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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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All sourcesNASA NTRSDOE OSTI
NASA NTRS1977

Materials and processes for shuttle engine, external tank, and solid rocket booster

The Shuttle flight system is composed of the Orbiter, an External Tank (ET) that contains the ascent propellant to be used by the Space Shuttle Main Engines (SSME), and two Solid Rocket Boosters (SRB). The ET is expended on each launch; the Orbiter and SRB's are reusable. It is the requirement for reuse which poses the exciting new materials and processes challenges in the development of the Space Shuttle. A brief description of the Space Shuttle and the mission profile is given. The Shuttle configuration is then described with emphasis on the SSME, ET, and SRB. The materials selection, tracking, and control system used to assure reliability and to minimize cost are described, and salient features and challenges in materials and processes associated with the SSME, ET, and SRB are subsequently discussed.

Schwinghamer, R. J.↗
NASA NTRS2026

Mechanical Properties of Carbon Fiber Reinforced Composites Exposed to Cryogenic Conditions and Space Radiation via Simulation and Testing

As NASA missions extend beyond low Earth orbit, increasing reliance is placed on carbon fiber reinforced polymer (CFRP) composites for spacecraft structures where mass efficiency, durability, and long-term reliability are critical. In service, these materials are subjected to a combination of ultraviolet radiation, vacuum, ionizing radiation, atomic oxygen, and extreme thermal excursions under sustained mechanical loading. Flight systems such as the Boeing Starliner and SpaceX Dragon employ external composite structures that will experience these environments for extended durations. Although prior spaceflight and ground studies have reported limited changes in bulk mechanical properties, the synergistic effects of these environments on composite microstructure, particularly at the fiber matrix interphase, remain insufficiently characterized and represent a potential qualification and reliability risk. This study investigates the effects of short-term cryogenic exposure on a radiation shielding carbon epoxy composite, SC2020, as a ground-based analog for space relevant thermal extremes. The SC2020 material system has previously flown on the International Space Station under the Materials International Space Station Experiment (MISSE) program. Composite specimens were exposed to liquid nitrogen for 6 and 24 hours and evaluated using a multiscale characterization framework that combined ASTM D3039 tensile testing, Atomic Force Microscopy (AFM) based interphase analysis, and helium gas permeability measurements. Tensile testing showed no statistically significant or permanent degradation in global strength or modulus following cryogenic exposure. In contrast, AFM measurements revealed reductions in interphase modulus, weakened adhesion, and increased nanoscale heterogeneity, indicating localized degradation mechanisms not captured by conventional bulk testing. Gas permeability measurements showed a progressive increase in helium diffusion with exposure duration, consistent with micro-void formation or partial interfacial debonding. The results indicate that cryogenic exposure initiates degradation at the fiber matrix interphase while leaving global mechanical properties largely unchanged over short durations. These findings underscore the importance of multiscale diagnostics for identifying early-stage damage mechanisms that may influence long term performance and qualification margins for spaceflight composite structures. The data presented establish a cryogenic baseline for comparison with forthcoming MISSE flight exposure results and support ongoing NASA Established Program to Stimulate Competitive Research (EPSCoR) efforts aimed at improving composite qualification methodologies, risk assessment, and reliability prediction for space environments.

composite reliability↗
NASA NTRS1990

Composite materials for space applications

The objectives of the program were to: generate mechanical, thermal, and physical property test data for as-fabricated advanced materials; design and fabricate an accelerated thermal cycling chamber; and determine the effect of thermal cycling on thermomechanical properties and dimensional stability of composites. In the current program, extensive mechanical and thermophysical property tests of various organic matrix, metal matrix, glass matrix, and carbon-carbon composites were conducted, and a reliable database was constructed for spacecraft material selection. Material property results for the majority of the as-fabricated composites were consistent with the predicted values, providing a measure of consolidation integrity attained during fabrication. To determine the effect of thermal cycling on mechanical properties, microcracking, and thermal expansion behavior, approximately 500 composite specimens were exposed to 10,000 cycles between -150 and +150 F. These specimens were placed in a large (18 cu ft work space) thermal cycling chamber that was specially designed and fabricated to simulate one year low earth orbital (LEO) thermal cycling in 20 days. With this rate of thermal cycling, this is the largest thermal cycling unit in the country. Material property measurements of the thermal cycled organic matrix composite laminate specimens exhibited less than 24 percent decrease in strength, whereas, the remaining materials exhibited less than 8 percent decrease in strength. The thermal expansion response of each of the thermal cycled specimens revealed significant reduction in hysteresis and residual strain, and the average CTE values were close to the predicted values.

