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NASA NTRS1927

Method of Correcting Wind Tunnel Data for Omitted Parts of Airplane Models

Wind tunnel models do not have complete similarity to the full scale airplane. Part of the dissimilarity is due to the difference between the stationary model in the artificial wind stream of the tunnel and the moving airplane in still air. There are a number of other reasons for departing from exact geometrical similitude. For reasons of accuracy and economy, all minor parts of the full scale airplane, such as struts, wires, fittings, control horns and other parts whose scale corrections are large are removed from wind tunnel models. By omitting the minor parts of the airplane in the wind tunnel model and adding to the forces and moments of the model those omitted parts measured full scale and properly reduced, the scale effects of such parts disappear from the model data. Scale effects due to major parts of the airplane, particularly the fuselage and wings, can be corrected by omitting the propeller and making the surface of the model as smooth as possible, two further departures from geometrical similitude between model and full scale that add considerably to the accuracy and economy of model tests.

Smith, R H↗

NASA NTRS1997

Database Development for Electrical, Electronic, and Electromechanical (EEE) Parts for the International Space Station Alpha

More effective electronic communication processes are needed to transfer contractor and international partner data into NASA and prime contractor baseline database systems. It is estimated that the International Space Station Alpha (ISSA) parts database will contain up to one million parts each of which may require database capabilities for approximately one thousand bytes of data for each part. The resulting gigabyte database must provide easy access to users who will be preparing multiple analyses and reports in order to verify as-designed, as-built, launch, on-orbit, and return configurations for up to 45 missions associated with the construction of the ISSA. Additionally, Internet access to this data base is strongly indicated to allow multiple user access from clients located in many foreign countries. This summer's project involved familiarization and evaluation of the ISSA Electrical, Electronic, and Electromechanical (EEE) Parts data and the process of electronically managing these data. Particular attention was devoted to improving the interfaces among the many elements of the ISSA information system and its global customers and suppliers. Additionally, prototype queries were developed to facilitate the identification of data changes in the data base, verifications that the designs used only approved parts, and certifications that the flight hardware containing EEE parts was ready for flight. This project also resulted in specific recommendations to NASA for further development in the area of EEE parts database development and usage.

Wassil-Grimm, Andrew D.↗

NASA NTRS1998

A Conceptual Approach to Assimilating Remote Sensing Data to Improve Soil Moisture Profile Estimates in a Surface Flux/Hydrology Model: Overview - Part 1

