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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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At least 199 records · Page 11
All sourcesNASA NTRSDOE OSTI
NASA NTRS2016

Failure Analysis and Recovery of a 50mm Highly Elastic Intermetallic NiTi Ball Bearing for an ISS Application

The ISS Distillation Assembly centrifuge is the pathfinder application for 50mm bore, deep-groove ball bearings made from the highly elastic intermetallic material 60NiTi. Superior corrosion and shock resistance are required to withstand the acidic wastewater exposure and heavy spacecraft launch related loads that challenge conventional steel bearings. During early ground testing one bearing unexpectedly and catastrophically failed after operating for only 200 hours of run time. A second bearing running on the same shaft was completely unaffected. A thorough investigation into the root cause of the failure determined that an excessively tight press-fit of the bearing outer race coupled with NiTis relatively low elastic modulus were key contributing factors. The proposed failure mode was successfully duplicated by experiment. To further corroborate the root cause theory, a successful bearing life test using improved installation practices (selective fitting) was conducted. The results show that NiTi bearings are suitable for space applications provided that care is taken to accommodate their unique material characteristics.

intermetallics↗
NASA NTRS2016

Failure Analysis and Recovery of a 50 MM Highly Elastic Intermetallic NiTi Ball Bearing for an ISS Application

The ISS Distillation Assembly centrifuge is the pathfinder application for 50mm bore, deep-groove ball bearings made from the highly elastic intermetallic material 60NiTi. Superior corrosion and shock resistance are required to withstand the acidic wastewater exposure and heavy spacecraft launch related loads that challenge conventional steel bearings. During early ground testing one bearing unexpectedly and catastrophically failed after operating for only 200 hours of run time. A second bearing running on the same shaft was completely unaffected. A thorough investigation into the root cause of the failure determined that an excessively tight press-fit of the bearing outer race coupled with NiTis relatively low elastic modulus were key contributing factors. The proposed failure mode was successfully duplicated by experiment. To further corroborate the root cause theory, a successful bearing life test using improved installation practices (selective fitting) was conducted. The results show that NiTi bearings are suitable for space applications provided that care is taken to accommodate their unique material characteristics.

failure analyses↗
NASA NTRS2000

Software Fault Tolerance: A Tutorial

Because of our present inability to produce error-free software, software fault tolerance is and will continue to be an important consideration in software systems. The root cause of software design errors is the complexity of the systems. Compounding the problems in building correct software is the difficulty in assessing the correctness of software for highly complex systems. After a brief overview of the software development processes, we note how hard-to-detect design faults are likely to be introduced during development and how software faults tend to be state-dependent and activated by particular input sequences. Although component reliability is an important quality measure for system level analysis, software reliability is hard to characterize and the use of post-verification reliability estimates remains a controversial issue. For some applications software safety is more important than reliability, and fault tolerance techniques used in those applications are aimed at preventing catastrophes. Single version software fault tolerance techniques discussed include system structuring and closure, atomic actions, inline fault detection, exception handling, and others. Multiversion techniques are based on the assumption that software built differently should fail differently and thus, if one of the redundant versions fails, it is expected that at least one of the other versions will provide an acceptable output. Recovery blocks, N-version programming, and other multiversion techniques are reviewed.

Torres-Pomales, Wilfredo↗
NASA NTRS2022

Remote Diagnosis and Operational Response to an In-Flight Failure of the Drill Feed Mechanism Onboard the Mars Science Laboratory Rover

On November 30th, 2016 (Sol 1536 of the mission), the Mars Science Laboratory (MSL) flight operations team commanded the Curiosity rover to drill into a Martian rock to acquire the mission’s 16th rock powder sample. The drilling operation was halted when the drill feed mechanism unexpectedly stalled shortly after disengaging its magnetically-actuated friction brake at the start of a long move to extend the drill bit into contact with the target rock. The drilling campaign was put on hold and later abandoned as diagnostic experimentation revealed a tendency for the actuator to transition in and out of a high-drag state in which the mechanism could not actuate. In the subsequent months, the team conducted a variety of in-flight and ground-based investigations to determine root cause and identify mitigation strategies for continued operation. Mechanism reliability continued to degrade and by June 2017, it became clear that the mechanism could not be relied upon to support drilling operations. The team succeeded in fully extending the feed, enabling the development of new sampling techniques that would not rely on the feed mechanism. The first feed-extended drilling sample was successfully collected on Sol 2057, 521 sols after the initial feed stall. This paper discusses the anomaly investigation process, failure analysis, and feed mechanism operation mitigation strategies. It concludes with key lessons learned about mechanism design, mission architecture, and operational best practices.