Rawal, Suraj P.↗
NASA NTRS1994

Probabilistic assessment of uncertain adaptive hybrid composites

Adaptive composite structures using actuation materials, such as piezoelectric fibers, were assessed probabilistically utilizing intraply hybrid composite mechanics in conjunction with probabilistic composite structural analysis. Uncertainties associated with the actuation material as well as the uncertainties in the regular (traditional) composite material properties were quantified and considered in the assessment. Static and buckling analyses were performed for rectangular panels with various boundary conditions and different control arrangements. The probability density functions of the structural behavior, such as maximum displacement and critical buckling load, were computationally simulated. The results of the assessment indicate that improved design and reliability can be achieved with actuation material.

Shiao, Michael C.↗
NASA NTRS1993

Monte Carlo modeling of atomic oxygen attack of polymers with protective coatings on LDEF

Characterization of the behavior of atomic oxygen interaction with materials on the Long Duration Exposure Facility (LDEF) assists in understanding of the mechanisms involved. Thus the reliability of predicting in-space durability of materials based on ground laboratory testing should be improved. A computational model which simulates atomic oxygen interaction with protected polymers was developed using Monte Carlo techniques. Through the use of an assumed mechanistic behavior of atomic oxygen interaction based on in-space atomic oxygen erosion of unprotected polymers and ground laboratory atomic oxygen interaction with protected polymers, prediction of atomic oxygen interaction with protected polymers on LDEF was accomplished. However, the results of these predictions are not consistent with the observed LDEF results at defect sites in protected polymers. Improved agreement between observed LDEF results and predicted Monte Carlo modeling can be achieved by modifying of the atomic oxygen interactive assumptions used in the model. LDEF atomic oxygen undercutting results, modeling assumptions, and implications are presented.

Banks, Bruce A.↗
NASA NTRS2016

Conceive, Believe and Achieve; A Path to Miniaturization, COTS Infusion, and Size Weight and Power Realization for Flight

JPL along with other aerospace agencies such as the US Air Force Space Pro-grams and a packaging technology innovator, i3 Electronics, Inc., are evaluating the use of state-of-the-art (SOA) commercial off-the-shelf (COTS) and alternative packaging technologies for future high performance and high reliability space applications. Utilization of SOA COTS technologies have resulted in large scale reduction in electronics volume, weight, power, cost and schedule with outstanding electrical performance and high reliability. We will share JPL’s joint design, architectural approach, alternative substrate materials selection, associated processes, and mission assurance role in identifying reliability and qualification risks, as part of the three year Heterogeneous Packaging/Device Integration effort under the guidance and leadership of JPL’s Mission Assurance Directorate.

Hunter, Don J.↗
NASA NTRS1993

Aerospace applications of advanced aluminum alloys

Advanced metallic materials within the Al-base family are being developed for applications on current and future aerospace vehicles. These advanced materials offer significant improvements in density, strength, stiffness, fracture resistance, and/or higher use temperature which translates into improved vehicle performance. Aerospace applications of advanced metallic materials include space structures, fighters, military and commercial transport aircraft, and missiles. Structural design requirements, including not only static and durability/damage tolerance criteria but also environmental considerations, drive material selections. Often trade-offs must be made regarding strength, fracture resistance, cost, reliability, and maintainability in order to select the optimum material for a specific application. These trade studies not only include various metallic materials but also many times include advanced composite materials. Details of material comparisons, aerospace applications, and material trades will be presented.

