A covering array CA(N;t,k,v) is an N×k array with entries
in {1,2,…,v}, for which every N×t subarray contains each
t-tuple of {1,2,…,v}t among its rows. Covering arrays find
application in interaction testing, including software and hardware testing,
advanced materials development, and biological systems. A central question is
to determine or bound CAN(t,k,v), the minimum number N of rows of
a CA(N;t,k,v). The well known bound
CAN(t,k,v)=O((t−1)vtlogk) is not too far from being
asymptotically optimal. Sensible relaxations of the covering requirement arise
when (1) the set {1,2,…,v}t need only be contained among the rows
of at least (1−ϵ)(tk) of the N×t subarrays and (2) the
rows of every N×t subarray need only contain a (large) subset of {1,2,…,v}t. In this paper, using probabilistic methods, significant
improvements on the covering array upper bound are established for both
relaxations, and for the conjunction of the two. In each case, a randomized
algorithm constructs such arrays in expected polynomial time