Chip Scale Package Implementation Issues
Availability of board solder joint reliability information is critical to the wider implementation of Chip Scale Packages (CSPs).
CSP Solder Joint Reliability↗
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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.
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Chip Scale Package Issues
Availability of board solder joint reliability information is critical to the wider implementation of Chip Scale Packages (CSPs).
solder↗
X-Ray Computed Tomography: The First Step in Mars Sample Return Processing
The Mars 2020 rover mission will collect and cache samples from the martian surface for possible retrieval and subsequent return to Earth. If the samples are returned, that mission would likely present an opportunity to analyze returned Mars samples within a geologic context on Mars. In addition, it may provide definitive information about the existence of past or present life on Mars. Mars sample return presents unique challenges for the collection, containment, transport, curation and processing of samples [1] Foremost in the processing of returned samples are the closely paired considerations of life detection and Planetary Protection. In order to achieve Mars Sample Return (MSR) science goals, reliable analyses will depend on overcoming some challenging signal/noise-related issues where sparse martian organic compounds must be reliably analyzed against the contamination background. While reliable analyses will depend on initial clean acquisition and robust documentation of all aspects of developing and managing the cache [2], there needs to be a reliable sample handling and analysis procedure that accounts for a variety of materials which may or may not contain evidence of past or present martian life. A recent report [3] suggests that a defined set of measurements should be made to effectively inform both science and Planetary Protection, when applied in the context of the two competing null hypotheses: 1) that there is no detectable life in the samples; or 2) that there is martian life in the samples. The defined measurements would include a phased approach that would be accepted by the community to preserve the bulk of the material, but provide unambiguous science data that can be used and interpreted by various disciplines. Fore-most is the concern that the initial steps would ensure the pristine nature of the samples. Preliminary, non-invasive techniques such as computed X-ray tomography (XCT) have been suggested as the first method to interrogate and characterize the cached samples without altering the materials [1,2]. A recent report [4] indicates that XCT may minimally alter samples for some techniques, and work is needed to quantify these effects, maximizing science return from XCT initial analysis while minimizing effects.
Welzenbach, L. C.↗
Expert system verification and validation study. Delivery 3A and 3B: Trip summaries
Key results are documented from attending the 4th workshop on verification, validation, and testing. The most interesting part of the workshop was when representatives from the U.S., Japan, and Europe presented surveys of VV&T within their respective regions. Another interesting part focused on current efforts to define industry standards for artificial intelligence and how that might affect approaches to VV&T of expert systems. The next part of the workshop focused on VV&T methods of applying mathematical techniques to verification of rule bases and techniques for capturing information relating to the process of developing software. The final part focused on software tools. A summary is also presented of the EPRI conference on 'Methodologies, Tools, and Standards for Cost Effective Reliable Software Verification and Validation. The conference was divided into discussion sessions on the following issues: development process, automated tools, software reliability, methods, standards, and cost/benefit considerations.
French, Scott↗
Serial Back-Plane Technologies in Advanced Avionics Architectures
Current back plane technologies such as VME, and current personal computer back planes such as PCI, are shared bus systems that can exhibit nondeterministic latencies. This means a card can take control of the bus and use resources indefinitely affecting the ability of other cards in the back plane to acquire the bus. This provides a real hit on the reliability of the system. Additionally, these parallel busses only have bandwidths in the 100s of megahertz range and EMI and noise effects get worse the higher the bandwidth goes. To provide scalable, fault-tolerant, advanced computing systems, more applicable to today s connected computing environment and to better meet the needs of future requirements for advanced space instruments and vehicles, serial back-plane technologies should be implemented in advanced avionics architectures. Serial backplane technologies eliminate the problem of one card getting the bus and never relinquishing it, or one minor problem on the backplane bringing the whole system down. Being serial instead of parallel improves the reliability by reducing many of the signal integrity issues associated with parallel back planes and thus significantly improves reliability. The increased speeds associated with a serial backplane are an added bonus.