Chellman, D. J.↗
NASA NTRS1996

Probabilistic Assessment of National Wind Tunnel

A preliminary probabilistic structural assessment of the critical section of National Wind Tunnel (NWT) is performed using NESSUS (Numerical Evaluation of Stochastic Structures Under Stress) computer code. Thereby, the capabilities of NESSUS code have been demonstrated to address reliability issues of the NWT. Uncertainties in the geometry, material properties, loads and stiffener location on the NWT are considered to perform the reliability assessment. Probabilistic stress, frequency, buckling, fatigue and proof load analyses are performed. These analyses cover the major global and some local design requirements. Based on the assumed uncertainties, the results reveal the assurance of minimum 0.999 reliability for the NWT. Preliminary life prediction analysis results show that the life of the NWT is governed by the fatigue of welds. Also, reliability based proof test assessment is performed.

Shah, A. R.↗
NASA NTRS2007

Reliability and Creep/Fatigue Analysis of a CMC Component

High temperature ceramic matrix composites (CMC) are being explored as viable candidate materials for hot section gas turbine components. These advanced composites can potentially lead to reduced weight and enable higher operating temperatures requiring less cooling; thus leading to increased engine efficiencies. There is a need for convenient design tools that can accommodate various loading conditions and material data with their associated uncertainties to estimate the minimum predicted life as well as the failure probabilities of a structural component. This paper presents a review of the life prediction and probabilistic analyses performed for a CMC turbine stator vane. A computer code, NASALife, is used to predict the life of a 2-D woven silicon carbide fiber reinforced silicon carbide matrix (SiC/SiC) turbine stator vane due to a mission cycle which induces low cycle fatigue and creep. The output from this program includes damage from creep loading, damage due to cyclic loading and the combined damage due to the given loading cycle. Results indicate that the trends predicted by NASALife are as expected for the loading conditions used for this study. In addition, a combination of woven composite micromechanics, finite element structural analysis and Fast Probability Integration (FPI) techniques has been used to evaluate the maximum stress and its probabilistic distribution in a CMC turbine stator vane. Input variables causing scatter are identified and ranked based upon their sensitivity magnitude. Results indicate that reducing the scatter in proportional limit strength of the vane material has the greatest effect in improving the overall reliability of the CMC vane.

Murthy, Pappu L. N.↗
NASA NTRS2011

Materials Science Research Rack Onboard the International Space Station

The Materials Science Research Rack (MSRR) allows for the study of a variety of materials including metals, ceramics, semiconductor crystals, and glasses onboard the International Space Station (ISS). MSRR was launched on STS-128 in August 2009, and is currently installed in the U. S. Destiny Laboratory Module. Since that time, MSRR has performed virtually flawlessly logging more than 550 hours of operating time. Materials science is an integral part of development of new materials for everyday life here on Earth. The goal of studying materials processing in space is to develop a better understanding of the chemical and physical mechanisms involved. Materials science research benefits from the microgravity environment of space, where the researcher can better isolate chemical and thermal properties of materials from the effects of gravity. With this knowledge, reliable predictions can be made about the conditions required on Earth to achieve improved materials. MSRR is a highly automated facility containing two furnace inserts in which Sample Cartridge Assemblies (SCAs), each containing one material sample, can be processed up to temperatures of 1400C. Once an SCA is installed by a Crew Member, the experiment can be run by automatic command or science conducted via telemetry commands from the ground. Initially, 12 SCAs were processed in the first furnace insert for a team of European and US investigators. The processed samples have been returned to Earth for evaluation and comparison of their properties to samples similarly processed on the ground. A preliminary examination of the samples indicates that the majority of the desired science objectives have been successfully met leading to significant improvements in the understanding of alloy solidification processes. The second furnace insert will be installed in the facility in January 2011 for processing the remaining SCA currently on orbit. Six SCAs are planned for launch summer 2011, and additional batches are planned for future processing. This facility is available to support additional materials science investigations through programs such as the US National Laboratory, Technology Development, NASA Research Announcements, ESA application oriented research programs, and others. The development of the research rack was a cooperative effort between NASA's Marshall Space Flight Center and the European Space Agency (ESA).

