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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 307 records · Page 17
All sourcesNASA NTRSDOE OSTI
NASA NTRSDate not supplied

Assembly and Integration Status of a High Fidelity Ground Test Bed for the Water Processor Assembly

The Water Recovery System (WRS) is a critical component of life support aboard the International Space Station (ISS) and will play an essential role in future missions beyond Low Earth Orbit (LEO). Its primary functional units – the Urine Processor Assembly (UPA), Brine Processor Assembly (BPA), and Water Processor Assembly (WPA) – must be evaluated for extended operation, dormancy resilience, material obsolescence, and reliability under exploration-driven constraints. Ground testing is vital for developing these technologies and generating statistically relevant reliability assessments, which requires extended runtime under integrated, Flight-like conditions. Currently, no high-fidelity, fully integrated WPA ground test bed exists to support these objectives. To address this gap, NASA is developing a WPA test bed at Marshall Space Flight Center (MSFC) that combines downgraded ISS flight hardware with functionally flight-like components in a cost-effective configuration while maintaining priority hardware investigations. This paper describes the current status of hardware assembly and integration, outlines key challenges such as simulating microgravity effects and mitigating obsolescence, and presents future test objectives including software development, reliability assessments, dormancy studies, and exploration-oriented upgrades.

Mary-Elizabeth Davis↗
DOE OSTI2020

GPU Lifetimes on Titan Supercomputer: Survival Analysis and Reliability

The Cray XK7 Titan was the top supercomputer system in the world for a long time and remained critically important throughout its nearly seven year life. It was an interesting machine from a reliability viewpoint as most of its power came from 18,688 GPUs whose operation was forced to execute three rework cycles, two on the GPU mechanical assembly and one on the GPU circuitboards. We write about the last rework cycle and a reliability analysis of over 100,000 years of GPU lifetimes during Titan’s 6-year-long productive period. Using time between failures analysis and statistical survival analysis techniques, we find that GPU reliability is dependent on heat dissipation to an extent that strongly correlates with detailed nuances of the cooling architecture and job scheduling. We describe the history, data collection, cleaning, and analysis and give recommendations for future supercomputing systems. We make the data and our analysis codes publicly available.

Ostrouchov, George↗
NASA NTRS2011

Reliability of Ceramic Column Grid Array Interconnect Packages Under Extreme Temperatures

A paper describes advanced ceramic column grid array (CCGA) packaging interconnects technology test objects that were subjected to extreme temperature thermal cycles. CCGA interconnect electronic package printed wiring boards (PWBs) of polyimide were assembled, inspected nondestructively, and, subsequently, subjected to ex - treme-temperature thermal cycling to assess reliability for future deep-space, short- and long-term, extreme-temperature missions. The test hardware consisted of two CCGA717 packages with each package divided into four daisy-chained sections, for a total of eight daisy chains to be monitored. The package is 33 33 mm with a 27 27 array of 80%/20% Pb/Sn columns on a 1.27-mm pitch. The change in resistance of the daisy-chained CCGA interconnects was measured as a function of the increasing number of thermal cycles. Several catastrophic failures were observed after 137 extreme-temperature thermal cycles, as per electrical resistance measurements, and then the tests were continued through 1,058 thermal cycles to corroborate and understand the test results. X-ray and optical inspection have been made after thermal cycling. Optical inspections were also conducted on the CCGA vs. thermal cycles. The optical inspections were conclusive; the x-ray images were not. Process qualification and assembly is required to optimize the CCGA assembly, which is very clear from the x-rays. Six daisy chains were open out of seven daisy chains, as per experimental test data reported. The daisy chains are open during the cold cycle, and then recover during the hot cycle, though some of them also opened during the hot thermal cycle..

Ramesham, Rajeshuni↗
NASA NTRSDate not supplied

Developmental Efforts of an Electrochemical Oxygen Recovery System for Advanced Life Support

