Reliability estimates for flawed mortar projectile bodies

The Army routinely screens mortar projectiles for defects in safety-critical parts. In 2003, several lots of mortar projectiles had a relatively high defect rate, 0.24%. Before releasing the projectiles, the Army reevaluated the chance of a safety-critical failure. Limit state functions and Monte Carlo simulations were used to estimate reliability. Measured distributions of wall thickness, defect rate, material strength, and applied loads were used with calculated stresses to estimate the probability of failure. The results predicted less than one failure in one million firings. As of 2008, the mortar projectiles have been used without any safety-critical incident.