Frazier, Natalie C.↗
NASA NTRS2012

Materials Science Research Rack Onboard the International Space Station Hardware and Operations

The Materials Science Research Rack (MSRR) is a research facility developed under a cooperative research agreement between NASA and ESA for materials science investigations on the International Space Station (ISS). MSRR was launched on STS-128 in August 2009, and is currently installed in the U.S. Destiny Laboratory Module. Since that time, MSRR has performed virtually flawlessly, logging more than 620 hours of operating time. The MSRR accommodates advanced investigations in the microgravity environment on the ISS for basic materials science research in areas such as solidification of metals and alloys. The purpose is to advance the scientific understanding of materials processing as affected by microgravity and to gain insight into the physical behavior of materials processing. MSRR allows for the study of a variety of materials including metals, ceramics, semiconductor crystals, and glasses. Materials science research benefits from the microgravity environment of space, where the researcher can better isolate chemical and thermal properties of materials from the effects of gravity. With this knowledge, reliable predictions can be made about the conditions required on Earth to achieve improved materials. MSRR is a highly automated facility with a modular design capable of supporting multiple types of investigations. Currently the NASA-provided Rack Support Subsystem provides services (power, thermal control, vacuum access, and command and data handling) to the ESA developed Materials Science Laboratory (MSL) which accommodates interchangeable Furnace Inserts (FI). Two ESA-developed FIs are presently available on the ISS: the Low Gradient Furnace (LGF) and the Solidification and Quenching Furnace (SQF). Sample-Cartridge Assemblies (SCAs), each containing one or more material samples, are installed in the FI by the crew and can be processed at temperatures up to 1400 C. Once an SCA is installed, the experiment can be run by automatic command or science conducted via telemetry commands from the ground. Initially, 12 SCAs were processed in the first furnace insert for a team of European and US investigators. After these samples were processed the Furnaces Inserts were exchanged and an additional single sample was processed. The processed samples have been returned to Earth for evaluation and comparison of their properties to samples similarly processed on the ground. A preliminary examination of the samples indicates that the majority of the desired science objectives have been successfully met leading to significant improvements in the understanding of alloy solidification processes. Six SCAs were launched on Space Shuttle Mission STS-135 in July 2011 for processing during the Fall of 2011. Additional batches are planned for future processing. This facility is available to support additional materials science investigations through programs such as the US National Laboratory, Technology Development, NASA Research Announcements, and others.

Lehman, John R.↗
NASA NTRS2013

Materials Science Research Rack Onboard the International Space Station

The Materials Science Research Rack (MSRR) is a research facility developed under a cooperative research agreement between NASA and ESA for materials science investigations on the International Space Station (ISS). MSRR was launched on STS-128 in August 2009 and currently resides in the U.S. Destiny Laboratory Module. Since that time, MSRR has logged more than 1000 hours of operating time. The MSRR accommodates advanced investigations in the microgravity environment on the ISS for basic materials science research in areas such as solidification of metals and alloys. The purpose is to advance the scientific understanding of materials processing as affected by microgravity and to gain insight into the physical behavior of materials processing. MSRR allows for the study of a variety of materials, including metals, ceramics, semiconductor crystals, and glasses. Materials science research benefits from the microgravity environment of space, where the researcher can better isolate chemical and thermal properties of materials from the effects of gravity. With this knowledge, reliable predictions can be made about the conditions required on Earth to achieve improved materials. MSRR is a highly automated facility with a modular design capable of supporting multiple types of investigations. The NASA-provided Rack Support Subsystem provides services (power, thermal control, vacuum access, and command and data handling) to the ESA-developed Materials Science Laboratory (MSL) that accommodates interchangeable Furnace Inserts (FI). Two ESA-developed FIs are presently available on the ISS: the Low Gradient Furnace (LGF) and the Solidification and Quenching Furnace (SQF). Sample Cartridge Assemblies (SCAs), each containing one or more material samples, are installed in the FI by the crew and can be processed at temperatures up to 1400C. ESA continues to develop samples with 14 planned for launch and processing in the near future. Additionally NASA has begun developing SCAs to support US PIs and their partners. The first of these Flight SCAs are being developed for investigations to support research in the areas of crystal growth and liquid phase sintering. Subsequent investigations are in various stages of development. US investigations will include a ground test program in order to distinguish the particular effects of the absence of gravity.