The current State of Art (SOA) Environmental Control and Life Support System (ECLSS) oxygen recovery system onboard the International Space Station (ISS) is a complex, heavy, and power consuming system that recovers approximately 50% of the oxygen (O2) from metabolic carbon dioxide (CO2). For future long-duration missions, O2recovery systems will need to be highly reliable, efficient, and recover maximum metabolic CO2. Investigations into various technologies to help meet these requirements for exploration are ongoing; however, most of these proposed technologies ultimately result in a more complex system. A Macrofluidic Electrochemical Reactor (MFECR) is one proposed technology development effort currently underway at NASA Marshall Space Flight Center (MSFC) that has the potential to significantly reduce the complexity of ECLSSO2recovery system. The MFECR operates at standard conditions, giving it an advantage over other technologies being investigated, which require high temperatures resulting in heavy reactors and high power consumption. The MFECR would replace three pieces of hardware for future ECLSS architectures: the current Carbon Dioxide Reduction Assembly (Sabatier reactor), the Plasma Pyrolysis Assembly (PPA), and the Oxygen Generation Assembly(OGA). It is designed to interface directly with the Carbon Dioxide Removal Assembly (CDRA) and the Water Processor Assembly (WPA). This allows for a less complex system and higher reliability than the current SOA as well as reduced power, weight and H2Oconsumption of ECLSS. Here, we will discuss the current development efforts of the MFECR and how this technology may aide in the advancement of future long-duration life support systems.

Brittany R Brown↗
DOE OSTI2023

Performance and durability of electrically conductive tape for shingled Si heterojunction technology cells

We report electrically conductive tape (ECT) was characterized and used to assemble shingled cell strings at low temperature to achieve high reliability Pb- and Ag-free interconnections. The volume resistivity for two considered ECTs are 0.13 ± 0.06 mΩ·cm and 0.47 ± 0.20 mΩ·cm and specific contact resistances, 6.85± 2.00 mΩ·cm 2 and 6.30 ± 0.37 mΩ·cm 2 using the emerging IEC 62788-8-1 Technical Specification for assessment of electrically conductive adhesives (ECA). Durability and performance of the technology in glass–glass mini modules were evaluated with temperature cycling, damp heat testing, and combined-accelerated stress testing (CAST). Through temperature cycling (-40°C to 85°C) applying five times the mini module short-circuit current in forward bias and in the multi climate CAST protocol, there was negligible degradation of fill factor after replacing connectors at the modules' cable leads; however, CAST resulted in short circuit current loss attributed to degradation in light collection by the cells, not the ECT. The IEC 61215-2 85°C, 85% relative humidity damp heat testing showed susceptibility of the HJT cells to effects of humidity in the electroluminescence intensity around the module perimeter that degraded power performance by 4% (relative). Contrasting the IEC 61215-2 qualification testing-based damp heat testing with CAST, factors such as the optical stress of CAST may precipitate the degradation of the modules whereas the humidity levels and duration of IEC 61215-2 damp heat testing may lead to excessive levels of humidity diffused into the modules, potentially resulting in degradation that is unrepresentative of the field.

14 SOLAR ENERGY↗
DOE OSTI2022

Versatile Test Reactor Conceptual Core Design

The VTR is a 300-MW(thermal) sodium-cooled fast reactor (SFR) designed for the specific purpose of delivering unique testing capabilities to enable the advancement of all reactor technologies. With its flux level, irradiation volume, and operational flexibility, the VTR will enable accelerated testing of materials, fuels, and various components needing irradiation testing. Proven SFR technologies and design approaches have been leveraged in designing the VTR core, ensuring the highest possible readiness level. This resulted in the VTR using ternary metallic fuel and delivering fast flux levels in excess of 4 x 10 15 n/cm 2 ∙ s over large useful volumes, corresponding to about 60 dpa/year in steel. As part of the design efforts, the VTR core performance has been determined for a representative configuration, ensuring that the reactivity control systems offer sufficient shutdown margins, that the core can be safely cooled in all situations, and that reactivity feedback coefficients are conducive to a favorable safety behavior. Furthermore, the incorporation of features such as fuel assembly storage in the shield region supports the flexible and reliable operation of the VTR. Additional design work has been ongoing as well. This includes thorough shielding performance evaluations to ensure safe operation of the VTR, verification and validation of the design tools used to achieve compliance with Nuclear Quality Assurance (NQA-1) requirements, early assessment of the impact of irradiation experiments on the core performance envelope and associated margins, and in-depth uncertainty quantification efforts to quantify the anticipated range of performance characteristics. An experimental program supporting the VTR core design has been set up, with the current focus being on thermal-hydraulic experiments. The purpose of this experimental program is to obtain confirmatory measurements to serve directly as part of the core design basis or as part of the validation cases supporting the simulation tools used.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2026