Lin, Megan Richardson↗
DOE OSTI2024

Process–Property–Performance Mapping of Additively Manufactured 316H Stainless Steel Components

The Advanced Materials and Manufacturing Technologies Program is focused on accelerating the development of advanced materials and components fabricated via additive manufacturing, and is using laser powder bed fusion (LPBF) of 316H stainless steel as an initial case study. In the previous fiscal year, miniature high-throughput specimens were printed on multiple LPBF systems to provide initial processing windows to minimize porosity and limit epitaxial grain growth during prints. This fiscal year, scaled builds were completed on three different LPBF systems at ORNL: a GE Concept Laser M2, a Renishaw AM400, and an EOS M290. Builds on the Concept Laser were conducted on multiple powder lots and processing parameter ranges to provide microstructure effects on time-independent and time-dependent mechanical properties. Builds on the Renishaw were produced using Oak Ridge National Laboratory (ORNL)-optimized printing parameters and Argonne National Laboratory (ANL)-optimized printing parameters to compare outcomes of parallel process optimization efforts at different national laboratories on the same LPBF system. Similarly, the build completed on the EOS M290 replicated the processing parameters of builds completed at Los Alamos National Laboratory (LANL). Optical microscopy and electron backscatter diffraction characterization was completed on all builds. In addition to the general round robin characterization, this work-package generated time-independent data, including tensile and fracture toughness test data on scaled Concept Laser builds as a function of processing parameters and post-build heat treatment. This analysis is complimentary to work in parallel work packages aiming to establish heat treatment and processing effects on time-dependent properties. It was found that although the stress-relief heat treatment provides the highest strength at lower-temperatures, tensile strength begins to converge at higher temperatures regardless of heat treatment condition. In addition, the more rigorous solution annealing and hot-isostatic pressing post-build heat treatments result in higher fracture toughness than the stress-relieved condition. The root-causes of the lower fracture toughness of the stress-relieved LPBF 316H material was informed via a stress-relief optimization study on a scaled concept laser print, where it was found that although dislocation recovery was largely complete after only a couple hours at 650°C, the extended hold of the current 24h heat treatment employed on scaled builds likely caused increased carbide volume fractions along the LPBF 316H grain boundaries, thereby deteriorating crack propagation resistance. This trend was seen to become more deleterious with additional increases of stress-relief temperature to 750°C or 850°C. These results have helped inform a new optimal stress-relief annealing condition for LPBF 316H for future campaign testing (650°C for 2h).

36 MATERIALS SCIENCE↗
DOE OSTI2024

Process–Property–Performance Mapping of Additively Manufactured 316H Stainless Steel Components