Reagan, Shawn↗
NASA NTRS2013

Materials Science Research Rack Onboard the International Space Station

The Materials Science Research Rack (MSRR) is a research facility developed under a cooperative research agreement between NASA and ESA for materials science investigations on the International Space Station (ISS). MSRR was launched on STS-128 in August 2009 and currently resides in the U.S. Destiny Laboratory Module. Since that time, MSRR has logged more than 1000 hours of operating time. The MSRR accommodates advanced investigations in the microgravity environment on the ISS for basic materials science research in areas such as solidification of metals and alloys. The purpose is to advance the scientific understanding of materials processing as affected by microgravity and to gain insight into the physical behavior of materials processing. MSRR allows for the study of a variety of materials, including metals, ceramics, semiconductor crystals, and glasses. Materials science research benefits from the microgravity environment of space, where the researcher can better isolate chemical and thermal properties of materials from the effects of gravity. With this knowledge, reliable predictions can be made about the conditions required on Earth to achieve improved materials. MSRR is a highly automated facility with a modular design capable of supporting multiple types of investigations. The NASA-provided Rack Support Subsystem provides services (power, thermal control, vacuum access, and command and data handling) to the ESA-developed Materials Science Laboratory (MSL) that accommodates interchangeable Furnace Inserts (FI). Two ESA-developed FIs are presently available on the ISS: the Low Gradient Furnace (LGF) and the Solidification and Quenching Furnace (SQF). Sample Cartridge Assemblies (SCAs), each containing one or more material samples, are installed in the FI by the crew and can be processed at temperatures up to 1400C. ESA continues to develop samples with 14 planned for launch and processing in the near future. Additionally NASA has begun developing SCAs to support US PIs and their partners. The first of these Flight SCAs are being developed for investigations to support research in the areas of crystal growth and liquid phase sintering. Subsequent investigations are in various stages of development. US investigations will include a ground test program in order to distinguish the particular effects of the absence of gravity.

Reagan, Shawn↗
NASA NTRS2016

Materials Science Research Rack Onboard the International Space Station

The Materials Science Research Rack (MSRR) is a research facility developed under a cooperative research agreement between NASA and ESA for materials science investigations on the International Space Station (ISS). MSRR was launched on STS-128 in August 2009 and currently resides in the U.S. Destiny Laboratory Module. Since that time, MSRR has logged more than 1400 hours of operating time. The MSRR accommodates advanced investigations in the microgravity environment on the ISS for basic materials science research in areas such as solidification of metals and alloys. The purpose is to advance the scientific understanding of materials processing as affected by microgravity and to gain insight into the physical behavior of materials processing. MSRR allows for the study of a variety of materials, including metals, ceramics, semiconductor crystals, and glasses. Materials science research benefits from the microgravity environment of space, where the researcher can better isolate chemical and thermal properties of materials from the effects of gravity. With this knowledge, reliable predictions can be made about the conditions required on Earth to achieve improved materials. MSRR is a highly automated facility with a modular design capable of supporting multiple types of investigations. The NASA-provided Rack Support Subsystem provides services (power, thermal control, vacuum access, and command and data handling) to the ESA-developed Materials Science Laboratory (MSL) that accommodates interchangeable Furnace Inserts (FI). Two ESA-developed FIs are presently available on the ISS: the Low Gradient Furnace (LGF) and the Solidification and Quenching Furnace (SQF). Sample Cartridge Assemblies (SCAs), each containing one or more material samples, are installed in the FI by the crew and can be processed at temperatures up to 1400C. ESA continues to develop samples with 14 planned for launch and processing in the near future. Additionally NASA has begun developing SCAs to support US PIs and their partners. The first of these Flight SCAs are being developed for investigations to support research in the areas of crystal growth and liquid phase sintering. Subsequent investigations are in various stages of development. US investigations will include a ground test program in order to distinguish the particular effects of the absence of gravity.

