I got denied on my Navy Federal card back in 2018 when I was driving out to Iowa.
Stopped for gas in western Ohio around 3:15 a.m. and the card was declined when I tried to pay for the gas, coffee, and some snacks. My phone lit up with *Possible fraud detected, call this number* texts from NFCU, so I called and got it straightened out.
My card usage was about 90% Northern Virginia with 10% up into Pennsylvania. Western Ohio is what tipped it off. That's when I found out that Navy Federal allows you to set up "travel plans" on your card. You simply enter locations (states) where you're going to be, roughly when you're going to be there, and your card won't be flagged.
I set that up in the parking lot at the gas station on my phone. Way easy, and I didn't get flagged again that trip.