The Advanced Materials and Manufacturing Technologies Program is focused on accelerating the development of advanced materials and components fabricated via additive manufacturing, and is using laser powder bed fusion (LPBF) of 316H stainless steel as an initial case study. In the previous fiscal year, miniature high-throughput specimens were printed on multiple LPBF systems to provide initial processing windows to minimize porosity and limit epitaxial grain growth during prints. This fiscal year, scaled builds were completed on three different LPBF systems at ORNL: a GE Concept Laser M2, a Renishaw AM400, and an EOS M290. Builds on the Concept Laser were conducted on multiple powder lots and processing parameter ranges to provide microstructure effects on time-independent and time-dependent mechanical properties. Builds on the Renishaw were produced using Oak Ridge National Laboratory (ORNL)-optimized printing parameters and Argonne National Laboratory (ANL)-optimized printing parameters to compare outcomes of parallel process optimization efforts at different national laboratories on the same LPBF system. Similarly, the build completed on the EOS M290 replicated the processing parameters of builds completed at Los Alamos National Laboratory (LANL). Optical microscopy and electron backscatter diffraction characterization was completed on all builds. In addition to the general round robin characterization, this work-package generated time-independent data, including tensile and fracture toughness test data on scaled Concept Laser builds as a function of processing parameters and post-build heat treatment. This analysis is complimentary to work in parallel work packages aiming to establish heat treatment and processing effects on time-dependent properties. It was found that although the stress-relief heat treatment provides the highest strength at lower-temperatures, tensile strength begins to converge at higher temperatures regardless of heat treatment condition. In addition, the more rigorous solution annealing and hot-isostatic pressing post-build heat treatments result in higher fracture toughness than the stress-relieved condition. The root-causes of the lower fracture toughness of the stress-relieved LPBF 316H material was informed via a stress-relief optimization study on a scaled concept laser print, where it was found that although dislocation recovery was largely complete after only a couple hours at 650°C, the extended hold of the current 24h heat treatment employed on scaled builds likely caused increased carbide volume fractions along the LPBF 316H grain boundaries, thereby deteriorating crack propagation resistance. This trend was seen to become more deleterious with additional increases of stress-relief temperature to 750°C or 850°C. These results have helped inform a new optimal stress-relief annealing condition for LPBF 316H for future campaign testing (650°C for 2h).

36 MATERIALS SCIENCE↗
NASA NTRS1995

Multiparameter linear least-squares fitting to Poisson data one count at a time

A standard problem in gamma-ray astronomy data analysis is the decomposition of a set of observed counts, described by Poisson statistics, according to a given multicomponent linear model, with underlying physical count rates or fluxes which are to be estimated from the data. Despite its conceptual simplicity, the linear least-squares (LLSQ) method for solving this problem has generally been limited to situations in which the number n(sub i) of counts in each bin i is not too small, conventionally more than 5-30. It seems to be widely believed that the failure of the LLSQ method for small counts is due to the failure of the Poisson distribution to be even approximately normal for small numbers. The cause is more accurately the strong anticorrelation between the data and the wieghts w(sub i) in the weighted LLSQ method when square root of n(sub i) instead of square root of bar-n(sub i) is used to approximate the uncertainties, sigma(sub i), in the data, where bar-n(sub i) = E(n(sub i)), the expected value of N(sub i). We show in an appendix that, avoiding this approximation, the correct equations for the Poisson LLSQ (PLLSQ) problems are actually identical to those for the maximum likelihood estimate using the exact Poisson distribution. We apply the method to solve a problem in high-resolution gamma-ray spectroscopy for the JPL High-Resolution Gamma-Ray Spectrometer flown on HEAO 3. Systematic error in subtracting the strong, highly variable background encountered in the low-energy gamma-ray region can be significantly reduced by closely pairing source and background data in short segments. Significant results can be built up by weighted averaging of the net fluxes obtained from the subtraction of many individual source/background pairs. Extension of the approach to complex situations, with multiple cosmic sources and realistic background parameterizations, requires a means of efficiently fitting to data from single scans in the narrow (approximately = 1.2 keV, HEAO 3) energy channels of a Ge spectrometer, where the expected number of counts obtained per scan may be very low. Such an analysis system is discussed and compared to the method previously used.

Wheaton, Wm. A.↗
NASA NTRS2018

Analysis of Performance Degradation of Silica Gels After Extended Use Onboard the ISS

The teardown of two flight desiccant beds from the Carbon Dioxide Removal Assembly (CDRA) revealed significant discoloration of the silica gel near the bed inlet as well as a coincidental performance loss. This material was analyzed for the presence of chemical contaminants, physical porosity changes, and adsorption performance. The material characteristics are compared against the location in the bed from which they were sampled in order to develop profiles through the bed. Additional testing of the beds prior to teardown provided more data points. Possible mechanisms for the loss of capacity are provided though no root cause has been found. Extrapolation of the performance loss is used to estimate the required oversizing of the silica gel layer for long-term operation.