Reagan, Shawn↗
NASA NTRS2016

Materials Science Research Rack Onboard the International Space Station

The Materials Science Research Rack (MSRR) is a research facility developed under a cooperative research agreement between NASA and ESA for materials science investigations on the International Space Station (ISS). MSRR was launched on STS-128 in August 2009 and currently resides in the U.S. Destiny Laboratory Module. Since that time, MSRR has logged more than 1400 hours of operating time. The MSRR accommodates advanced investigations in the microgravity environment on the ISS for basic materials science research in areas such as solidification of metals and alloys. The purpose is to advance the scientific understanding of materials processing as affected by microgravity and to gain insight into the physical behavior of materials processing. MSRR allows for the study of a variety of materials, including metals, ceramics, semiconductor crystals, and glasses. Materials science research benefits from the microgravity environment of space, where the researcher can better isolate chemical and thermal properties of materials from the effects of gravity. With this knowledge, reliable predictions can be made about the conditions required on Earth to achieve improved materials. MSRR is a highly automated facility with a modular design capable of supporting multiple types of investigations. The NASA-provided Rack Support Subsystem provides services (power, thermal control, vacuum access, and command and data handling) to the ESA-developed Materials Science Laboratory (MSL) that accommodates interchangeable Furnace Inserts (FI). Two ESA-developed FIs are presently available on the ISS: the Low Gradient Furnace (LGF) and the Solidification and Quenching Furnace (SQF). Sample Cartridge Assemblies (SCAs), each containing one or more material samples, are installed in the FI by the crew and can be processed at temperatures up to 1400degC. ESA continues to develop samples with 14 planned for launch and processing in the near future. Additionally NASA has begun developing SCAs to support US PIs and their partners. The first of these Flight SCAs are being developed for investigations to support research in the areas of crystal growth and liquid phase sintering. Subsequent investigations are in various stages of development. US investigations will include a ground test program in order to distinguish the particular effects of the absence of gravity.

Reagan, S. E.↗
NASA NTRS2017

MSRR Rack Materials Science Research Rack

The Materials Science Research Rack (MSRR) is a research facility developed under a cooperative research agreement between NASA and the European Space Agency (ESA) for materials science investigations on the International Space Station (ISS). The MSRR is managed at the Marshall Space Flight Center (MSFC) in Huntsville, AL. The MSRR facility subsystems were manufactured by Teledyne Brown Engineering (TBE) and integrated with the ESA/EADS-Astrium developed Materials Science Laboratory (MSL) at the MSFC Space Station Integration and Test Facility (SSITF) as part of the Systems Development Operations Support (SDOS) contract. MSRR was launched on STS-128 in August 2009, and is currently installed in the U. S. Destiny Laboratory Module on the ISS. Materials science is an integral part of developing new, safer, stronger, more durable materials for use throughout everyday life. The goal of studying materials processing in space is to develop a better understanding of the chemical and physical mechanisms involved, and how they differ in the microgravity environment of space. To that end, the MSRR accommodates advanced investigations in the microgravity environment of the ISS for basic materials science research in areas such as solidification of metals and alloys. MSRR allows for the study of a variety of materials including metals, ceramics, semiconductor crystals, and glasses. Materials science research benefits from the microgravity environment of space, where the researcher can better isolate chemical and thermal properties of materials from the effects of gravity. With this knowledge, reliable predictions can be made about the conditions required on Earth to achieve improved materials. MSRR is a highly automated facility with a modular design capable of supporting multiple types of investigations. Currently the NASA-provided Rack Support Subsystem provides services (power, thermal control, vacuum access, and command and data handling) to the ESA developed Materials Science Laboratory (MSL) which accommodates interchangeable Furnace Inserts (FI). Two ESA-developed FIs are presently available on the ISS: the Low Gradient Furnace (LGF) and the Solidification and Quenching Furnace (SQF). Sample-Cartridge Assemblies (SCAs), each containing one or more material samples, are installed in the FI by the crew and can be processed at temperatures up to 1400 C. Once an SCA is installed, the experiment can be run by automatic command or science conducted via telemetry commands from the ground. This facility is available to support materials science investigations through programs such as the US National Laboratory, Technology Development, NASA Research Announcements, and others. TBE and MSFC are currently developing NASA Sample Cartridge Assemblies (SCA's) with a planned availability for launch in 2017.