Knowledge of the amount of water in the soil is of great importance to many earth science disciplines. Soil moisture is a key variable in controlling the exchange of water and energy between the land surface and the atmosphere. Thus, soil moisture information is valuable in a wide range of applications including weather and climate, runoff potential and flood control, early warning of droughts, irrigation, crop yield forecasting, soil erosion, reservoir management, geotechnical engineering, and water quality. Despite the importance of soil moisture information, widespread and continuous measurements of soil moisture are not possible today. Although many earth surface conditions can be measured from satellites, we still cannot adequately measure soil moisture from space. Research in soil moisture remote sensing began in the mid 1970s shortly after the surge in satellite development. Recent advances in remote sensing have shown that soil moisture can be measured, at least qualitatively, by several methods. Quantitative measurements of moisture in the soil surface layer have been most successful using both passive and active microwave remote sensing, although complications arise from surface roughness and vegetation type and density. Early attempts to measure soil moisture from space-borne microwave instruments were hindered by what is now considered sub-optimal wavelengths (shorter than 5 cm) and the coarse spatial resolution of the measurements. L-band frequencies between 1 and 3 GHz (10-30 cm) have been deemed optimal for detection of soil moisture in the upper few centimeters of soil. The Electronically Steered Thinned Array Radiometer (ESTAR), an aircraft-based instrument operating a 1,4 GHz, has shown great promise for soil moisture determination. Initiatives are underway to develop a similar instrument for space. Existing space-borne synthetic aperture radars (SARS) operating at C- and L-band have also shown some potential to detect surface wetness. The advantage of radar is its much higher resolution than passive microwave systems, but it is currently hampered by surface roughness effects and the lack of a good algorithm based on a single frequency and single polarization. In addition, its repeat frequency is generally low (about 40 days). In the meantime, two new radiometers offer some hope for remote sensing of soil moisture from space. The Tropical Rainfall Measuring Mission (TRMM) Microwave Imager (TMI), launched in November 1997, possesses a 10.65 GHz channel and the Advanced Microwave Scanning Radiometer (AMSR) on both the ADEOS-11 and Earth Observing System AM-1 platforms to be launched in 1999 possesses a 6.9 GHz channel. Aside from issues about interference from vegetation, the coarse resolution of these data will provide considerable challenges pertaining to their application. The resolution of TMI is about 45 km and that of AMSR is about 70 km. These resolutions are grossly inconsistent with the scale of soil moisture processes and the spatial variability of factors that control soil moisture. Scale disparities such as these are forcing us to rethink how we assimilate data of various scales in hydrologic models. Of particular interest is how to assimilate soil moisture data by reconciling the scale disparity between what we can expect from present and future remote sensing measurements of soil moisture and modeling soil moisture processes. It is because of this disparity between the resolution of space-based sensors and the scale of data needed for capturing the spatial variability of soil moisture and related properties that remote sensing of soil moisture has not met with more widespread success. Within a single footprint of current sensors at the wavelengths optimal for this application, in most cases there is enormous heterogeneity in soil moisture created by differences in landcover, soils and topography, as well as variability in antecedent precipitation. It is difficult to interpret the meaning of 'mean' soil moisture under such conditions and even more difficult to apply such a value. Because of the non-linear relationships between near-surface soil moisture and other variables of interest, such as surface energy fluxes and runoff, mean soil moisture has little applicability at such large scales. It is for these reasons that the use of remote sensing in conjunction with a hydrologic model appears to be of benefit in capturing the complete spatial and temporal structure of soil moisture. This paper is Part I of a four-part series describing a method for intermittently assimilating remotely-sensed soil moisture information to improve performance of a distributed land surface hydrology model. The method, summarized in section II, involves the following components, each of which is detailed in the indicated section of the paper or subsequent papers in this series: Forward radiative transfer model methods (section II and Part IV); Use of a Kalman filter to assimilate remotely-sensed soil moisture estimates with the model profile (section II and Part IV); Application of a soil hydrology model to capture the continuous evolution of the soil moisture profile within and below the root zone (section III); Statistical aggregation techniques (section IV and Part II); Disaggregation techniques using a neural network approach (section IV and Part III); and Maximum likelihood and Bayesian algorithms for inversely solving for the soil moisture profile in the upper few cm (Part IV).

Crosson, William L.↗

NASA NTRS2005

Automated Rapid Prototyping of 3D Ceramic Parts

An automated system of manufacturing equipment produces three-dimensional (3D) ceramic parts specified by computational models of the parts. The system implements an advanced, automated version of a generic rapid-prototyping process in which the fabrication of an object having a possibly complex 3D shape includes stacking of thin sheets, the outlines of which closely approximate the horizontal cross sections of the object at their respective heights. In this process, the thin sheets are made of a ceramic precursor material, and the stack is subsequently heated to transform it into a unitary ceramic object. In addition to the computer used to generate the computational model of the part to be fabricated, the equipment used in this process includes: 1) A commercially available laminated-object-manufacturing machine that was originally designed for building woodlike 3D objects from paper and was modified to accept sheets of ceramic precursor material, and 2) A machine designed specifically to feed single sheets of ceramic precursor material to the laminated-object-manufacturing machine. Like other rapid-prototyping processes that utilize stacking of thin sheets, this process begins with generation of the computational model of the part to be fabricated, followed by computational sectioning of the part into layers of predetermined thickness that collectively define the shape of the part. Information about each layer is transmitted to rapid-prototyping equipment, where the part is built layer by layer. What distinguishes this process from other rapid-prototyping processes that utilize stacking of thin sheets are the details of the machines and the actions that they perform. In this process, flexible sheets of ceramic precursor material (called "green" ceramic sheets) suitable for lamination are produced by tape casting. The binder used in the tape casting is specially formulated to enable lamination of layers with little or no applied heat or pressure. The tape is cut into individual sheets, which are stacked in the sheet-feeding machine until used. The sheet-feeding machine can hold enough sheets for about 8 hours of continuous operation.

