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NASA NTRS2010

Reliability Quantification of Advanced Stirling Convertor (ASC) Components

The Advanced Stirling Convertor, is intended to provide power for an unmanned planetary spacecraft and has an operational life requirement of 17 years. Over this 17 year mission, the ASC must provide power with desired performance and efficiency and require no corrective maintenance. Reliability demonstration testing for the ASC was found to be very limited due to schedule and resource constraints. Reliability demonstration must involve the application of analysis, system and component level testing, and simulation models, taken collectively. Therefore, computer simulation with limited test data verification is a viable approach to assess the reliability of ASC components. This approach is based on physics-of-failure mechanisms and involves the relationship among the design variables based on physics, mechanics, material behavior models, interaction of different components and their respective disciplines such as structures, materials, fluid, thermal, mechanical, electrical, etc. In addition, these models are based on the available test data, which can be updated, and analysis refined as more data and information becomes available. The failure mechanisms and causes of failure are included in the analysis, especially in light of the new information, in order to develop guidelines to improve design reliability and better operating controls to reduce the probability of failure. Quantified reliability assessment based on fundamental physical behavior of components and their relationship with other components has demonstrated itself to be a superior technique to conventional reliability approaches based on utilizing failure rates derived from similar equipment or simply expert judgment.

Shah, Ashwin R.↗

NASA NTRS2005

Electrochemical Impedance Spectroscopy of Alloys in a Simulated Space Shuttle Launch Environment

Corrosion studies began at NASA/Kennedy Space Center in 1966 during the Gemini/Apollo Programs with the evaluation of long-term protective coatings for the atmospheric protection of carbon steel. An outdoor exposure facility on the beach near the launch pad was established for this purpose at that time. The site has provided over 35 years of technical information on the evaluation of the long-term corrosion performance of many materials and coatings as well as on maintenance procedures. Results from these evaluations have helped NASA find new materials and processes that increase the safety and reliability of our flight hardware, launch structures, and ground support equipment. The launch environment at the Kennedy Space Center (KSC) is extremely corrosive due to the combination of ocean salt spray, heat, humidity, and sunlight. With the introduction of the Space Shuttle in 1981, the already highly corrosive conditions at the launch pad were rendered even more severe by the acidic exhaust from the solid rocket boosters. Over the years, many materials have been evaluated for their corrosion performance under conditions similar to those found at the launch pads. These studies have typically included atmospheric exposure and evaluation with conventional electrochemical methods such as open circuit potential (OCP) measurements, polarization techniques, and electrochemical impedance spectroscopy (EIS). The atmosphere at the Space Shuttle launch site is aggressive to most metals and causes severe pitting in many of the common stainless steel alloys such as type 304L stainless steel (304L SS). A study was undertaken to find a more corrosion resistant material to replace the existing 304L SS tubing. This paper presents the results from atmospheric exposure as well as electrochemical measurements on the corrosion resistance of AL-6XN (UNS N08367) and 254-SMO (UNS S32154). Type 304L SS (UNS S30403) was used as a control. Conditions at the Space Shuttle launch pad were simulated by using a hydrochloric acid (HC1) and alumina (Al203) slurry rinse for the atmospheric exposure and an electrolyte consisting of 3.55% sodium chloride (NaC1) with increased concentrations of hydrochloric acid (HC1) for the electrochemical measurements. The results from both types of measurements revealed the superior corrosion performance of the higher-alloyed materials. Unlike 304L SS, 254-SMO and AL-6XN exhibited a significantly improved resistance to corrosion as the concentration of hydrochloric acid in he 3.55% NaCl electrolyte solution was increased.