Fundamentals of Solar PV Bolted Joint Loosening and Prevention

The photovoltaic (PV) industry has long reported anecdotal accounts of systems exhibiting intermittent or chronic fastener loosening, including joints that fail to maintain preload despite multiple re-tightening attempts. These occurrences are frequently, and often incorrectly, attributed to installer errors, vibration, or loading beyond design expectations (e.g., extreme weather events). Loose fasteners have serious implications and can significantly impact solar PV systems’ performance, reliability, and safety. However, effective bolted joint design and proper assembly practices can mitigate or eliminate loosening. Until the US Department of Energy’s Solar Energy Technologies Office (SETO) funded research on fasteners and solar PV structures, there was a notable gap in understanding the causes of loosening in solar PV systems.

14 SOLAR ENERGY↗
NASA NTRS1984

Liquid-Oxygen-Compatible Cement for Gaskets

Fluorelastomer and metal bonded reliably by new procedure. To cure fluoroelastomer cement, metal plate/gasket assembly placed in vacuum bag evacuated to minimum vacuum of 27 inches (69 cm) of mercury. Vacuum maintained throughout heating process and until assembly returns to ambient room temperature. Used to seal gaskets and O-rings or used to splice layers of elastomer to form non-standard sized O-rings. Another possible use is to apply protective, liquid-oxygen-compatible coating to metal parts.

Elmore, N. L.↗
NASA NTRS1992

NASA preferred reliability-practices for design and test

NASA HQ established the NASA R&M Steering Committee (R&MSC) comprised of membership from each NASA field center. The primary charter of the R&MSC is to obtain, record, and share the best design practices that NASA has applied to successful space flight programs and current design considerations (guidelines) that should enhance flight reliability on emerging programs. The practices and guidelines are being assembled in a living document for distribution to NASA centers and the aerospace community. The document will be updated annually with additional practices and guidelines as contributions from the centers are reviewed and approved by the R&MSC. Practices and guidelines are not requirements, but rather a means of sharing procedures and techniques that a given center and the R&MSC together feel have strong technical merit and application to the design of space-related equipment.

Lisk, Ronald C.↗
DOE OSTI2013

Characterization of Polarizing Splitter Optics in Extreme Environments

Development of laser systems capable of surviving extreme conditions experienced in military applications requires mounts and components that are able to survive these conditions. The characterization of mounted and/or bonded optical assemblies in harsh environments is critical for the development of laser and optical systems for functionality in these extreme conditions. Customized mounts, bonding assemblies and packaging strategies are utilized to develop and field reliable and robust optical subassemblies. Thin film polarizers operating at 45o and polarizing beam splitter cubes were chosen for initial testing based on past experiences, advancements in optical coating and construction technologies and material properties. Shock, vibration, shear strength, tensile strength and temperature testing are performed on mounted polarizing beam splitter cubes and thin film polarizers from two manufacturers. Previous testing showed that polarizing beam splitter cubes constructed using epoxy would become damaged in the laser resonator. The cubes being tested in this report are constructed using epoxy- free direct optical contact bonding. Thin film polarizers operating at 45o are chosen opposed to Brewster’s angle thin film polarizers to reduce the size and simplify design and construction since an optical wedge is not required. The components and mounts are each environmentally tested beyond the manufacturers’ specifications for shock, vibration, and temperature. Component functionality is monitored during and after the environmental testing. Experimental results from the testing will be discussed as will the impact on future laser resonator designs.