McMillin, Scott G.↗

NASA NTRS2011

Cryogenic Quenching Process for Electronic Part Screening

The use of electronic parts at cryogenic temperatures (less than 100 C) for extreme environments is not well controlled or developed from a product quality and reliability point of view. This is in contrast to the very rigorous and well-documented procedures to qualify electronic parts for mission use in the 55 to 125 C temperature range. A similarly rigorous methodology for screening and evaluating electronic parts needs to be developed so that mission planners can expect the same level of high reliability performance for parts operated at cryogenic temperatures. A formal methodology for screening and qualifying electronic parts at cryogenic temperatures has been proposed. The methodology focuses on the base physics of failure of the devices at cryogenic temperatures. All electronic part reliability is based on the bathtub curve, high amounts of initial failures (infant mortals), a long period of normal use (random failures), and then an increasing number of failures (end of life). Unique to this is the development of custom screening procedures to eliminate early failures at cold temperatures. The ability to screen out defects will specifically impact reliability at cold temperatures. Cryogenic reliability is limited by electron trap creation in the oxide and defect sites at conductor interfaces. Non-uniform conduction processes due to process marginalities will be magnified at cryogenic temperatures. Carrier mobilities change by orders of magnitude at cryogenic temperatures, significantly enhancing the effects of electric field. Marginal contacts, impurities in oxides, and defects in conductor/conductor interfaces can all be magnified at low temperatures. The novelty is the use of an ultra-low temperature, short-duration quenching process for defect screening. The quenching process is designed to identify those defects that will precisely (and negatively) affect long-term, cryogenic part operation. This quenching process occurs at a temperature that is at least 25 C colder than the coldest expected operating temperature. This quenching process is the opposite of the standard burn-in procedure. Normal burn-in raises the temperature (and voltage) to activate quickly any possible manufacturing defects remaining in the device that were not already rejected at a functional test step. The proposed inverse burn-in or quenching process is custom-tailored to the electronic device being used. The doping profiles, materials, minimum dimensions, interfaces, and thermal expansion coefficients are all taken into account in determining the ramp rate, dwell time, and temperature.

Sheldon, Douglas J.↗

NASA NTRS2012

In Situ Manufacturing is a Necessary Part of Any Planetary Architecture

The key to any sustainable presence in space is the ability to manufacture necessary tools, parts, structures, spares, etc. in situ and on demand. Cost, volume, and up-mass constraints prohibit launching everything needed for long-duration or long-distance missions from Earth, including spare parts and replacement systems. There are many benefits to building items as-needed in situ using computer aided drafting (CAD) models and additive manufacturing technology: (1) Cost, up-mass, and volume savings for launch due to the ability to manufacture specific parts when needed. (2) CAD models can be generated on Earth and transmitted to the station or spacecraft, or they can be designed in situ for any task. Thus, multiple people in many locations can work on a single problem. (3) Items can be produced that will enhance the safety of crew and vehicles (e.g., latches or guards). (4) Items can be produced on-demand in a small amount of time (i.e., hours or days) compared to traditional manufacturing methods and, therefore, would not require the lengthy amount of time needed to machine the part from a solid block of material nor the wait time required if the part had to be launched from Earth. (5) Used and obsolete parts can be recycled into powder or wire feedstock for use in later manufacturing. (6) Ultimately, the ability to produce items as-needed will reduce mission risk, as one will have everything they need to fix a broken system or fashion a new part making it available on a more timely basis.

Edmunson, Jennifer E.↗

NASA NTRS2014

Cleaning Process Development for Metallic Additively Manufactured Parts

Additive Manufacturing of metallic components for aerospace applications offers many advantages over traditional manufacturing techniques. As a new technology, many aspects of its widespread utilization remain open to investigation. Among these are the cleaning processes that can be used for post finishing of parts and measurements to verify effectiveness of the cleaning processes. Many cleaning and drying processes and measurement methods that have been used for parts manufactured using conventional techniques are candidates that may be considered for cleaning and verification of additively manufactured parts. Among these are vapor degreasing, ultrasonic immersion and spray cleaning, followed by hot air drying, vacuum baking and solvent displacement drying. Differences in porosity, density, and surface finish of additively manufactured versus conventionally manufactured parts may introduce new considerations in the selection of cleaning and drying processes or the method used to verify their effectiveness. This presentation will review the relative strengths and weaknesses of different candidate cleaning and drying processes as they may apply to additively manufactured metal parts for aerospace applications. An ultrasonic cleaning technique for exploring the cleanability of parts will be presented along with an example using additively manufactured Inconel 718 test specimens to illustrate its use. The data analysis shows that this ultrasonic cleaning approach results in a well-behaved ultrasonic cleaning/extraction behavior. That is, it does not show signs of accelerated cavitation erosion of the base material, which was later confirmed by neutron imaging. In addition, the analysis indicated that complete cleaning would be achieved by ultrasonic immersion cleaning at approximately 5 minutes, which was verified by subsequent cleaning of additional parts.