Varnavas, Kosta↗
Residue detection for real-time removal of paint from metallic surfaces
Paint stripping from large steel ships and other metallic surfaces is a major issue in the maintenance and refurbishing of structures, and environmental concerns are greatly limiting the possible options. As a result, waterjet with water recycling has become the leading form of paint stripping and robotic manipulators with scanning bridges were constructed by various manufacturers to address this need. The application of such scanning bridges is slow and their access is constrained by the complex shape of the ship hull and various features on the surface. To overcome these limitations, a robotic system that is called Ultrastrip (UltraStrip Systems, Inc., Stuart, FL) is developed. This system uses magnetic wheels to attach the stripper to the structure and travel on it while performing paint stripping. To assure efficient paint stripping feedback data is required to control the travel speed by monitoring the paint thickness before and during the stripping process. Efforts at JPL are currently underway to develop the required feedback capability to assure effective paint stripping. Various possible sensors were considered and issues that can affect the sensitivity, reliability and applicability of the sensors are being investigated with emphasis on measuring the initial conditions of the paint. Issues that affect the sensory data in dynamic conditions are addressed while providing real-time real feedback for the control of the paint stripper speed of travel.
NDT↗
How Can We Efficiently Build A Spacecraft That Has Longevity? Experiences From the GSFC Perspective to Inform Lunar Exploration and Science Orbiter’s Architecture
Recent successes in NASA planetary science missions has shown that long-lived missions can yield significant science return. These missions, despite their longevity, were not planned to operate beyond their deign life. For example, the Lunar Reconnaissance Orbiter has a design life of 2-3 years, and yet we are entering its 14th year on orbit. Spacecraft longevity in practice has been related to: 1) mission class; 2) did we test it long enough and resolve all the anomalies to be beyond the early failure curve; 3) consumables budgets, and 4) how components are de-signed and tested. Mission class has been perceived as one of the primary ways to drive longevity. But higher mission class is a significant cost and mission driver. Parts selection only from the limited military standard parts and extensive parts qualification adds to development time and cost. Largely redundant (often erroneously interpreted as fully redundant) adds to launch mass and increases testing complexity (which may reduce the amount of testing in the nominal con-figuration). Lower Risk Posture (reflected in a higher mission class) drives significant additional processes and quality assurance analyses. Higher mission class also drives significantly greater sparing and life testing costs. This discussion focuses on whether this is indeed the best way to achieve longevity efficiently or whether there are more efficient ways to achieve longevity. Empirical evidence shows that lower mission classes that implement effective risk reduction and selective redundancy generally results in long life at a lower Spacecraft bus cost. By evaluating redundancy careful-ly, spacecraft cost can be lowered which can enable a more capable payload. Risk of the mission is highly dependent on the complexity of the mission and is only loosely dependent on Class of Mission. High complexity missions can have many single point failures and require the development of new technology, while lower class mission can have lower risk by baselining or incorporating: (selective) redundancy, fault-tolerant design, design for minimum risk, ability to reset, and/or design for graceful degradation. The team met with Goddard Space Flight Center Space Systems Mission Operations leaders to discuss which avionics have proven in flight to be the most reliable and which have had lifetime issues. The paper proposes a list of components to focus on for redundancy for a long-lived lunar mission. Reliability numbers are presented for both single string and dual string missions. The history of life-time performance versus planned mission life according to mission class is presented. A mission with well thought out selective redundancy and effective on the ground test program, can be expected to last well beyond its mission lifetime and provided enhanced return for the community. This approach minimizes project expenditures that do not retire significant risk and allows the project to focus risk mitigation efforts on those risks that will have a significant likelihood of threatening mission success. This is aided by keeping the amount of technology maturation and mission complexity low, while focusing effort on ensuring all component stress-ing parameters well within the bounds of their capabilities.
