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The development of a qualification test for modules bypass diodes is reviewed. Diode junction temperature is measured, indirectly, under laboratory ambient conditions, and extrapolated to field conditions. Criteria are given for diode reliability.
The SP-100 is a compact space power system driven by a nuclear reactor that provides 100 kWe to the user at 200 VDC. The thermal energy generated by the nuclear reactor is converted into electrical energy by passive thermoelectric devices. Various options for tailoring the MIL-STD-1540B guidelines to the SP-100 nuclear power system are discussed. This study aids in selecting the appropriate qualification test program based on the cost, schedule, and test effectiveness of the various options.
Paint type coatings are often used as engineering materials in critical satellite temperature control applications. The functional features of coatings used for temperature control purposes must remain stable throughout the satellite manufacturing process and the satellite mission. The selection of a particular coating depends on matching coating characteristics to mission requirements. The use of paint coatings on satellites, although having an extensive history, requires that the paint be qualified to each application on an individual basis. Thus, the qualification process through testing serves to ensure that paint coatings as engineering materials will fulfill design requirements.
Qualification testing of the Redesigned Solid Rocket Motor improved igniter-to-case joint and field joint heaters was conducted on the fired TEM-04 static test motor and was completed on 7 Sep. 1989. The purpose of the test was to certify the installation and performance of the improved joint heaters for use on flight motors. The changes incorporated in the improved heaters improve durability and should reduce handling damage. The igniter-to-case joint and field joint primary heater circuits were subjected to five 20-hr ON cycles. The heater redundant circuits were then subjected to one 20-hr ON cycle. Voltage, current, and temperature set point values were maintained within the specified limits for both heaters during each ON cycle. When testing was complete, both heaters were removed and inspected. No discolorations or any other anomalies were found on either of the heaters. Based on the successful completion of this test, it is recommended that the improved igniter-to-case joint and field joint heaters be used on future flight motors.
Transportation monitoring unit (TMU) qualification testing was performed between 3 Mar. and 14 Dec. 1989. The purpose of the testing was to qualify the TMUs to monitor and store temperature and acceleration data on redesigned solid rocket motor segments and exit cones while they are being shipped from Utah's Thiokol Corporation, Space Operations, to Kennedy Space Center. TMUs were subjected to transportation tests that concerned the structural integrity of the TMUs only, and did not involve TMU measuring capability. This testing was terminated prior to completion due to mounting plate failures, high and low temperature shutdown failures, and data collection errors. Corrective actions taken by the vendor to eliminate high temperature shutdowns were ineffective. An evaluation was performed on the TMUs to determine the TMU vibration and temperature measuring accuracy at a variety of temperatures. This test demonstrated that TMU measured shock levels are high, and that TMUs are temperature sensitive because of decreased accuracy at high and low temperatures. It was determined that modifications to the current TMU system, such that it could be qualified for use, would require a complete redesign and remanufacture. Because the cost of redesigning and remanufacturing the present TMU system exceeds the cost of procuring a new system that could be qualified without modification, it is recommended that an alternate transportation monitoring system be qualified.
Qualification testing of Combustion Engineering's AMDATA Intraspect/98 Data Acquisition and Imaging System that applies to the redesigned solid rocket motor (RSRM) case membrane case-to-insulation bondline inspection was performed. Testing was performed at M-67, the Thiokol Corp. RSRM Assembly Facility. The purpose of the inspection was to verify the integrity of the case membrane case-to-insulation bondline. The case membrane scanner was calibrated on the redesigned solid rocket motor case segment calibration standard, which had an intentional 1.0 by 1.0 in. case-to-insulation unbond. The case membrane scanner was then used to scan a 20 by 20 in. membrane area of the case segment. Calibration of the scanner was then rechecked on the calibration standard to ensure that the calibration settings did not change during the case membrane scan. This procedure was successfully performed five times to qualify the unbond detection capability of the case membrane scanner.
Qualification testing of Combustion Engineering's AMDATA Intraspect/98 Data Acquisition and Imaging System that applies to the redesigned solid rocket motor field joint capture feature case-to-insulation bondline inspection was performed. Testing was performed at M-111, the Thiokol Corp. Inert Parts Preparation Building. The purpose of the inspection was to verify the integrity of the capture feature area case-to-insulation bondline. The capture feature scanner was calibrated over an intentional 1.0 to 1.0 in. case-to-insulation unbond. The capture feature scanner was then used to scan 60 deg of a capture feature field joint. Calibration of the capture feature scanner was then rechecked over the intentional unbond to ensure that the calibration settings did not change during the case scan. This procedure was successfully performed five times to qualify the unbond detection capability of the capture feature scanner. The capture feature scanner qualified in this test contains many points of mechanical instability that can affect the overall ultrasonic signal response. A new generation scanner, designated the sigma scanner, should be implemented to replace the current configuration scanner. The sigma scanner eliminates the unstable connection points of the current scanner and has additional inspection capabilities.