Calle, L. M.↗

NASA NTRS2004

Electrochemical Investigation of Corrosion in the Space Shuttle Launch Environment

Calle, L. M.↗

NASA NTRS2017

Designing for Reliability and Robustness

Long duration spaceflight has a negative effect on the human body, and exercise countermeasures are used on-board the International Space Station (ISS) to minimize bone and muscle loss, combatting these effects. Given the importance of these hardware systems to the health of the crew, this equipment must continue to be readily available. Designing spaceflight exercise hardware to meet high reliability and availability standards has proven to be challenging throughout the time the crewmembers have been living on ISS beginning in 2000. Furthermore, restoring operational capability after a failure is clearly time-critical, but can be problematic given the challenges of troubleshooting the problem from 220 miles away. Several best-practices have been leveraged in seeking to maximize availability of these exercise systems, including designing for robustness, implementing diagnostic instrumentation, relying on user feedback, and providing ample maintenance and sparing. These factors have enhanced the reliability of hardware systems, and therefore have contributed to keeping the crewmembers healthy upon return to Earth. This paper will review the failure history for three spaceflight exercise countermeasure systems identifying lessons learned that can help improve future systems. Specifically, the Treadmill with Vibration Isolation and Stabilization System (TVIS), Cycle Ergometer with Vibration Isolation and Stabilization System (CEVIS), and the Advanced Resistive Exercise Device (ARED) will be reviewed, analyzed, and conclusions identified so as to provide guidance for improving future exercise hardware designs. These lessons learned, paired with thorough testing, offer a path towards reduced system down-time.

Svetlik, Randall G.↗

NASA NTRS2019

Space Communications and Navigation Validation: Extracting Data for the Strategic Center for Networking, Integration, and Communications Scheduling Algorithms

Efficiency in communication system architecture performance between Space Communications and Navigation (SCaN) assets and missions is crucial, as space communication is varied, complex, and often not utilized to its full potential. The SCaN Strategic Center for Networking, Integration, and Communications (SCENIC) new scheduling algorithms, which are designed to simulate the allocation of resources between SCaN assets and missions, have the potential to simulate an increase of this efficiency; however, they require real-world data to be validated against. The purpose of this project was to extract said validation data, which details the frequency and duration of utilized contact windows between missions and assets in the Near Earth Network (NEN), Space Network (SN), and Deep Space Network (DSN). Stored as images in daily operations summaries (DOSs), the tabular data existed in a variety of file formats such as.pdf, .docx, and .doc. Since the tables were stored as images, ABBYY® FineReader® (ABBYY Software Ltd.) optical character recognition (OCR) was implemented, which is a proprietary software that reads images from text. The comma separated value (CSV) output was utilized as input to a series of MATLAB® (The MathWorks, Inc.) methods for reformatting, at which point it was ready to be machine-read. Finally, the results were converted to a Microsoft Excel format for human readability. Along with being used for validation purposes, the data will also be used to map equipment degradation as a function of time to analyze the reliability of network assets.

Kontur, Noah P.↗

NASA NTRS1977

Highly reliable multiprocessors

Highly reliable fault-tolerant computer systems are discussed for use in flight-critical avionic and control systems of future commercial transport aircraft. Such aircraft are envisioned to have integrated systems, to be terminally configured, and to be equipped with fly-by-wire flight control systems, all of which require highly reliable, fault-tolerant computers. Two candidate computer architectures are identified as having the potential of satisfying the commercial transport aircraft requirements.

Murray, N. D.↗

NASA NTRS1966

LEM electronics reliability.

Lunar Excursion Module /LEM/ reliability program, discussing engineering, manufacturing and techniques of design and qualification testing of electronic components

QUALITY CONTROL↗

NASA NTRS1986

Hydrogen Refrigerator Would Cool Below 10 K

Closed-cycle hydrogen refrigerator uses low-level heat energy to cool objects to temperature of 10 K. Refrigerator needs only fraction of energy of previous equipment with similar low-temperature capability. Unit compact and light in weight. With valves as only moving parts, reliable for many years. Refrigeration concept adapted to cooling superconducting magnets on magnetically levitated railcars, nuclear-particle accelerators, and variety of other cryogenic equipment.

Jones, J. A.↗

NASA NTRS2003

PEM-INST-001: Instructions for Plastic Encapsulated Microcircuit (PEM) Selection, Screening, and Qualification