Tramel, Terri L.↗

NASA NTRS2017

Packaging Technology for Dielectric-Coating-Less Heavy Ion Radiation Testing of High-Voltage (HV) Electronic Parts

Testing high voltage (HV) electronic parts (greater than 300 V) for sudden event effects (SEE) caused by cosmic rays in the space environment, consisting of energetic heavy-ions, and neutron radiation in the upper atmosphere is a crucial step towards using these parts in spacecraft and aircraft. Due to the nature of cosmic radiation and neutrons, electronic parts are tested for SEE without any packaging and/or shielding over the top of the device. In the case of commercial HV parts, the top of the packaging is etched off and then a thin dielectric coating is placed over the part in order to avoid electrical arcing between the device surface and wire bonds and other components. Even though the effects of the thin dielectric layer on SEE testing can be accounted for, the dielectric layer significantly hinders post testing failure analysis. Replicating the test capability of state-of-the-art packaging while eliminating the need for post radiation test processing of the die surface (that obscures failure analysis) is the goal. To that end, a new packaging concept for HV parts has been developed that requires no dielectric coating over the part. Testing of prototype packages used with Schottky diodes (rated at 1200V) has shown no electrical arcing during testing and leakage currents during reverse bias testing are within the manufactures specifications.

High Voltage↗

NASA NTRS2020

TURBOMAT-FR: Turbomachinery Aeroelastic Forced Response Analysis Automation Using MATLAB®: PART 1

The primary aim of this effort is to develop a software tool named “Turbomachinery Aeroelastic Analysis Tool for Forced Response (TURBOMAT-FR)” using MATLAB® (The MathWorks, Inc.) scripts. The tool will aid in performing routine forced response analysis of turbomachinery fan blades with the aid of the modal summation method (MSUM). The MSUM approach requires a modal solution consisting of modal displacements, modal frequencies, and modal stresses. The MATLAB® scripts facilitate easy extraction of the required quantities from the computational fluid dynamics (CFD) and MSC Nastran (Hexagon AB) solution files. These quantities are subsequently utilized by the MSUM approach to perform a complete forced response analysis.The MATLAB® scripts in TURBOMAT-FR are utilized in postprocessing of the MSC Nastran finite element analysis outputs in three types of solutions or steps, namely (1) stresses and displacements from static and steady response solution, (2) unsteady stresses and displacements from direct forced response solution, and (3) modal solution containing modal displacements and modal stresses. In step (4), separate MATLAB® scripts are also developed to read the processed outputs in step (3) and perform forced response analysis using MSUM. The TURBOMAT-FR MATLAB® scripts mentioned previously are presented in two reports designated “Part 1” and “Part 2”. The current report, Part 1, presents the scripts needed to accomplish steps (1) and (2), noted previously. This will be exclusively useful for performing only the static and steady response analysis and the forced response analysis using the direct forced response solution approach. Part 2 contains the TURBOMAT-FR MATLAB® scripts needed to accomplish steps (3) and (4). The MATLAB® scripts given in Part 2 facilitate the calculation of unsteady stresses using MSUM and provide an automated procedure associated with aeroelastic forced response analysis with different pressure files for the same structural model. The unsteady stresses calculated using MSUM in Part 2 can be compared with those presented in Part 1. A cantilevered blade-alone model subjected to a realistic pressure loading to a boundary was used for static and unsteady direct forced response analysis to demonstrate the effectiveness of the TURBOMATFR MATLAB® scripts.

MATLAB-Scripts↗

NASA NTRS1986

Reusable software parts and the semi-abstract data type

The development of reuable software parts has been an area of intense discussion within the software community for many years. An approach is described for developing reusable parts for the applications of missile guidance, navigation and control which meet the following criteria: (1) Reusable; (2) Tailorable; (3) Efficient; (4) Simple to use; and (5) Protected against misuse. Validating the feasibility of developing reusable parts which possess these characteristics is the basis of the Common Ada Missile Packages Program (CAMP). Under CAMP, over 200 reusable software parts were developed, including part for navigation, Kalman filter, signal processing and autopilot. Six different methods are presented for designing reusable software parts.