Cmarik, Gregory E.↗
NASA NTRS2018

Analysis of Performance Degradation of Silica Gels After Extended Use Onboard the ISS

The disassembly of two flight desiccant beds from the Carbon Dioxide Removal Assembly (CDRA) revealed significant discoloration of the silica gel near the bed inlet as well as a coincidental performance loss. This material was analyzed for the presence of chemical contaminants, physical porosity changes, and adsorption performance. The material characteristics are compared against the location in the bed from which they were sampled in order to develop profiles through the bed. Additional testing of the beds prior to disassembly provided more data points. Possible mechanisms for the loss of capacity are provided though no root cause has been confirmed. Extrapolation of the performance loss is used to estimate the required oversizing of the silica gel layer for long-term operation.

Cmarik, Gregory E.↗
NASA NTRS2016

Failure Analysis and Recovery of a 50-mm Highly Elastic Intermetallic NiTi Ball Bearing for an ISS Application

Ball bearings used inside the ISS Distillation Assembly centrifuge require superior corrosion and shock resistance to withstand acidic wastewater exposure and heavy spacecraft launch related loads. These requirements challenge conventional steel bearings and provide an ideal pathfinder application for 50-mm bore, deep-groove ball bearings made from the corrosion immune and highly elastic intermetallic material 60NiTi. During early ground testing in 2014 one 60NiTi bearing unexpectedly and catastrophically failed after operating for only 200 hr. A second bearing running on the same shaft was completely unaffected. An investigation into the root cause of the failure determined that an excessively tight press fit of the bearing outer race coupled with NiTi's relatively low elastic modulus were key contributing factors. The proposed failure mode was successfully replicated by experiment. To further corroborate the root cause theory, a successful bearing life test using improved installation practices (selective fitting) was conducted. The results show that NiTi bearings are suitable for space applications provided that care is taken to accommodate their unique material characteristics.

DellaCorte, Christopher↗
NASA NTRS2023

Hot Cracking Behavior and Beam-Induced Grain Refinement in Electron Beam Freeform Fabricated Al 7075

Electron beam freeform fabrication (EBF 3 ) is a high deposition rate, wire-based directed energy deposition (DED) additive manufacturing (AM) process used to print metallic parts in a vacuum environment. While high specific strength 7xxx-series Al alloys are of interest in the aerospace and automotive industries, these alloys suffer from hot cracking issues during fusion welding and AM. In this work, linear deposits of Al 7075 were fabricated with EBF 3 to study the effects of baseplate thickness, preheat temperature, and beam focus on hot cracking behavior. Solidification cracks were observed in the first deposition layer, and by the third layer coalesced into large “macrocracks” running vertically through the build height. Fine, intergranular liquation “microcracks” appeared between macrocracks below the root of the final deposit layer fusion zone. Increasing the substrate preheat temperature from 165°C to 320°C deepened the partially melted zone and resulted in a more than twofold increase in the liquation microcrack density. Analysis of Scheil solidification diagrams revealed that fugitive losses of Zn and Mg during deposition increased the susceptibility to solidification cracking and promoted substrate liquation cracking. Focused electron beam (EB) conditions combined with a high aspect ratio elliptical raster pattern resulted in bands of refined, equiaxed grains. The refined microstructure suppressed solidification macrocracking and caused a nearly fivefold reduction in liquation crack density, demonstrating that beam-induced grain refinement may be a promising low-cost method for reducing hot cracking during AM.

aluminum↗
NASA NTRS2014

Addressing the Hard Factors for Command File Errors by Probabilistic Reasoning

Command File Errors (CFE) are managed using standard risk management approaches at the Jet Propulsion Laboratory. Over the last few years, more emphasis has been made on the collection, organization, and analysis of these errors for the purpose of reducing the CFE rates. More recently, probabilistic modeling techniques have been used for more in depth analysis of the perceived error rates of the DAWN mission and for managing the soft factors in the upcoming phases of the mission. We broadly classify the factors that can lead to CFE's as soft factors, which relate to the cognition of the operators and hard factors which relate to the Mission System which is composed of the hardware, software and procedures used for the generation, verification & validation and execution of commands. The focus of this paper is to use probabilistic models that represent multiple missions at JPL to determine the root cause and sensitivities of the various components of the mission system and develop recommendations and techniques for addressing them. The customization of these multi-mission models to a sample interplanetary spacecraft is done for this purpose.

