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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 217 records · Page 12
All sourcesNASA NTRSDOE OSTI
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↗
DOE OSTI2021

Powder spreading, densification, and part deformation in binder jetting additive manufacturing

Binder jetting additive manufacturing (AM) can print complex structures in economical and scalable manner. Binder jetting AM comprises of deposition and weak binding of particles, known as green part, at room temperature and subsequent binder removal and sintering densification at high temperatures. However, during the densification (i.e., sintering), the part significantly deforms due to volume shrinkage. The deformation during sintering is difficult to predict, which prevents the widespread application of this technology. In this research, powder spreading simulation using discrete element method (DEM) was performed first to capture local variations in powder bed configuration. Second, finite element method (FEM) with a phenomenological continuum constitutive model was used to predict part shrinkage during the sintering process. DEM simulation showed variations in packing density, particle segregation, formation of uneven powder bed surface, and shift in particle size distribution (PSD). The sintering simulation modeled part deformation with a reasonable accuracy of 3% for solid-state sintering and intermediate liquid phase sintering. A demonstration case with non-uniform initial packing density showed that inhomogeneous green part density and PSD should be accounted for prediction of part deformation in binder jetting AM.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Impact of controlled prewetting on part formation in binder jet additive manufacturing

Binder jetting is an additive manufacturing process that bonds powder through selectively depositing binder by inkjet printing. The part is then extracted and densified by sintering and/or infiltration. The process offers low costs and fast build rates, but properties can be poor due to residual porosity after sintering. The inkjet printing process may contribute to this residual porosity by creating large pores. The droplet kinetic energy ejects some powder particles from the bed and rearranges others. Particle ejection and rearrangement are theorized to create porous regions in binder-jetted parts. In this work, small amounts of moisture are added to the spread powder before printing and the impact on part formation, part properties, and printing parameters measured with varied droplet spacing, droplet velocity, and print frequency. Moisture is added by applying an atomized fluid mixture to the powder between layer spreading and binder printing. The fluid mixture partially evaporates but leaves a stable residue to increase cohesion and enhance imbibition. Moisture addition to the powder increases the range of droplet spacings for line formation while reducing particle ejection, powder rearrangement, and balling in layer and multilayer parts. Excessive moisture addition decreases the effective saturation of printed lines, but saturation in 3D parts is less impacted. Increased surface roughness in the first few layers of a print was also mitigated with prewetting. Finally, high-speed X-ray imaging verified prewetting reduction in particle ejection and rearrangement.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Mass spectrometric investigations into 3D printed parts to assess radiopurity as ultralow background materials for rare event physics detectors

The mass concentrations of 232 Th and 238 U in several 3D printing filaments and printed polymer parts are reported as measures of their radiopurity. In order to minimize background signals in rare event physics detectors, radiopure polymers are necessary as dielectric and structural materials in their construction. New data are reported for polyvinylidene fluoride (PVDF), polyphenylene sulfide (PPS), and two forms of polyetherimide (PEI, branded ULTEM 1010 and 9085). Data for starting filaments and both simple and complex printed parts are reported. PVDF filaments and simple printed beads, were found to have values of approximately 30 and 50 pg g -1 for 232 Th and 238 U, respectively, while a more complex spring clip part had slightly elevated 232 Th levels of 65 pg g -1 , with 238 U remaining at 50 pg g -1 . PPS filament was found to have concentrations of 270 and 710 pg g -1 for 232 Th and 238 U, respectively, and were not chosen to be printed as those levels were already higher than other material options. ULTEM 1010 filaments and printed complex spring clip parts were found to have concentrations of around 5 and 7 pg g -1 for 232 Th and 238 U, respectively, illustrating no significant contamination from the printing process. ULTEM 9085 filaments were found to have concentrations of around 9 and 5 pg g -1 for 232 Th and 238 U, respectively, while the printed complex spring clip part was found to have slightly elevated concentrations of 25 and 7 pg g -1 for 232 Th and 238 U, respectively. All these results were obtained using a novel dry ashing method in crucibles constructed of ultralow background electroformed copper or, when applicable, microwave assisted wet ashing digestion. Samples and process blanks were spiked with 229 Th and 233 U as internal standards prior to dry/wet ashing and determinations were made by inductively coupled plasma mass spectrometry (ICP-MS). In order to maintain high radiopurity levels, pre-cleaning the filaments before printing and post-cleaning the parts is recommended, although the printing process itself has shown to contribute very minute amounts of radiocontaminants.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2022

Modeling interconnections of safety and financial performance of nuclear power plants, part 3: Spatiotemporal probabilistic physics-of-failure analysis and its connection to safety and financial performance