45 MILITARY TECHNOLOGY, WEAPONRY, AND NATIONAL DEF↗
DOE OSTI2016

Modified versions of the fuel performance codes RTOP and RTOP-CA

RTOP code predicts thermal and mechanical behavior of LWR fuel rods and release of GFPs both in normal stationary and transient operation modes, and transient power ramps, specific to the reactivity-initiated accidents (RIA). Computational domains of the code include fuel column, zirconium cladding, gas under cladding, and fuel microstructure - UO{sub 2} grain and the development of gaseous porosity of different origin during irradiation. RTOP-CA code is based on the RTOP code. It simulates the behavior of a fuel rod with cladding rupture opening and RFPs release into the primary coolant circuit in normal operation modes. The paper presents the results of development and validation of engineering models, which take into account characteristics of the neutron spectrum during the fuel cycle and are integrated into modernized versions of the fuel performance codes RTOP and RTOP-CA. The paper focuses on the detailed description of two models. Four-group neutron-physical engineering model describes burn-out of gadolinium isotopes and calculates spatial power profile in a Gd-doped fuel rod pellet. The second engineering model presented is developed for fast estimation of fuel burnup in case of fuel rod cladding leakage accident. The comparison of the present calculations with the results of calculations by neutron codes shows that the model describes the heat rate distribution and the gadolinium burn-out with sufficient accuracy. The code also calculates the LHR of Gd-doped fuel rods given the heat rate of the adjacent UO{sub 2} fuel rods. This work allows determining the histories of LHR for the Gd-doped fuel rod from the average LHR of FA for various equilibrium WWER fuel cycles, power units and fuel enrichments. The presented model is implemented in the RTOP fuel performance code to calculate the thermomechanical behavior of the fuel rods. An engineering-physical model is developed for fast estimation of {sup 134}Cs/{sup 137}Cs activity ratio in fuel taking into account the parameters of the neutron spectrum during the fuel cycle. Implementation of the model enables to increase the reliability of correct fuel burnup determination in a failed fuel assembly (FA)based on the FERDS activity measurements during reactor operation. Results of the model calculations obtained for the FAs with a higher fuel enrichment and the NPP activity measurements have shown a higher {sup 134}Cs/{sup 137}Cs activity ratio compared to the values for the fuel with enrichment up to 3.6 wt. % in {sup 235}U. Currently, the engineering model is applicable within the range of UO{sub 2} enrichment from 3 to 5 wt. % in {sup 235}U, and Gd{sub 2}O{sub 3} enrichment from 5 to 8 wt. %.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
NASA NTRS2020

Developmental Efforts of an Electrochemical Oxygen Recovery System for Advanced Life Support

The current State of Art (SOA) Environmental Control and Life Support System (ECLSS) oxygen recovery system onboard the International Space Station (ISS) is complex, heavy, and power consuming system that recovers approximately 50% of the oxygen (O2) from metabolic carbon dioxide (CO2). For future long-duration missions, O2 recovery systems will need to be highly reliable, efficient, and recover maximum metabolic CO2. A minimum of 75% O2 recovery is required for future O2 recovery systems. Investigations into various technologies to help meet these requirements for exploration are ongoing; however, most of these proposed technologies ultimately result in a more complex system. A Macrofluidic Electrochemical Reactor (MFECR) is one proposed technology development effort currently underway at NASA Marshall Space Flight Center (MSFC) that has the potential to significantly reduce the complexity of ECLSS O2 recovery system. The MFECR operates at standard conditions, giving it an advantage over other technologies being investigated, which require high temperatures resulting in heavy reactors and high power consumption. The MFECR would replace three pieces of hardware for future ECLSS architectures: the current Carbon Dioxide Reduction Assembly (Sabatier reactor), the Plasma Pyrolysis Assembly (PPA), and the Oxygen Generation Assembly (OGA). It is designed to interface directly with the Carbon Dioxide Removal Assembly (CDRA) and the Water Processor Assembly (WPA). This allows for a less complex system and higher reliability than the current SOA as well as reduced power, weight and H2O consumption of ECLSS. Here, we will discuss the current technology development efforts of the MFECR and how this technology may aide in the advancement of future long-duration life support systems.

Brown, Brittany R.↗
NASA NTRS1982

Visible charge-coupled device (CCD) focal plane design considerations for multispectral applications

The typical Multispectral Linear Array (MLA) Instrument mission would be to gather high-resolution, radiometrically accurate earth resources data in several spectral bands over a prolonged period of time. These bands would include the visible (VIS), near infrared (NIR) and short wavelength infrared. Silicon charge-coupled imaging devices (CCDs) can be assembled into contiguous pixel focal planes which will cover the VIS/NIR region and operate reliably for several years in a space environment. A typical MLA focal plane would have approximately 12,000 pixels, with a pixel-to-pixel registration requirement on the order of + or - 0.1 pixel. The technology to assemble such focal planes has been developed and is described. The problem of polarization sensitivity associated with certain types of focal plane assemblies is addressed. Radiation effects on CCDs are also discussed, and a practical solution to the problem through the use of shielding is described.