Lessons Learned↗
Space Station Technology Summary
The completion of the Space Station Propulsion Advanced Technology Programs established an in-depth data base for the baseline gaseous oxygen/gaseous hydrogen thruster, the waste gas resistojet, and the associated system operations. These efforts included testing of a full end-to-end system at National Aeronautics and Space Administration (NASA)-Marshall Space Flight Center (MSFC) in which oxygen and hydrogen were generated from water by electrolysis at 6.89 MPa (1,000 psia), stored and fired through the prototype thruster. Recent end-to-end system tests which generate the oxygen/hydrogen propellants by electrolysis of water at 20.67 MPa (3,000 psia) were completed on the Integrated Propulsion Test Article (IPTA) at NASA-Johnson Space Center (JSC). Resistojet testing has included 10,000 hours of life testing, plume characterization, and electromagnetic interference (EMI) testing. Extensive 25-lbf thruster testing was performed defining operating performance characteristics across the required mixture ratio and thrust level ranges. Life testing has accumulated 27 hours of operation on the prototype thruster. A total of seven injectors and five thrust chambers were fabricated to the same basic design. Five injectors and three thrust chambers designed to incorporate improved life, performance, and producibility characteristics are ready for testing. Five resistojets were fabricated and tested, with modifications made to improve producibility. The lessons learned in the area of producibility for both the O2/H2 thrusters and for the resistojet have resolved critical fabrication issues. The test results indicate that all major technology issues for long life and reliability for space station application were resolved.
Iacabucci, R.↗
U.S. Space Station Freedom waste fluid disposal system with consideration of hydrazine waste gas injection thrusters
The results are reported of a study of various methods for propulsively disposing of waste gases. The options considered include hydrazine waste gas injection, resistojets, and eutectic salt phase change heat beds. An overview is given of the waste gas disposal system and how hydrozine waste gas injector thruster is implemented within it. Thruster performance for various gases are given and comparisons with currently available thruster models are made. The impact of disposal on station propellant requirements and electrical power usage are addressed. Contamination effects, reliability and maintainability assessments, safety issues, and operational scenarios of the waste gas thruster and disposal system are considered.
Winters, Brian A.↗
System considerations, projected requirements and applications for aeronautical mobile satellite communications for air traffic services
The projected application and requirements in the near term (to 1995) and far term (to 2010) for aeronautical mobile services supporting air traffic control operations are addressed. The implications of these requirements on spectrum needs, and the resulting effects on the satellite design and operation are discussed. The U.S. is working with international standards and regulatory organizations to develop the necessary aviation standards, signalling protocols, and implementation methods. In the provision of aeronautical safety services, a number of critical issues were identified, including system reliability and availability, access time, channel restoration time, interoperability, pre-emption techniques, and the system network interfaces. Means for accomplishing these critical services in the aeronautical mobile satellite service (AMSS), and the various activities relating to the future provision of aeronautical safety services are addressed.
Mcdonald, K. D.↗
Automation of closed environments in space for human comfort and safety
The development of Environmental Control and Life Support Systems (ECLSS) for Space Station Freedom, future colonization of the Moon, and Mars missions presents new challenges for present technologies. ECLSS that operate during long-duration missions must be semi-autonomous to allow crew members environmental control without constant supervision. A control system for the ECLSS must address these issues as well as being reliable. The Kansas State University Advanced Design Team is in the process of researching and designing controls for the automation of the ECLSS for Space Station Freedom and beyond. The ECLSS for Freedom is composed of six subsystems. The temperature and humidity control (THC) subsystem maintains the cabin temperature and humidity at a comfortable level. The atmosphere control and supply (ACS) subsystem insures proper cabin pressure and partial pressures of oxygen and nitrogen. To protect the space station from fire damage, the fire detection and suppression (FDS) subsystem provides fire-sensing alarms and extinguishers. The waste management (WM) subsystem compacts solid wastes for return to Earth, and collects urine for water recovery. The atmosphere revitalization (AR) subsystem removes CO2 and other dangerous contaminants from the air. The water recovery and management (WRM) subsystem collects and filters condensate from the cabin to replenish potable water supplies, and processes urine and other waste waters to replenish hygiene water supplies. These subsystems are not fully automated at this time. Furthermore, the control of these subsystems is not presently integrated; they are largely independent of one another. A fully integrated and automated ECLSS would increase astronauts' productivity and contribute to their safety and comfort.
Source record↗
STGT program: Ada coding and architecture lessons learned
STGT (Second TDRSS Ground Terminal) is currently halfway through the System Integration Test phase (Level 4 Testing). To date, many software architecture and Ada language issues have been encountered and solved. This paper, which is the transcript of a presentation at the 3 Dec. meeting, attempts to define these lessons plus others learned regarding software project management and risk management issues, training, performance, reuse, and reliability. Observations are included regarding the use of particular Ada coding constructs, software architecture trade-offs during the prototyping, development and testing stages of the project, and dangers inherent in parallel or concurrent systems, software, hardware, and operations engineering.