Meshkat, Leila↗
DOE OSTI2024

Leveraging Hydropower Multi-Sensor Data for Inference and Age-Informed Modeling

Increased demand of operational flexibility such as faster ramp up/down in generation, and more frequent start/stops are putting hydropower plants and their associated components in unprecedented stress. Consequently, these plants are at the high risk of extended and more frequent outage to accommodate unscheduled, and unexpected maintenance. Therefore, hydropower plants are in critical need of data driven and age-informed analysis for their regular and unscheduled operation. Yet not all hydropower plants are exhaustively equipped with sensors and/or measurement streams for their respective components – demanding solutions on how to detect, identify, and locate the cause of any event from the unobservable. Idaho National Laboratory (INL) analyzed the anonymized measurements and event records from the Hydropower Research Institute (HRI) to address this issue, as part of the Water Power Technologies Office (WPTO) funded one year multi-lab project. First, we investigated how time series of multiple sensor measurements can be leveraged to identify an event “root cause” as well as to develop an inference (i.e., estimate the unobservable) problem. INL also investigated how individual hydropower components’ reaction or response times vary across the pre-event, during event, and post-event conditions – enabling the hydropower dynamic models to be age-informed. Finally, the impact of clustering multi-sensor time series on short-term vibration prediction is analyzed. INL will present key findings from these analyses and recommend next steps for stakeholder adoption.

13 HYDRO ENERGY↗
NASA NTRS2004

Space-Based Telemetry And Range Safety Flight Demonstration #1

The basic ability of STARS to maintain a satellite communications link with TDRSS satellites during dynamic aircraft flights was successfully demonstrated during FD 1. The Range Safety and Range User systems' link margins were measured. The ability to acquire/reacquire and maintain lock between a high-dynamic vehicle and a satellite-based system was demonstrated. The Range Safety system simultaneously received and processed command links from space and ground transmitters and provided near real-time Range Safety telemetry to DFRC, which then sent it in near real time to KSC, GSFC, and WFF for monitoring. The GPS receiver maintained track except during extremely dynamic maneuvers. The Range User system sent data at three different data rates. There were excellent cooperation and support from the different Centers, contractors, and Ranges. A large amount of data was recorded and extensive post-flight analysis was performed. The Range User TDRSS link margin met or exceeded the predicted performance at three different data rates. The Range Safety launch-head link margins generally agreed with the predicted performance. The UPS positions and velocities agreed with those from tracking radar to within about 20 m and a few rn/s. The link margins for the Range Safety TDRSS telemetry link were less than expected. The link margin for one TDRSS command link LPT channel was occasionally much less than the other. Additional post-flight testing has yet to identify the root causes of these results. There were many lessons learned from this first set of test flights. The most important one is that more time and testing are needed for each step to deal with the inevitable problems. It is vital that these lessons be among the primary areas of study that will carry over from FD#1 to FD#2, which is currently scheduled for early FY05 at DFRC and will use a specially designed Ku-band phased array antenna for the Range User system. The next series of flight demonstrations scheduled for late 2004 at DFRC will incorporate many lessons learned from FD#1. A specially designed Ku-band phased array antenna will be used with the Range User system. A test flight on a hypersonic vehicle is planned by the end of 2006.

Demspm. Erol↗
NASA NTRS2014

Spacesuit Water Membrane Evaporator Integration with the ISS Extravehicular Mobility Unit

NASA has developed a Solid Water Membrane Evaporation (SWME) to provide cooling for the next generation spacesuit. The current spacesuit team has looked at this technology from the standpoint of using the ISS EMU to demonstrate the SWME technology while EVA, and from the standpoint of augmenting EMU cooling in the case of a fouled EMU cooling system. One approach to increasing the TRL of the system is to incorporate this hardware with the existing EMU. Several integration issues were addressed to support a potential demonstration of the SWME with the existing EMU. Systems analysis was performed to assess the capability of the SWME to maintain crewmember cooling and comfort as a replacement for sublimation. The materials of the SWME were reviewed to address compatibility with the EMU. Conceptual system placement and integration with the EMU via an EVA umbilical system to ensure crew mobility and Airlock egress were performed. A concept of operation for EVA use was identified that is compatible with the existing system. This concept is extensible as a means to provide cooling for the existing EMU. The cooling system of one of the EMUs on orbit has degraded, with the root cause undetermined. Should there be a common cause resident on ISS, this integration could provide a means to recover cooling capability for EMUs on orbit.