Reagan, Shawn↗
NASA NTRS2020

Quasi-Static and Dynamic Analysis of Composite Panels: Challenges in Engineering-Level Commercial Software

In engineering applications, where analysis time and efficiency are essential, analytical models and commercially available finite element (FE) material models are the two mainstream methods used to analyze composite crush scenarios. A reliable numerical model addressing the crushing response of composite materials requires a nonlinear progressive damage analysis which includes appropriate failure mechanisms such as matrix cracking, fragmentation, delamination, and fiber breakage. One might be able to address all these interacting failure responses through implementation/validation of a user defined material model or by utilization of a commercially available model, the latter being the most efficient engineering approach. In this paper, the quasi-static and dynamic crushing response of composite specimens, consisting of a C-channel and a corrugated geometry manufactured with carbon fiber/epoxy matrix fabric, are modeled using the progressive composite damage model within ABAQUS. The novel part of this work, which has not been previously addressed in the literature, is the utilization of a detailed parametric study to optimize composite damage model parameters for a given quasi-static crush simulation in ABAQUS. C-channel experiments were used to calibrate the model and then refine/optimize a set of material parameters that best fit the experimental results. These identical parameters were then used to simulate the crush response of the corrugated channel specimens, thereby making it a pure prediction and not a double recalibration. Next, the dynamic response of both panels were predicted, further confirming the predictive capability of the developed numerical model. The effect of parameter variation on the crush response is fully documented for future use in engineering applications utilizing this specific ABAQUS damage model.

Paria Naghipour↗
NASA NTRS2010

Advanced Flip Chips in Extreme Temperature Environments

The use of underfill materials is necessary with flip-chip interconnect technology to redistribute stresses due to mismatching coefficients of thermal expansion (CTEs) between dissimilar materials in the overall assembly. Underfills are formulated using organic polymers and possibly inorganic filler materials. There are a few ways to apply the underfills with flip-chip technology. Traditional capillary-flow underfill materials now possess high flow speed and reduced time to cure, but they still require additional processing steps beyond the typical surface-mount technology (SMT) assembly process. Studies were conducted using underfills in a temperature range of -190 to 85 C, which resulted in an increase of reliability by one to two orders of magnitude. Thermal shock of the flip-chip test articles was designed to induce failures at the interconnect sites (-40 to 100 C). The study on the reliability of flip chips using underfills in the extreme temperature region is of significant value for space applications. This technology is considered as an enabling technology for future space missions. Flip-chip interconnect technology is an advanced electrical interconnection approach where the silicon die or chip is electrically connected, face down, to the substrate by reflowing solder bumps on area-array metallized terminals on the die to matching footprints of solder-wettable pads on the chosen substrate. This advanced flip-chip interconnect technology will significantly improve the performance of high-speed systems, productivity enhancement over manual wire bonding, self-alignment during die joining, low lead inductances, and reduced need for attachment of precious metals. The use of commercially developed no-flow fluxing underfills provides a means of reducing the processing steps employed in the traditional capillary flow methods to enhance SMT compatibility. Reliability of flip chips may be significantly increased by matching/tailoring the CTEs of the substrate material and the silicon die or chip, and also the underfill materials. Advanced packaging interconnects technology such as flip-chip interconnect test boards have been subjected to various extreme temperature ranges that cover military specifications and extreme Mars and asteroid environments. The eventual goal of each process step and the entire process is to produce components with 100 percent interconnect and satisfy the reliability requirements. Underfill materials, in general, may possibly meet demanding end use requirements such as low warpage, low stress, fine pitch, high reliability, and high adhesion.

Ramesham, Rajeshuni↗