Cohen, Sanford G.↗

NASA NTRS1994

High Velocity Oxygen Fuel Spraying of Erosion and Wear Resistant Coatings on Jet Engine Parts

High velocity oxygen fuel (HVOF) spraying is the most recent development in the field of thermal spraying. The importance of this technique for the repair and new part manufacturing of jet engine parts is rapidly increasing. The HVOF uses a supersonic oxygen-fuel flame to heat and accelerate the powder particles that form the coating. The high particle velocity results in a high density and a low porosity, a high bond strength, and a high macro and micro hardness of the coating. The high quality of the HVOF coatings makes it possible to use these coatings on high loaded, rotating parts in jet engines. This paper will highlight the use of HVOF processes to apply erosion resistant cermet coatings to high pressure compressor blades. These blades are exposed to severe erosion. Next to the D-gun process, HVOF spraying is the only nonproprietary technique that can be used to apply these high performance coatings. Also the use of the HVOF process to apply wear resistant coatings and superalloys to jet engine parts will be discussed. The difference between HVOF coatings and plasma sprayed coatings will be highlighted. During HVOF spraying, the parts are exposed to a high heat flow. Solutions to avoid overheating, especially of titanium parts, will be presented.

A T J Verbeek↗

NASA NTRS2002

STS-109 Mission Highlights Resource Tape: Flight Days 8 - 12 - Part 4 of 4

This video, Part 4 of 4, shows footage of crew activities from flight days 8 through 12 of STS-109. The crew included: Scott Altman, Commander; Duane Carey, Pilot; John Grunsfeld, Payload Commander; Nancy Currie, Richard Linnehan, James Newman, Michael Massimino, Mission Speicalists. The activities from other flights days can be seen on 'STS-109 Mission Highlights Resource Tape' Part 1 of 4 (internal ID 2002139471), 'STS-109 Mission Highlights Resource Tape' Part 2 of 4 (internal ID 2002137664), and 'STS-109 Mission Highlights Resource Tape' Part 3 of 4 (internal ID 2002139476). The primary activity on flight day 8 was an EVA (extravehicular activity) by Grunsfeld and Linnehan to install a cryocooler and radiator for the NICMOS (Near Infrared Camera and Multi-Object Spectrometer) on the HST (Hubble Space Telescope). Before returning to Columbia's airlock, the astronauts, with a cloudy background, hold onto the orbiter and offer their thoughts on the significance of their mission, the HST, and spaceflight. Footage from flight day 9 includes the grappling, unbearthing, and deployment of the HST from Columbia, and the crew coordinating and videotaping Columbia's departure. Flight day 10 was a relatively inactive day, and flight day 11 includes a checkout of Columbia's aerodynamic surfaces. Columbia landed on flight day 12, which is covered by footage of the crew members speaking during reentry, and their night landing, primarily shown through the orbiter's head-up display. The video includes numerous views of the HST, as well as views of the the Galapagos Islands, Madagascar, and Southern Africa with parts of the Atlantic, Indian, and Pacific Oceans, and part of the coast of Chile. The pistol grip space tool is shown in use, and the crew answers two messages from the public, including a message to Massimino from the Fire Department of New York.

Source record↗

NASA NTRS2004

Alternative Test Methods for Electronic Parts

It is common practice within NASA to test electronic parts at the manufacturing lot level to demonstrate, statistically, that parts from the lot tested will not fail in service using generic application conditions. The test methods and the generic application conditions used have been developed over the years through cooperation between NASA, DoD, and industry in order to establish a common set of standard practices. These common practices, found in MIL-STD-883, MIL-STD-750, military part specifications, EEE-INST-002, and other guidelines are preferred because they are considered to be effective and repeatable and their results are usually straightforward to interpret. These practices can sometimes be unavailable to some NASA projects due to special application conditions that must be addressed, such as schedule constraints, cost constraints, logistical constraints, or advances in the technology that make the historical standards an inappropriate choice for establishing part performance and reliability. Alternate methods have begun to emerge and to be used by NASA programs to test parts individually or as part of a system, especially when standard lot tests cannot be applied. Four alternate screening methods will be discussed in this paper: Highly accelerated life test (HALT), forward voltage drop tests for evaluating wire-bond integrity, burn-in options during or after highly accelerated stress test (HAST), and board-level qualification.