Sadowski, H.↗
DOE OSTI2017

Classification and imaging of spent nuclear fuel dry casks using cosmic ray muons - 132

The present work explores alternative approaches for in situ monitoring with near real-time data analysis and imaging of dry casks using muons. Monitoring can provide useful signals about the cask contents in a yes/no decision format faster and with fewer muons than traditional imaging. Imaging can be performed as a second step in this process if specific information about the location of the fuel assemblies is needed. To explore and analyze these two modalities, simulations of muon scattering and displacement were performed for various scenarios, including vertical and horizontal fully loaded dry casks, half-loaded dry casks, dry casks with one row of fuel assemblies missing, dry casks with one fuel assembly missing, and empty dry casks. This work demonstrates monitoring can provide fast and reliable indication about the contents of the cask. For 100,000 muons, a few minutes of measurement time with a 3.6 m{sup 2} detector at a 45 deg. zenith angle, 90% detection probability for missing fuel assemblies can be achieved with a false alarm rate lower than 1%. If a positive signal is detected, then longer measurements can be performed and coupled with muon imaging algorithms to determine the location of missing nuclear material. In these cases, transmission muon radiography can produce images of acceptable resolution for all scenarios. In the horizontal dry cask case, all scenarios can be identified and separated adequately. In the vertical dry cask case, similar conclusions can be drawn, but because of shadowing from other fuel assemblies, the location of a missing fuel assembly cannot be identified in the 2-D transmission map. However, views from different directions may resolve this. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
NASA NTRS1992

Design and testing of the Space Station Freedom Propellant Tank Assembly

Propellant storage and management functions for the Propulsion Module of the U.S. Space Station Freedom are provided by the Propellant Tank Assembly (PTA). The PTA consists of a surface-tension type propellant acquisition device contained within a welded titanium pressure vessel. The PTA design concept was selected with high reliability and low program risk as primary goals in order to meet stringent NASA structural, expulsion, fracture control and reliability requirements. The PTA design makes use of Shuttle Orbital Maneuvering System and Peacekeeper Propellant Storage Assembly design and analysis techniques. This paper summarizes the PTA design solution and discusses the underlying detailed analyses. In addition, design verification and qualification test activities are discussed.

Dudley, D. D.↗
NASA NTRS1973

An investigation of a sterile access technique for the repair and adjustment of sterile spacecraft

A description is presented of a unique system for the sterilization and sterile repair of spacecraft and the results of a test program designed to assess the biological integrity and engineering reliability of the system. This trailer-mounted system, designated the model assembly sterilizer for testing (MAST), is capable of the dry-heat sterilization of spacecraft and/or components less than 2.3 meters in diameter at temperatures up to 433 K and the steam sterilization of components less than 0.724 meter in diameter. Sterile access to spacecraft is provided by two tunnel suits, called the bioisolator suit systems (BISS), which are contiguous with the walls of the sterilization chambers. The test program was designed primarily to verify the biological and engineering reliability of the MAST system by processing simulated space hardware. Each test cycle simulated the initial sterilization of a spacecraft, sterile repair of a failed component, removal of the spacecraft from the MAST for mating with the bus, and a sterile recycle repair.

Farmer, F. H.↗
NASA NTRS1994

Status of Hollow Cathode Heater Development for the Space Station Plasma Contactor

A hollow cathode-based plasma contactor has been selected for use on the Space Station. During the operation of the plasma contactor, the hollow cathode heater will endure approximately 12000 thermal cycles. Since a hollow cathode heater failure would result in a plasma contactor failure, a hollow cathode heater development program was established to produce a reliable heater. The development program includes the heater design, process documents for both heater fabrication and assembly, and heater testing. The heater design was a modification of a sheathed ion thruster cathode heater. Heater tests included testing of the heater unit alone and plasma contactor and ion thruster testing. To date, eight heaters have been or are being processed through heater unit testing, two through plasma contactor testing and three through ion thruster testing, all using direct current power supplies. Comparisons of data from heater unit performance tests before cyclic testing, plasma contactor tests, and ion thruster tests at the ignition input current level show the average deviation of input power and tube temperature near the cathode tip to be +/-0.9 W and +/- 21 C, respectively. Heater unit testing included cyclic testing to evaluate reliability under thermal cycling. The first heater, although damaged during assembly, completed 5985 ignition cycles before failing. Four additional heaters successfully completed 6300, 6300, 700, and 700 cycles. Heater unit testing is currently ongoing for three heaters which have to date accumulated greater than 7250, greater than 5500, and greater than 5500 cycles, respectively.

Soulas, George C.↗