Usavage, Paul↗
Metallurgical Evaluations of Depainting Processes on Aluminum Substrate
In December 1993, the Environmental Protection Agency (EPA) Emission Standards Division and the National Aeronautics and Space Administration's (NASA's) Marshall Space Flight Center (MSFC) signed an Interagency Agreement (IA) initiating a task force for the technical assessment of alternative technologies for aerospace depainting operations. The United States Air Force (USAF) joined the task force in 1994. The mandates of the task force were: (1) To identify available alternative depainting systems that do not rely on methylene chloride or other ozone-depleting, chlorinated, and volatile organic carbon solvents. (2) To determine the viability, applicability, and pollution prevention potential of each identified alternative. (3) To address issues of safety, environmental impact, reliability, and maintainability. Through a Technical Implementation Committee (TIC), the task force selected and evaluated eight alternative paint stripping technologies: chemical stripping, carbon dioxide (CO2) blasting, xenon flashlamp and CO2 coatings removal (FLASHJET(R)), CO2 laser stripping, plastic media blasting (PMB), sodium bicarbonate wet stripping, high-pressure water blasting (WaterJet), and wheat starch abrasive blasting (Enviro-Strip(R)). (The CO2 blasting study was discontinued after the first depainting sequence.) This final report presents the results of the Joint EPA/NASA/USAF Interagency Depainting Study. Significant topics include: (1) Final depainting sequence data for the chemical stripping, PMB, sodium bicarbonate wet stripping, and WaterJet processes. (2) Strip rates for all eight technologies. (3) Sequential comparisons of surface roughness measurements for the seven viable depainting technologies. (4) Chronological reviews of and lessons learned in the conduct of all eight technologies. (5) An analysis of the surface roughness trends for each of the seven technologies. (6) Metallurgic evaluations of panels Summaries of corrosion and hydrogen embrittlement evaluations of chemical stripping panels, detailed descriptions of which appear in previous reports. Because the requirements for alternative systems are diverse, as are initial setup, training, and on-going operational considerations, this study does not recommend a particular product or process. Users of this study will draw their own conclusions from the data presented herein.
McGill, Preston↗
Deformation and Life Analysis of Composite Flywheel Disk and Multi-disk Systems
In this study an attempt is made to put into perspective the problem of a rotating disk, be it a single disk or a number of concentric disks forming a unit. An analytical model capable of performing an elastic stress analysis for single/multiple, annular/solid, anisotropic/isotropic disk systems, subjected to both pressure surface tractions, body forces (in the form of temperature-changes and rotation fields) and interfacial misfits is derived and discussed. Results of an extensive parametric study are presented to clearly define the key design variables and their associated influence. In general the important parameters were identified as misfit, mean radius, thickness, material property and/or load gradation, and speed; all of which must be simultaneously optimized to achieve the "best" and most reliable design. Also, the important issue of defining proper performance/merit indices (based on the specific stored energy), in the presence of multiaxiality and material anisotropy is addressed. These merit indices are then utilized to discuss the difference between flywheels made from PMC and TMC materials with either an annular or solid geometry. Finally two major aspects of failure analysis, that is the static and cyclic limit (burst) speeds are addressed. In the case of static limit loads, upper, lower, and out-of-plane bounds for disks with constant thickness are presented for both the case of internal pressure loading (as one would see in a hydroburst test) and pure rotation (as in the case of a free spinning disk). The results (interaction diagrams) are displayed graphically in designer friendly format. For the case of fatigue, a representative fatigue/life master curve is illustrated in which the normalized limit speed versus number of applied cycles is given for a cladded TMC disk application.