Plante, Jeannette↗

NASA NTRS2004

Urethane/Silicone Adhesives for Bonding Flexing Metal Parts

Adhesives that are blends of commercially available urethane and silicone adhesives have been found to be useful for bonding metal parts that flex somewhat during use. These urethane/silicone adhesives are formulated for the specific metal parts to be bonded. The bonds formed by these adhesives have peel and shear strengths greater than those of bonds formed by double-sided tapes and by other adhesives, including epoxies and neat silicones. In addition, unlike the bonds formed by epoxies, the bonds formed by these adhesives retain flexibility. In the initial application for which the urethane/silicone adhesives were devised, there was a need to bond spring rings, which provide longitudinal rigidity for inflatable satellite booms, with the blades that provide the booms axial strength. The problem was to make the bonds withstand the stresses, associated with differences in curvature between the bonded parts, that arose when the booms were deflated and the springs were compressed. In experiments using single adhesives (that is, not the urethane/ silicone blends), the bonds were broken and, in each experiment, it was found that the adhesive bonded well with either the ring or with the blade, but not both. After numerous experiments, the adhesive that bonded best with the rings and the adhesive that bonded best with the blades were identified. These adhesives were then blended and, as expected, the blend bonded well with both the rings and the blades. The two adhesives are Kalex (or equivalent) high-shear-strength urethane and Dow Corning 732 (or equivalent) silicone. The nominal mixture ratio is 5 volume parts of the urethane per 1 volume part of the silicone. Increasing the proportion of silicone makes the bond weaker but more flexible, and decreasing the proportion of silicone makes the bond stronger but more brittle. The urethane/silicone blend must be prepared and used quickly because of the limited working time of the urethane: The precursor of the urethane adhesive is supplied in a two-part form, comprising a resin and a hardener that must be mixed. The resulting urethane adhesive has a working time of 3 to 5 minutes. To prepare the urethane/silicone blend, one must quickly add the silicone to the urethane adhesive and mix it in thoroughly within the working time of the urethane. Once the urethane/silicone blend has been mixed and applied to the bond surfaces, it takes about 2 hours for the adhesive to cure under pressure. However, it takes about 24 hours for the adhesive to reach full strength.

Edwards, Paul D.↗

NASA NTRS2000

Development of a Methodology to Conduct Usability Evaluation for Hand Tools that May Reduce the Amount of Small Parts that are Dropped During Installation while Processing Space Flight Hardware

Foreign object debris (FOD) is an important concern while processing space flight hardware. FOD can be defined as "The debris that is left in or around flight hardware, where it could cause damage to that flight hardware," (United Space Alliance, 2000). Just one small screw left unintentionally in the wrong place could delay a launch schedule while it is retrieved, increase the cost of processing, or cause a potentially fatal accident. At this time, there is not a single solution to help reduce the number of dropped parts such as screws, bolts, nuts, and washers during installation. Most of the effort is currently focused on training employees and on capturing the parts once they are dropped. Advances in ergonomics and hand tool design suggest that a solution may be possible, in the form of specialty hand tools, which secure the small parts while they are being handled. To assist in the development of these new advances, a test methodology was developed to conduct a usability evaluation of hand tools, while performing tasks with risk of creating FOD. The methodology also includes hardware in the form of a testing board and the small parts that can be installed onto the board during a test. The usability of new hand tools was determined based on efficiency and the number of dropped parts. To validate the methodology, participants were tested while performing a task that is representative of the type of work that may be done when processing space flight hardware. Test participants installed small parts using their hands and two commercially available tools. The participants were from three groups: (1) students, (2) engineers / managers and (3) technicians. The test was conducted to evaluate the differences in performance when using the three installation methods, as well as the difference in performance of the three participant groups.

