FMECA and FTA analysis applied to the manufacturing process of pulsating heat pipes

Abstract

Pulsating heat pipes (PHPs) offer significant advantages for the thermal control of electronic components due to their simple manufacturing and high heat transfer rates. The reliability of PHPs has traditionally been assessed through long-life testing, but detailed reliability analyses from an equipment perspective are limited. The study of PHP reliability is essential due to its application and operational conditions. For instance, in aerospace applications these devices operate under severe conditions, and maintenance or replacement is impossible during operation, making them critical components in system functionality. The reliability analysis of PHPs focuses on the manufacturing process, considering future operating conditions. Although preliminary PHP testing will be conducted on Earth, laboratory conditions are less stringent due to the difficulty of replicating launch acceleration and space conditions for long-term testing under microgravity. This study presents an FMECA (Failure Modes, Effects, and Criticality Analysis) of the pulsating heat pipe manufacturing process, breaking down the production of each component. The results indicate that the most critical point is concentrated in the assembly of these components, leading to a higher incidence of welding failures. It recommends further work to improve welding and analyze mechanical stresses within the heat pipe.