feat(iace): FMEA P1 — open methodology anchors + bp_iace_fmea_kb
P1 of the auto-FMEA build plan: establish the public-domain methodology foundation (no AIAG-VDA/SAE/IEC tables reproduced). - fmea_data_sources.go: MIL-STD-882E severity (Cat I-IV→1-10) + probability (A-F→1-10 with per-hour λ bands), OccurrenceFromRate(λp·α), SeverityForCategory, MIL-STD-1629A CriticalityCm = λp·α·β·t. Own 1-10 projection, government-anchored. - 4 versioned source docs (MIL-STD-1629A, MIL-STD-882E, NASA RCM, FMD-91/NPRD-91) ingested into the new RAG collection bp_iace_fmea_kb (whitelisted). - Tests for all scales/mappings/criticality (green). Next (P1 step 2): fetch FMD-91/NPRD-91 bulk λ/α tables from DTIC. Co-Authored-By: Claude Opus 4.7 <noreply@anthropic.com>
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# Failure-mode taxonomy & reliability data — FMD-91 / NPRD-91 (public domain)
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Open component→failure-mode taxonomy and failure-rate (λ) / mode-ratio (α)
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anchor for the IACE auto-FMEA. Ingested into `bp_iace_fmea_kb`. The bulk numeric
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tables are fetched from the DTIC PDFs in a follow-up P1 step; this doc fixes the
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sources + the per-component mode lists used to seed the gated library (P2).
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## Sources
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- **FMD-91** (RAC/DTIC) — *Failure Mode / Mechanism Distributions* — modes +
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mechanisms with **% distribution (α)** per part class. **Public domain**
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("Approved for Public Release; Distribution Unlimited"). DTIC ADA259655.
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- **NPRD-91 / NPRD-95** (RAC/DTIC) — *Nonelectronic Parts Reliability Data* —
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field **failure rates λ** for mechanical / electromechanical parts. **Public
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domain.** DTIC ADA242083.
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- **MIL-HDBK-217F** (US DoD) — electronic-part failure-rate models λ. Public
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domain (obsolete 1995 but legally free).
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- **Attribution:** `Source: FMD-91 / NPRD-91 (RAC, DTIC), public domain`
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- **AVOID:** Quanterion NPRD-2023 / FMD-2016 / EPRD-2024 (proprietary reissues),
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OREDA (commercial), FIDES tables (© DGA — read-only), ISO 14224 (copyrighted).
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## Failure modes by component class (open — FMD-91 + CC-BY-SA Wikipedia)
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| Component class | Typical failure modes |
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|---|---|
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| Bearings | fatigue spalling/pitting, wear, brinelling, seizure, contamination |
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| Gears | pitting, scuffing/scoring, tooth-fatigue fracture, wear |
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| Shafts / fasteners / springs | fatigue fracture, fretting, loosening, set/relaxation |
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| Seals / hoses / cylinders | leakage (external/internal), extrusion, hardening, rupture |
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| Valves / pumps | stuck-open, stuck-closed, leakage, fail-to-open/close, degraded flow |
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| Motors / contactors | winding short, open circuit, insulation breakdown, contact weld/stick |
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| Sensors / cabling | drift/bias, loss of signal, intermittent, open/short |
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FMD-91 additionally gives the **% weighting (α)** of each mode per class — that
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is the mode-ratio in `Cm = λp·α·β·t` and lets the engine RANK modes rather than
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enumerate them flatly.
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## How used in IACE
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- Taxonomy → seeds/expands the gated failure-mode library (P2).
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- λ (NPRD/217) × α (FMD-91) → mode rate → `OccurrenceFromRate` → 1–10 occurrence.
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- Each `source`/`license` tagged; allowlist rejects copyrighted/proprietary data.
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