Potential users of plastic encapsulated microcircuits (PEMs) need to be reminded that unlike the military system of producing robust high-reliability microcircuits that are designed to perform acceptably in a variety of harsh environments, PEMs are primarily designed for use in benign environments where equipment is easily accessed for repair or replacement. The methods of analysis applied to military products to demonstrate high reliability cannot always be applied to PEMs. This makes it difficult for users to characterize PEMs for two reasons: 1. Due to the major differences in design and construction, the standard test practices used to ensure that military devices are robust and have high reliability often cannot be applied to PEMs that have a smaller operating temperature range and are typically more frail and susceptible to moisture absorption. In contrast, high-reliability military microcircuits usually utilize large, robust, high-temperature packages that are hermetically sealed. 2. Unlike the military high-reliability system, users of PEMs have little visibility into commercial manufacturers proprietary design, materials, die traceability, and production processes and procedures. There is no central authority that monitors PEM commercial product for quality, and there are no controls in place that can be imposed across all commercial manufacturers to provide confidence to high-reliability users that a common acceptable level of quality exists for all PEMs manufacturers. Consequently, there is no guaranteed control over the type of reliability that is built into commercial product, and there is no guarantee that different lots from the same manufacturer are equally acceptable. And regarding application, there is no guarantee that commercial products intended for use in benign environments will provide acceptable performance and reliability in harsh space environments. The qualification and screening processes contained in this document are intended to detect poor-quality lots and screen out early random failures from use in space flight hardware. However, since it cannot be guaranteed that quality was designed and built into PEMs that are appropriate for space applications, users cannot screen in quality that may not exist. It must be understood that due to the variety of materials, processes, and technologies used to design and produce PEMs, this test process may not accelerate and detect all failure mechanisms. While the tests herein will increase user confidence that PEMs with otherwise unknown reliability can be used in space environments, such testing may not guarantee the same level of reliability offered by military microcircuits. PEMs should only be used where due to performance needs there are no alternatives in the military high-reliability market, and projects are willing to accept higher risk.

Teverovsky, Alexander↗

NASA NTRS2012

Integrated Atmosphere Resource Recovery and Environmental Monitoring Technology Demonstration for Deep Space Exploration

Exploring the frontiers of deep space continues to be defined by the technological challenges presented by safely transporting a crew to and from destinations of scientific interest. Living and working on that frontier requires highly reliable and efficient life support systems that employ robust, proven process technologies. The International Space Station (ISS), including its environmental control and life support (ECLS) system, is the platform from which humanity's deep space exploration missions begin. The ISS ECLS system Atmosphere Revitalization (AR) subsystem and environmental monitoring (EM) technical architecture aboard the ISS is evaluated as the starting basis for a developmental effort being conducted by the National Aeronautics and Space Administration (NASA) via the Advanced Exploration Systems (AES) Atmosphere Resource Recovery and Environmental Monitoring (ARREM) Project.. An evolutionary approach is employed by the ARREM project to address the strengths and weaknesses of the ISS AR subsystem and EM equipment, core technologies, and operational approaches to reduce developmental risk, improve functional reliability, and lower lifecycle costs of an ISS-derived subsystem architecture suitable for use for crewed deep space exploration missions. The most promising technical approaches to an ISS-derived subsystem design architecture that incorporates promising core process technology upgrades will be matured through a series of integrated tests and architectural trade studies encompassing expected exploration mission requirements and constraints.

Perry, Jay L.↗

NASA NTRS1965

Space vacuum investigations

Inaccessible-Non Repairable- Costly: The meaning of these words is absolute in the event of a complete failure of an orbiting spacecraft. Adequate design, or rather, minimizing chance of failure, challenges all scientists and engineers. Where experience has not been developed, the risk involved in a new application must be weighed against the consequence of a design failure. In space work, the spectrum of consequence is extremely wide. It ranges from loss of scientific data on one hand, to loss of life on the other.. There is little question that knowledge of the space environment and its effects must be determined to produce reliable spacecraft. Tests to prove the design must be performed with equipment capable of simulating the effects of the environment in which the design is to operate. This does not necessarily mean that the natural environment must be duplicated. The degree of environmental simulation that should be achieved depends primarily upon the significance of the physical effects it causes. The purpose of space vacuum simulation in an environmental test program should be accurately conceived and the testing phased to obtain maximum information from the limited samples available for test. This discussion is confined to some of the factors involved in simulating the effects of space vacuum environment. This survey is by no means complete, but will touch on some of the highlights in this field: 1. A description of the environment 2. The level of simulation necessary to evaluate its effects 3. Test equipment capability 4. Experience in test 5. Experience in orbit 6. Observations & future emphasis

VACUUM EFFECT↗

NASA NTRS1973

Surface electrical properties experiment study phase, volume 3

The reliability and quality assurance system and procedures used in developing test equipment for the Lunar Experiment projects are described. The subjects discussed include the following: (1) documentation control, (2) design review, (3) parts and materials selection, (4) material procurement, (5) inspection procedures, (6) qualification and special testing, and failure modes and effects analysis.