The procedures, performance, and results obtained from the M-52 spray booth qualification test are documented. The test was conducted at Thiokol Corporation, Space Operations, M-52 Inert Parts Preparation facility. The purpose of this testing sequence was to ensure the spray booth would produce flight qualified hardware. The testing sequence was conducted in two series. The first series was conducted under CTP-0142, Revision 1. The second series was conducted in accordance with CTP-0142, Revision 2. The test sequence started with CTP-0142, Revision 1. The series consisted of the contamination removal test and the performance test. The contamination removal test was used to assess the Teflon level in the spray booth. The performance test consisted of painting and Chemloking a forward dome inside the spray booth per flight procedures. During the performance test, two sets of witness panels (case/insulation and steel/epoxy/steel) were prepared and pull tested. The CTP-0142, Revision 2, series of testing consisted of re-testing the steel/epoxy/steel witness panels. The pull tests analysis indicates the results of the tensile tests were comparable to the systems tunnel witness panel database. The exposed panel set and the control panel set average tensile values were above the 1-basis lower limits established on the systems tunnel witness panel database. It is recommended that the M-52 spray booth be qualified for producing flight hardware.
NASA's Cosmic Background Explorer (COBE) is designed to investigate the Cosmic Background Radiation (CBR), that permeates the universe as a consequence of the Big Bang. This 3 degree Kelvin radiation is a fossil that contains much information about the early universe. The Far Infrared Absolute Spectrophotometer (FIRAS), will investigate the spectral isotropy of this ancient remnant and look for clues as to the subsequent evolution of the universe. The instrument is a cryogenically cooled, modified Michelson interferometer which operates in the 1 cm to 100 micron wavelength range. FIRAS is designed to provide absolute spectral information, therefore, all possible perturbations to the instrument response must be investigated to minimize distortions of the data. This paper discusses the methodology and resultant variations in the instrument performance noted during room temperature, and liquid nitrogen, (LN2) temperature vibration qualification. Reference alignment shifts in critical components such as the instrument wire-grid beamsplitter are correlated to changes in the instrument spectral response.
The results of a space flight qualification test program for a low-voltage, quartz tungsten-halogen light are presented. The test program was designed to qualify a halogen light for use in the Pool Boiling Experiment, a Get Away Special (GAS) payload that will be flown in the space shuttle payload bay. Vibration and thermal vacuum tests were performed. The test results indicated that the halogen light will survive the launch and ascent loads, and that the convection-free environment associated with the GAS payload system will not detrimentally affect the operation of the halogen light.
A test chip set being developed to aid in the qualification of spaceborne Application Specific Integrated Circuits (ASICs) is described. The chip set consists of a process monitor for process parameter verification, a fault chip for yield analysis, a reliability chip for ASIC failure rate analysis, and total ionizing dose and single event upset chips for radiation effect analysis. The test structures contained in these chips are discussed along with representative test results.
This paper summarizes the findings of a Tri-Agency panel consisting of members from the National Aeronautics and Space Administration (NASA), U.S. Department of Energy (DOE), and U.S. Department of Defense (DOD) that were charged with reviewing the status and availability of facilities to test components and subsystems for megawatt-class nuclear electric propulsion (NEP) systems. The facilities required to support development of NEP are available in NASA centers, DOE laboratories, and industry. However, several key facilities require significant and near-term modification in order to perform the testing required to meet a 2014 launch date. For the higher powered Mars cargo and piloted missions, the priority established for facility preparation is: (1) a thruster developmental testing facility, (2) a thruster lifetime testing facility, (3) a dynamic energy conversion development and demonstration facility, and (4) an advanced reactor testing facility (if required to demonstrate an advanced multiwatt power system). Facilities to support development of the power conditioning and heat rejection subsystems are available in industry, federal laboratories, and universities. In addition to the development facilities, a new preflight qualifications and acceptance testing facility will be required to support the deployment of NEP systems for precursor, cargo, or piloted Mars missions. Because the deployment strategy for NEP involves early demonstration missions, the demonstration of the SP-100 power system is needed by the early 2000's.
