considers how AST may be integrated into a production workflow and used to generate objective evidence in a processthat delivers certified aerospace software.The research includes evaluation of alignment with both DO-178C and Overarching Properties(OP). The paper addresses questions such as “where should AST fit in the Plan for Software Aspects of Certification (PSAC) and Software Verification Plan (SVP), what aspects of AST do not fit, and what objectives does it satisfy?” The paper concludes that AST is in fact useful at locating errors in complex airborne application software and in doing so provides benefits to suppliers and end users. Furthermore, AST appears appropriate to add value in both DO-178Cbased and Overarching Properties based certification approaches.
certification↗
Correlation of Advanced Accelerated Stress Testing with Polyamide-Based Photovoltaic Backsheet Field-Failures
Cracking of polyamide (PA)-based photovoltaic (PV) backsheet materials has been widely reported for field-aged modules. Failure was not detected by conventional accelerated stress tests (ASTs), which lacked the necessary combination of stress factors and/or factor sequences. PA-based AAA backsheet cracking has since been reproduced through combined and sequential stress testing. Planar- and cross-sectional-optical microscopy as well as Fourier-transform Infrared Spectroscopy (FTIR), have been used to elucidate the mechanical and chemical changes which lead to failure of the backsheet. Field-aged backsheet samples demonstrating failure in various climates (including locations in China and Italy) are also analyzed. Through the analysis, a comparison is made between the different stress testing protocols and the field-aged samples to validate relevance of the advanced stress tests. It is shown that the changes induced through combined-accelerated stress testing (C-AST) were most representative of changes induced by the field, supporting the relevance of C-AST and providing validity for the test protocol.
14 SOLAR ENERGY↗
Accelerated stress testing of terrestrial solar cells
A program to investigate the reliability characteristics of unencapsulated low-cost terrestrial solar cells using accelerated stress testing is described. Reliability (or parametric degradation) factors appropriate to the cell technologies and use conditions were studied and a series of accelerated stress tests was synthesized. An electrical measurement procedure and a data analysis and management system was derived, and stress test fixturing and material flow procedures were set up after consideration was given to the number of cells to be stress tested and measured and the nature of the information to be obtained from the process. Selected results and conclusions are presented.
Prince, J. L.↗
Differential Adaptive Stress Testing of Airborne Collision Avoidance Systems
The next-generation Airborne Collision Avoidance System (ACAS X) is currently being developed and tested to replace the Traffic Alert and Collision Avoidance System (TCAS) as the next international standard for collision avoidance. To validate the safety of the system, stress testing in simulation is one of several approaches for analyzing near mid-air collisions (NMACs). Understanding how NMACs can occur is important for characterizing risk and informingdevelopment of the system. Recently, adaptive stress testing (AST) has been proposed as a way to find the most likely path to a failure event. The simulation-based approach accelerates search by formulating stress testing as a sequential decision process then optimizing it using reinforcement learning. The approach has been successfully applied to stress test a prototype of ACAS Xin various simulated aircraft encounters. In some applications, we are not as interestedin the system's absolute performance as its performance relative to another system. Such situations arise, for example, during regression testing or when deciding whether a new system should replace an existing system. In our collision avoidance application, we are interested in finding cases where ACAS X fails but TCAS succeeds in resolving a conflict. Existing approaches do not provide an efficient means to perform this type of analysis. This paper extends the AST approach to differential analysis by searching two simulators simultaneously and maximizing the difference between their outcomes. We call this approach differential adaptive stress testing (DAST). We apply DAST to compare a prototype of ACAS X against TCAS and show examples of encounters found by the algorithm.
Lee, Ritchie↗