Source record↗

NASA NTRS1973

Investigation of prototype volcano-surveillance network

The author has identified the following significant results. The equipment installed in the volcano surveillance network continues to work quite reliably and earthquakes are being recorded at all sites. A summary of platform receptions per day has been prepared.

Eaton, J. P.↗

NASA NTRS1977

A research program to reduce interior noise in general aviation airplanes. Design of an acoustic panel test facility

The design, construction, and costs of a test facility for determining the sound transmission loss characteristics of various panels and panel treatments are described. The pressurization system and electronic equipment used in experimental testing are discussed as well as the reliability of the facility and the data gathered. Tests results are compared to pertinent acoustical theories for panel behavior and minor anomalies in the data are examined. A method for predicting panel behavior in the stiffness region is also presented.

Roskam, J.↗

NASA NTRS1981

Emergency Medical Service (EMS): Rotorcraft Technology Workshop

A lead organization on the national level should be designated to establish concepts, locations, and the number of shock trauma air medical services. Medical specialists desire a vehicle which incorporates advances in medical technology trends in health care. Key technology needs for the emergency medical services helicopter of the future include the riding quality of fixed wing aircraft (reduced noise and vibration), no tail rotor, small rotor, small rotor diameter, improved visibility, crashworthy vehicle, IFR capability, more affordability high reliability, fuel efficient, and specialized cabins to hold medical/diagnostic and communications equipment. Approaches to a national emergency medical service are discussed.

Bauchspies, J. S.↗

NASA NTRS1984

The historical development and basis of human factors guidelines for automated systems in aeronautical operations

In order to derive general design guidelines for automated systems a study was conducted on the utilization and acceptance of existing automated systems as currently employed in several commercial fields. Four principal study area were investigated by means of structured interviews, and in some cases questionnaires. The study areas were aviation, a both scheduled airline and general commercial aviation; process control and factory applications; office automation; and automation in the power industry. The results of over eighty structured interviews were analyzed and responses categoried as various human factors issues for use by both designers and users of automated equipment. These guidelines address such items as general physical features of automated equipment; personnel orientation, acceptance, and training; and both personnel and system reliability.

Ciciora, J. A.↗

NASA NTRS1984

A real-time interferometer technique for compressible flow research

Strengths and shortcomings in the application of interferometric techniques to transonic flow fields are examined and an improved method is elaborated. Such applications have demonstrated the value of interferometry in obtaining data for compressible flow research. With holographic techniques, interferometry may be applied in large scale facilities without the use of expensive optics or elaborate vibration isolation equipment. Results obtained using holographic interferometry and other methods demonstrate that reliable qualitative and quantitative data can be acquired. Nevertheless, the conventional method can be difficult to set up and apply, and it cannot produce real-time data. A new interferometry technique is investigated that promises to be easier to apply and can provide real-time information. This single-beam technique has the necessary insensitivity to vibration for large scale wind tunnel operations. Capabilities of the method and preliminary tests on some laboratory scale flow fluids are described.

Bachalo, W. D.↗

NASA NTRS2003

Static Frequency Converter System Installed and Tested

A new Static Frequency Converter (SFC) system has been installed and tested at the NASA Glenn Research Center s Central Air Equipment Building to provide consistent, reduced motor start times and improved reliability for the building s 14 large exhausters and compressors. The operational start times have been consistent around 2 min, 20 s per machine. This is at least a 3-min improvement (per machine) over the old variable-frequency motor generator sets. The SFC was designed and built by Asea Brown Boveri (ABB) and installed by Encompass Design Group (EDG) as part of a Construction of Facilities project managed by Glenn (Robert Scheidegger, project manager). The authors designed the Central Process Distributed Control Systems interface and control between the programmable logic controller, solid-state exciter, and switchgear, which was constructed by Gilcrest Electric.

Brown, Donald P.↗