Uralane 5750 A/B (LV) is a POLYURETHANE which was to be considered for use as a thin CONFORMAL COATING on printed circuit boards for JPL flight projects. As part of the qualification process several properties of Uralane 5750 A/B (LV) were measured for the as-cured material and after various environmental exposures. The properties that were measured included outgassing i.e. Total Mass Loss (TML) and Vacuum Condensable Mass (VCM) and mass accumulation rates on cold surfaces, Static Elastic Modulus and coefficient of Thermal Expansion (CTE). The Uralane 5750 A/B (LV) that was tested consisted of sheets which varied in both thickness and curing procedures. The environmental exposures consisted of vacuum, thermal and combined thermal vacuum. The physical properties of Uralane 5750 A/B (LV) met the JPL requirements for flight in both the as-cured condition and after environmental exposures.
Payload G-534, the prototype Pool Boiling Experiment (PBE), is scheduled to fly on the STS-47 mission in September 1992. This paper describes the purpose of the experiment and the environmental qualification testing program that was used to prove the integrity of the hardware. Component and box level vibration and thermal cycling tests were performed to give an early level of confidence in the hardware designs. At the system level, vibration, thermal extreme soaks, and thermal vacuum cycling tests were performed to qualify the complete design for the expected shuttle environment. The system level vibration testing included three axis sine sweeps and random inputs. The system level hot and cold soak tests demonstrated the hardware's capability to operate over a wide range of temperatures and gave wider latitude in determining which shuttle thermal attitudes were compatible with the experiment. The system level thermal vacuum cycling tests demonstrated the hardware's capability to operate in a convection free environment. A unique environmental chamber was designed and fabricated by the PBE team and allowed most of the environmental testing to be performed within the hardware build laboratory. The completion of the test program gave the project team high confidence in the hardware's ability to function as designed during flight.
The prototype Pool Boiling Experiment (PBE) flew on the STS-47 mission in September 1992. This report describes the purpose of the experiment and the environmental qualification testing program that was used to prove the integrity of the prototype hardware. Component and box level vibration and thermal cycling tests were performed to give an early level of confidence in the hardware designs. At the system level, vibration, thermal extreme soaks, and thermal vacuum cycling tests were performed to qualify the complete design for the expected shuttle environment. The system level vibration testing included three axis sine sweeps and random inputs. The system level hot and cold soak tests demonstrated the hardware's capability to operate over a wide range of temperatures and gave the project team a wider latitude in determining which shuttle thermal altitudes were compatible with the experiment. The system level thermal vacuum cycling tests demonstrated the hardware's capability to operate in a convection free environment. A unique environmental chamber was designed and fabricated by the PBE team and allowed most of the environmental testing to be performed within the project's laboratory. The completion of the test program gave the project team high confidence in the hardware's ability to function as designed during flight.
The generic qualification of aerospace nickel-cadmium cells is discussed. The test program includes the following: all available manufacturers, all available designs, cells from the previous program, and high and low orbit life cycling. It is the purpose of this program to characterize the beginning of life performance.
Transfer of training studies at Fort Rucker using the backward-transfer paradigm have shown that existing flight simulators are not entirely adequate for meeting training requirements. Using an ab initio training research simulator, a simulation of the UH-1, training effectiveness ratios were developed. The data demonstrate it to be a cost-effective primary trainer. A simulator qualification method was suggested in which a combination of these transfer-of-training paradigms is used to determine overall simulator fidelity and training effectiveness.
Currently the U.S. is sponsoring production of radioisotope thermoelectric generators (RTGs) for the Cassini mission to Saturn; the SP-100 space nuclear reactor power system for NASA applications; a thermionic space reactor program for DoD applications as well as early work on nuclear propulsion. In an era of heightened public concern about having successful space ventures it is important that a full understanding be developed of what it means to 'flight qualify' a space nuclear system. As a contribution to the ongoing work this paper reviews several qualification programs, including the general-purpose heat source radioisotope thermoelectric generators (GPHS-RTGs) as developed for the Galileo and Ulysses missions, the SNAP-10A space reactor, the Nuclear Engine for Rocket Vehicle Applications (NERVA), the F-1 chemical engine used on the Saturn-V, and the Space Shuttle Main Engines (SSMEs). Similarities and contrasts are noted.