Arnold, S. M.↗
Enhanced Low Dose Rate Effects in Bipolar Circuits: A New Hardness Assurance Problem for NASA
Many bipolar integrated circuits are much more susceptible to ionizing radiation at low dose rates than they are at high dose rates typically used for radiation parts testing. Since the low dose rate is equivalent to that seen in space, the standard lab test no longer can be considered conservative and has caused the Air Force to issue an alert. Although a reliable radiation hardness assurance test has not yet been designed, possible mechanisms for low dose rate enhancement and hardness assurance tests are discussed.
bipolar integrated circuits↗
Efficient and Robust Data Collection Using Compact Micro Hardware, Distributed Bus Architectures and Optimizing Software
Future In-Space propulsion systems for exploration programs will invariably require data collection from a large number of sensors. Consider the sensors needed for monitoring several vehicle systems states of health, including the collection of structural health data, over a large area. This would include the fuel tanks, habitat structure, and science containment of systems required for Lunar, Mars, or deep space exploration. Such a system would consist of several hundred or even thousands of sensors. Conventional avionics system design will require these sensors to be connected to a few Remote Health Units (RHU), which are connected to robust, micro flight computers through a serial bus. This results in a large mass of cabling and unacceptable weight. This paper first gives a survey of several techniques that may reduce the cabling mass for sensors. These techniques can be categorized into four classes: power line communication, serial sensor buses, compound serial buses, and wireless network. The power line communication approach uses the power line to carry both power and data, so that the conventional data lines can be eliminated. The serial sensor bus approach reduces most of the cabling by connecting all the sensors with a single (or redundant) serial bus. Many standard buses for industrial control and sensor buses can support several hundreds of nodes, however, have not been space qualified. Conventional avionics serial buses such as the Mil-Std-1553B bus and IEEE 1394a are space qualified but can support only a limited number of nodes. The third approach is to combine avionics buses to increase their addressability. The reliability, EMI/EMC, and flight qualification issues of wireless networks have to be addressed. Several wireless networks such as the IEEE 802.11 and Ultra Wide Band are surveyed in this paper. The placement of sensors can also affect cable mass. Excessive sensors increase the number of cables unnecessarily. Insufficient number of sensors may not provide adequate coverage of the system. This paper also discusses an optimal technique to place and validate sensors.
micro hardware↗
Environmental Control and Life Support (ECLS) Integrated Roadmap Development
This white paper documents a roadmap for development of Environmental Control and Life Support (ECLS) Systems (ECLSS) capabilities required to enable beyond-Low Earth Orbit (LEO) Exploration missions. In many cases, the execution of this Exploration-based roadmap will directly benefit International Space Station (ISS) operational capability by resolving known issues and/or improving overall system reliability. In addition, many of the resulting products will be applicable across multiple Exploration elements such as Multi-Purpose Crew Vehicle (MPCV), Multi-Mission Space Exploration Vehicle (MMSEV), Deep Space Habitat (DSH), and Landers. Within the ECLS community, this white paper will be a unifying tool that will improve coordination of resources, common hardware, and technologies. It will help to align efforts to focus on the highest priority needs that will produce life support systems for future human exploration missions that will simply run in the background, requiring minimal crew interaction.
Metcalf, Jordan L.↗
Chromium Oxidation State in Planetary Basalts: Oxygen Fugacity Indicator and Critical Variable for Cr-Spinel Stability
Cr is a ubiquitous and relatively abundant minor element in basaltic, planetary magmas. At the reduced oxidation states (<FMQ) of many planetary basalts Cr is present in melts as both divalent and trivalent forms. The ratio of trivalent to divalent Cr present in the melt has many consequences for the stability and Cr concentration of magmatic phases such as spinel, clinopyroxene, and olivine. However, understanding the Cr valence in quenched melts has historically been plagued with analytical issues, and only recently has reliable methodology for quantifying Cr valence in quenched melts been developed. Despite this substantial difficulty, the pioneering works of Hanson and Jones and Berry and O'Neill provided important insights into the oxidation state of Cr in in silicate melts. Here we present a series of 1-bar gas mixing experiments performed with a Fe-rich basaltic melt in which have determined the Cr redox ratio of the melt at over a range of fO2 values by measuring this quantity in olivine with X-ray Absorption Near Edge Spectroscopy (XANES). The measured Cr redox ratio of the olivine phenocrysts can be readily converted to the ratio present in the conjugate melt via the ratio of crystal-liquid partition coefficients for Cr3+ and Cr2+. We have applied these results to modeling Cr spinel stability and Cr redox ratios in a primitive, iron-rich martian basalt.
Bell, A. S.↗