Margiott, Victoria↗
NASA NTRS2014

Spacesuit Water Membrane Evaporator Integration with the ISS Extravehicular Mobility

NASA has developed a Solid Water Membrane Evaporation (SWME) to provide cooling for the next generation spacesuit. One approach to increasing the TRL of the system is to incorporate this hardware with the existing EMU. Several integration issues were addressed to support a potential demonstration of the SWME with the existing EMU. Systems analysis was performed to assess the capability of the SWME to maintain crewmember cooling and comfort as a replacement for sublimation. The materials of the SWME were reviewed to address compatibility with the EMU. Conceptual system placement and integration with the EMU via an EVA umbilical system to ensure crew mobility and Airlock egress were performed. A concept of operation for EVA use was identified that is compatible with the existing system. This concept is extensible as a means to provide cooling for the existing EMU. The cooling system of one of the EMUs on orbit has degraded, with the root cause undetermined. Should there be a common cause resident on ISS, this integration could provide a means to recover cooling capability for EMUs on orbit.

Margiott, Victoria↗
NASA NTRS1994

Comments on the statistical analysis of excess variance in the COBE differential microwave radiometer maps

Cosmic anisotrophy produces an excess variance sq sigma(sub sky) in the Delta maps produced by the Differential Microwave Radiometer (DMR) on cosmic background explorer (COBE) that is over and above the instrument noise. After smoothing to an effective resolution of 10 deg, this excess sigma(sub sky)(10 deg), provides an estimate for the amplitude of the primordial density perturbation power spectrum with a cosmic uncertainty of only 12%. We employ detailed Monte Carlo techniques to express the amplitude derived from this statistic in terms of the universal root mean square (rms) quadrupole amplitude, (Q sq/RMS)(exp 0.5). The effects of monopole and dipole subtraction and the non-Gaussian shape of the DMR beam cause the derived (Q sq/RMS)(exp 0.5) to be 5%-10% larger than would be derived using simplified analytic approximations. We also investigate the properties of two other map statistics: the actual quadrupole and the Boughn-Cottingham statistic. Both the sigma(sub sky)(10 deg) statistic and the Boughn-Cottingham statistic are consistent with the (Q sq/RMS)(exp 0.5) = 17 +/- 5 micro K reported by Smoot et al. (1992) and Wright et al. (1992).

Wright, E. L.↗
NASA NTRS1997

Spaceflight exposure effects on transcription, activity, and localization of alcohol dehydrogenase in the roots of Arabidopsis thaliana

Although considerable research and speculation have been directed toward understanding a plant's perception of gravity and the resulting gravitropic responses, little is known about the role of gravity-dependent physical processes in normal physiological function. These studies were conducted to determine whether the roots of plants exposed to spaceflight conditions may be experiencing hypoxia. Arabidopsis thaliana (L.) Heynh. plants were grown in agar medium during 6 or 11 d of spaceflight exposure on shuttle missions STS-54 (CHROMEX-03) and STS-68 (CHROMEX-05), respectively. The analysis included measurement of agar redox potential and root alcohol dehydrogenase (ADH) activity, localization, and expression. ADH activity increased by 89% as a result of spaceflight exposure for both CHROMEX-03 and -05 experiments, and ADH RNase protection assays revealed a 136% increase in ADH mRNA. The increase in ADH activity associated with the spaceflight roots was realized by a 28% decrease in oxygen availability in a ground-based study; however, no reduction in redox potential was observed in measurements of the spaceflight bulk agar. Spaceflight exposure appears to effect a hypoxic response in the roots of agar-grown plants that may be caused by changes in gravity-mediated fluid and/or gas behavior.

STS-68 Shuttle Project↗