Here, this paper is a byproduct of a line of research by the authors to analyze interrelationships of safety and financial performance of nuclear power plants (NPPs). The result of this line of research is summarized in three parts: Part 1 covers a categorical review of relevant literature and the theoretical bases that support the methodological developments in Part 2. Part 2 introduces an Integrated Enterprise Risk Management (I-ERM) methodological framework to quantify the interconnections of safety and financial performance with a focus on operation and maintenance (O&M) of NPPs. Part 2 has also demonstrated the applicability and values of the I-ERM methodology through an NPP case study. This paper is Part 3, where detailed development and implementation of one of the I-ERM modules, i.e., probabilistic physics-of-failure (PPoF) analysis, and its connection with safety and financial performance is reported. In this article, the physical failure modeling for hardware components is advanced by incorporating finite element analysis (FEA) into PPoF analysis and coupling the FEA-based PPoF with the maintenance performance through a renewal process model. This article covers two scientific contributions: (i) first-of-its-kind incorporation of FEA into the PPoF model of thermal fatigue for NPP components; and (ii) advancing the interface between the PPoF analysis and the renewal process model in order to deal with spatiotemporal FEA outputs and to efficiently estimate the physical transition rates even when the PPoF outputs are dominated by success data. Through the incorporation of FEA, the resolution of the PPoF analysis is enhanced as spatiotemporal conditions such as stress and temperature can be considered explicitly instead of relying on simplified assumptions or analytical models with reduced spatiotemporal dimensions. To demonstrate an application of the FEA-based PPoF analysis and its coupling with maintenance through the renewal process model, a case study is conducted using excess letdown elbow piping in the chemical and volume control system of a Pressurized Water Reactor.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2026

Model-based, in-situ, non-destructive qualification and certification of parts made by autonomous additive manufacturing

To address the significant productivity challenges associated with the qualification and certification (Q&C) tasks of additively manufactured (AM) parts, which have traditionally relied on rigorous post‐build inspection and testing, we propose an integrated framework that combines model‐based qualification and certification (MBQ&C) with autonomous additive manufacturing (AAM). MBQ&C employs high‐fidelity predictive models, developed within the Integrated Computational Materials Engineering (ICME) paradigm, to simulate process–structure–property–performance relationships for assessing a part’s fitness for use. Since predictive models are commonly machine learning (ML)-based or reduced-order surrogates of validated physics models, they run efficiently, enabling timely inference. In parallel, the self-driving AAM utilises ML-based adaptive, closed‐loop control strategies to avoid, mitigate, or repair defects and anomalies during fabrication, thereby increasing the likelihood of producing acceptable parts. A key feature of the combined AAM-MBQ&C framework is that predictive models explicitly incorporate defects or anomalies that persist after the build, using instance-specific data captured via in-situ sensing. This customisation enables a build‐specific assessment of fitness for use, rather than relying on nominal or generic parameters. Such individualised evaluation provides a robust basis for Q&C-related acceptance decisions relating to each build. Additionally, the rapid solution capabilities of ML or reduced-order models enable the determination of a part’s suitability for service shortly after build completion. As the framework matures, it has the potential to substantially reduce reliance on conventional point‐design approaches—such as time‐consuming post‐build computed tomography scanning and costly destructive testing. Thus, the AAM-MBQ&C framework represents a transformative, scalable strategy for quality assurance of AM components, as parts produced within a stable, validated, and certified envelope can be certified with reduced testing. Key benefits include: (1) significant gains in Q&C productivity through efficient, model-centric assessment; (2) performance-based classification of defects into critical and non-critical categories; (3) the ability to predict potential deviations in the performance of parts affected by real-time, adaptive process control interventions relative to those produced under a certified process, and (4) the enabling of virtual Q&C for service environments that are difficult, hazardous, or impractical to access or reproduce experimentally. Collectively, these capabilities strengthen the business case for AM, particularly for high‐consequence and mission‐critical applications. Finally, although this work focuses on powder-based AM, the proposed techniques could be extended to AM processes employing alternative feedstock forms.

Gunasegaram, Dayalan↗
DOE OSTI2020

General approaches for shear-correcting coordinate transformations in Bragg coherent diffraction imaging. Part I

This two-part article series provides a generalized description of the scattering geometry of Bragg coherent diffraction imaging (BCDI) experiments, the shear distortion effects inherent in the 3D image obtained from presently used methods and strategies to mitigate this distortion. Part I starts from fundamental considerations to present the general real-space coordinate transformation required to correct this shear, in a compact operator formulation that easily lends itself to implementation with available software packages. Such a transformation, applied as a final post-processing step following phase retrieval, is crucial for arriving at an undistorted, correctly oriented and physically meaningful image of the 3D crystalline scatterer. As the relevance of BCDI grows in the field of materials characterization, the available sparse literature that addresses the geometric theory of BCDI and the subsequent analysis methods are generalized here. This geometrical aspect, specific to coherent Bragg diffraction and absent in 2D transmission CDI experiments, gains particular importance when it comes to spatially resolved characterization of 3D crystalline materials in a reliable nondestructive manner. This series of articles describes this theory, from the diffraction in Bragg geometry to the corrections needed to obtain a properly rendered digital image of the 3D scatterer. Part I of this series provides the experimental BCDI community with the general form of the 3D real-space distortions in the phase-retrieved object, along with the necessary post-retrieval correction method. Part II builds upon the geometric theory developed in Part I with the formalism to correct the shear distortions directly on an orthogonal grid within the phase-retrieval algorithm itself, allowing more physically realistic constraints to be applied. Taken together, Parts I and II provide the X-ray science community with a set of generalized BCDI shear-correction techniques crucial to the final rendering of a 3D crystalline scatterer and for the development of new BCDI methods and experiments.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Beam Hardening Artifact Reduction in X-Ray CT Reconstruction of 3D Printed Metal Parts Leveraging Deep Learning and CAD Models