Miller, Darcy↗

NASA NTRS2019

James Webb Space Telescope Optical Telescope Element / Integrated Science Instrument Module (OTIS) Cryogenic Vacuum Test Part I: Thermal Architecture

The James Webb Space Telescope (JWST), set to launch in early 2019, is currently undergoing a series of system-level environmental tests to verify its workmanship and end-to-end functionality. As part of this series, the Optical Telescope Element and Integrated Science Instrument Module (OTIS) Cryo-Vacuum (CV) test, the most complex cryogenic test executed to date by NASA, was completed in 2017 at the Johnson Space Center's Chamber A facility. The OTIS CV test was intended as a comprehensive test of the integrated instrument and telescope systems to fully understand its optical, structural, and thermal performance within its intended flight environment. Due to its complexity, extensive pre-test planning was required to ensure payload safety and compliance with all limits and constraints. A comprehensive thermal analysis campaign was undertaken to predict the behavior of the test payload during its transition to cryogenic temperatures and back to ambient, and exhaustive preparations for off-nominal scenarios were studied due to the increased possibility of unanticipated events during the 100-day test length. This current four-part online course for the NASA Engineering and Safety Center (NESC) Academy gives a thorough overview of the mutiple years of preparation executed by hundreds of individuals to ensure the success of the JWST OTIS CV Test. Part I will introduce the major components of James Webb and specifically the OTIS CV Test thermal architecture. Part II will encompass the extensive thermal analysis performed to prepare for the test. Part III will talk about the preparations for off-nominal events: what analysis was done, and how steps were taken pre-test to anticipate unexpected circumstances and mitigate their impacts to hardware and test timeline. Part IV is a recap of the lessons learned from the thermal perspective for both the payload and ground support equipment (GSE) test conductors. It is hoped that the insight gained from the OTIS CV test campaign will benefit planning and execution for upcoming large cryogenic missions.

OTIS↗

NASA NTRS2019

James Webb Space Telescope Optical Telescope Element / Integrated Science Instrument Module (OTIS) Cryogenic Vacuum Test Part II: Thermal Analysis

The James Webb Space Telescope (JWST), set to launch in early 2019, is currently undergoing a series of system-level environmental tests to verify its workmanship and end-to-end functionality. As part of this series, the Optical Telescope Element and Integrated Science Instrument Module (OTIS) Cryo-Vacuum (CV) test, the most complex cryogenic test executed to date by NASA, was completed in 2017 at the Johnson Space Center's Chamber A facility. The OTIS CV test was intended as a comprehensive test of the integrated instrument and telescope systems to fully understand its optical, structural, and thermal performance within its intended flight environment. Due to its complexity, extensive pre-test planning was required to ensure payload safety and compliance with all limits and constraints. A comprehensive thermal analysis campaign was undertaken to predict the behavior of the test payload during its transition to cryogenic temperatures and back to ambient, and exhaustive preparations for off-nominal scenarios were studied due to the increased possibility of unanticipated events during the 100-day test length. This current four-part online course for the NASA Engineering and Safety Center (NESC) Academy gives a thorough overview of the multiple years of preparation executed by hundreds of individuals to ensure the success of the JWST OTIS CV Test. Part I will introduce the major components of James Webb and specifically the OTIS CV Test thermal architecture. Part II will encompass the extensive thermal analysis performed to prepare for the test. Part III will talk about the preparations for off-nominal events: what analysis was done, and how steps were taken pre-test to anticipate unexpected circumstances and mitigate their impacts to hardware and test timeline. Part IV is a recap of the lessons learned from the thermal perspective for both the payload and ground support equipment (GSE) test conductors. It is hoped that the insight gained from the OTIS CV test campaign will benefit planning and execution for upcoming large cryogenic missions.

Testing↗

NASA NTRS2022

Assurance of Electronic Parts for Aerospace System Reliability: Past, Present, and Future

Over the last two to three decades, the balance of influence within the electronics industry has shifted decisively towards the consumer electronics and information technology products, away from the defense or aerospace markets. This shift towards the commercial markets has changed certain ground rules in the electronics industry. Reliance of the aerospace industry, in particular, on components from supply chains dedicated to other products, or cross-vertical product integration, creates a supply web and introduces significant risks that are not necessarily present for volume-driven electronic products. Many of the unique risks in the aerospace industry emanate from the key characteristics of this industry. Although selection and usage of commercial electronics in NASA flight hardware is possible at a comparable (and in many cases lower) level of risk to that of employing parts that are screened to military or NASA specifications, for a large majority of flight projects it is difficult to distinguish the difference in on-orbit performance or reliability for parts screened at any level, or commercial parts that have no additional screening performed by the government. This paper identifies several bases for establishing context and developing unique or alternative approaches for successful parts selection and application within NASA and across the commercial space community.

electronic parts↗