Nondestructive evaluation (NDE) of additively manufactured (AM) parts is important for understanding the impacts of various process parameters and qualifying the built part. X-ray computed tomography (XCT) has played a critical role in rapid NDE and characterization of AM parts. However, XCT of metal AM parts can be challenging because of artifacts produced by standard reconstruction algorithms as a result of a confounding effect called “beam hardening.” Beam hardening artifacts complicate the analysis of XCT images and adversely impact the process of detecting defects, such as pores and cracks, which is key to ensuring the quality of the parts being printed. In this work, we propose a novel framework based on using available computer-aided design (CAD) models for parts to be manufactured, accurate XCT simulations, and a deep-neural network to produce high-quality XCT reconstructions from data that are affected by noise and beam hardening. Using extensive experiments with simulated data sets, we demonstrate that our method can significantly improve the reconstruction quality, thereby enabling better detection of defects compared with the state of the art. We also present promising preliminary results of applying the deep networks trained using CAD models to experimental data obtained from XCT of an AM jet-engine turbine blade.

Ziabari, Amir↗
DOE OSTI2023

Convective and Turbulent Motions in Nonprecipitating Cu. Part III: Characteristics of Turbulence Motions

Velocity field in a nonprecipitating Cu under BOMEX conditions, simulated by SAM with 10-m resolution and spectral bin microphysics is separated into the convective part and the turbulent part, using a wavelet filtering. In Part II of the study properties of convective motions of this Cu were investigated. Here in Part III of the study, the parameters of cloud turbulence are calculated in the cloud updraft zone at different stages of cloud development. The main points of this study are (i) application of a fine-scale LES model of a single convective cloud allowed a direct estimation of turbulence parameters using the resolved flow in the cloud and (ii) the separation of the resolved flow into the turbulence flow and the nonturbulence flow allowed us to estimate different turbulent parameters with sufficient statistical accuracy. We calculated height and time dependences of the main turbulent parameters such as turbulence kinetic energy (TKE), spectra of TKE, dissipation rate, and the turbulent coefficient. It was found that the main source of turbulence in the cloud is buoyancy whose contribution is described by the buoyancy production term (BPT). The shear production term (SPT) increases with height and reaches its maximum near cloud top, and so does BPT. In agreement with the behavior of BPT and SPT, turbulence in the lower cloud part (below the inversion level) is weak and hardly affects the processes of mixing and entrainment. The fact that BPT is larger than SPT determines many properties of cloud turbulence. For instance, the turbulence is nonisotropic, so the vertical component of TKE is substantially larger than the horizontal components. Another consequence of the fact that BPT is larger than STP manifests itself in the finding that the turbulence spectrum largely obeys the -11/5 Bolgiano–Obukhov scaling. The classical Kolmogorov -5/3 scaling dominates for the low part of a cloud largely at the dissolving stage of cloud evolution. Using the spectra obtained we evaluated an “effective” dissipation rate which increases with height from nearly zero at cloud base up to 20 cm 2 s -3 near cloud top. The coefficient of turbulent diffusion was found to increase with height and ranged from 5 m 2 s -1 near cloud base to 25 m 2 s -1 near cloud top. In conclusion, the possible role of turbulence in the process of lateral entrainment and mixing is discussed.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2021

Combining In-situ Diagnostics and Data Analytics for Discovery of Process-Structure-Property Relationships in AM parts – A Step Toward Digital Twins

In-situ additive manufacturing (AM) diagnostic tools (e.g., optical/infrared imaging, acoustic, etc.) already exist to correlate process anomalies to printed part defects. This current work aimed to augment existing capabilities by: 1) Incorporating in-situ imaging w/ machine learning (ML) image processing software (ORNL- developed "Peregrine") for AM process anomaly detection 2) Synchronizing multiple in-situ sensors for simultaneous analysis of AM build events 3) Correlating in-situ AM process data, generated part defects and part mechanical properties The key R&D question investigated was to determine if these new combined hardware/software tools could be used to successfully quantify defect distributions for parts build via SNL laser powder bed fusion (LPBF) machines, aiming to better understand data-driven process-structure-property- performance relationships. High resolution optical cameras and acoustic microphones were successfully integrated in two LPBF machines and linked to the Peregrine ML software. The software was successfully calibrated on both machines and used to image hundreds of layers of multiple builds to train the ML software in identifying printed part vs powder. The software's validation accuracy to identify this aspect increased from 56% to 98.8% over three builds. Lighting conditions inside the chamber were found to significantly impact ML algorithm predictions from in-situ sensors, so these were tailored to each machine's internal framework. Finally, 3D part reconstructions were successfully generated for a build from the compressed stack of layer-wise images. Resolution differences nearest and furthest from the optical camera were discussed. Future work aims to improve optical resolution, increase process anomalies identified, and integrate more sensor modalities.

36 MATERIALS SCIENCE↗
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↗