Research for space enters the electronics age.
Electronic equipment performance and reliability improvement to meet technological advances for deep space communication
SPACE COMMUNICATION↗
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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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Cascade Distiller System Performance Testing Interim Results
The Cascade Distillation System (CDS) is a rotary distillation system with potential for greater reliability and lower energy costs than existing distillation systems. Based upon the results of the 2009 distillation comparison test (DCT) and recommendations of the expert panel, the Advanced Exploration Systems (AES) Water Recovery Project (WRP) project advanced the technology by increasing reliability of the system through redesign of bearing assemblies and improved rotor dynamics. In addition, the project improved the CDS power efficiency by optimizing the thermoelectric heat pump (TeHP) and heat exchanger design. Testing at the NASA-JSC Advanced Exploration System Water Laboratory (AES Water Lab) using a prototype Cascade Distillation Subsystem (CDS) wastewater processor (Honeywell d International, Torrance, Calif.) with test support equipment and control system developed by Johnson Space Center was performed to evaluate performance of the system with the upgrades as compared to previous system performance. The system was challenged with Solution 1 from the NASA Exploration Life Support (ELS) distillation comparison testing performed in 2009. Solution 1 consisted of a mixed stream containing human-generated urine and humidity condensate. A secondary objective of this testing is to evaluate the performance of the CDS as compared to the state of the art Distillation Assembly (DA) used in the ISS Urine Processor Assembly (UPA). This was done by challenging the system with ISS analog waste streams. This paper details the results of the AES WRP CDS performance testing.
Callahan, Michael R.↗
Recommendations to Advance Space Trusted Autonomy
While the various space agencies of the U.S. federal government have distinctly different visions for future operational space systems, all share important foundational commonalities: improve mission performance, reduce mission costs, incorporate technology advances more rapidly, increase reliability and resiliency, reduce risk, and adapt to anomalies and environmental hazards. These common needs, combined with the maturation of autonomous technology and the prospect of leveraging autonomous systems to address these needs, have led each agency to consider how and when to implement increasing levels of autonomy in their space systems. Simultaneously, the related question of how to determine the trustworthiness of an autonomous system is also escalating in significance.
Christopher A Jones↗
Analysis and design of a high power laser adaptive phased array transmitter
The feasibility of delivering substantial quantities of optical power to a satellite in low earth orbit from a ground based high energy laser (HEL) coupled to an adaptive antenna was investigated. Diffraction effects, atmospheric transmission efficiency, adaptive compensation for atmospheric turbulence effects, including the servo bandwidth requirements for this correction, and the adaptive compensation for thermal blooming were examined. To evaluate possible HEL sources, atmospheric investigations were performed for the CO2, (C-12)(O-18)2 isotope, CO and DF wavelengths using output antenna locations of both sea level and mountain top. Results indicate that both excellent atmospheric and adaption efficiency can be obtained for mountain top operation with a micron isotope laser operating at 9.1 um, or a CO laser operating single line (P10) at about 5.0 (C-12)(O-18)2um, which was a close second in the evaluation. Four adaptive power transmitter system concepts were generated and evaluated, based on overall system efficiency, reliability, size and weight, advanced technology requirements and potential cost. A multiple source phased array was selected for detailed conceptual design. The system uses a unique adaption technique of phase locking independent laser oscillators which allows it to be both relatively inexpensive and most reliable with a predicted overall power transfer efficiency of 53%.
Mevers, G. E.↗
Preliminary Characterization and Evaluation on FFF Manufactured 316H and ODS Steels
The Advanced Materials and Manufacturing Technology (AMMT) program develops cross-cutting technologies in support of a broad range of nuclear reactor technologies and maintains U.S. leadership in materials and manufacturing technologies for nuclear energy applications. The overarching vision of AMMT is to accelerate the development, qualification, demonstration, and deployment of advanced materials and manufacturing technologies to enable reliable and economical nuclear energy. Solid-state advanced manufacturing techniques can overcome some of the challenges in liquid-based additive manufacturing (AM) processes and should therefore be considered in material design and manufacturing as well. The work presented in this report forms part of a study on solid-state AM techniques of 316 stainless steels (SS) and oxide dispersion strengthened (ODS) steel components and supports the vision and goals of the AMMT program relevant to accelerate the development and deployment of advanced manufacturing processes. Achieving this can provide a safety improvement through larger safety margins, economic benefit for higher efficiency during operation, and a cost reduction through more effective manufacturing processes and less waste. This study provides preliminary information on development of the fused-filament fabrication (FFF) process using different powder types to demonstrate the sensitivity, and therefore the characterization of these sample components. The full solid-state manufacturing feasibility study will be completed and reported in a final feasibility evaluation during 2025. The study investigation used two 14YWT ODS powder batches, which provided information and the effect of different powder morphologies on manufacturability. The two 316SS powders demonstrated the effect of powder size on the manufacturability using FFF. Two product forms, namely a honeycomb structure and flat samples, were manufactured to demonstrate the flexibility of product form.
36 MATERIALS SCIENCE↗
Preliminary Characterization and Evaluation on ShAPE Manufactured 316H and ODS Steels
This study provides the first- of- a- kind results of direct tube formation through shear assisted processing and extrusion (ShAPE) for oxide dispersion strengthened (ODS) steel material; previously only bar was successfully made. The Advanced Materials and Manufacturing Technology (AMMT) program develops cross-cutting technologies in support of a broad range of nuclear reactor technologies and maintains U.S. leadership in materials and manufacturing technologies for nuclear energy applications. The overarching vision of AMMT is to accelerate the development, qualification, demonstration, and deployment of advanced materials and manufacturing technologies to enable reliable and economical nuclear energy. Solid-state advanced manufacturing techniques can overcome some of the challenges in liquid-based additive manufacturing processes and should therefore be considered in material design and manufacturing as well. The work presented in this report forms part of a study on solid-state additive manufacturing techniques of 316 stainless steels and ODS steel components and supports the vision and goals of the AMMT program relevant to accelerate the development and deployment of advanced manufacturing processes. Achieving this can provide a safety improvement through larger safety margins, economic benefit for higher efficiency during operation, and a cost reduction through more effective manufacturing processes and less waste.
36 MATERIALS SCIENCE↗
Monolithic microwave integrated circuit technology for advanced space communication
Future Space Communications subsystems will utilize GaAs Monolithic Microwave Integrated Circuits (MMIC's) to reduce volume, weight, and cost and to enhance system reliability. Recent advances in GaAs MMIC technology have led to high-performance devices which show promise for insertion into these next generation systems. The status and development of a number of these devices operating from Ku through Ka band will be discussed along with anticipated potential applications.
Ponchak, George E.↗
Long-duration Operation of 2-micron Coherent Doppler Lidar in Space
The reliability and lifetime of laser remote sensing systems that can operate autonomously over a sufficiently long period are mainly constrained by the laser diode arrays (LDAs) used for pumping their laser transmitters. The lifetime of a 2-micron coherent lidar operating in space is particularly of concern in lieu of required pump pulse duration of Thulium and Holmium solid state lasers (approx. 1msec) that are considerably longer than those of more widely used 1-micron lasers (< 0.2 msec). A factor of 5 to 10 times longer pulse duration can easily translate to over an order of magnitude shorter lifetime for a typical commercially available high-power 2-D array. Therefore, it is imperative to address the lifetime and reliability of LDAs for pumping 2-micron lasers by exploring all the potential options that significantly prolong their life meeting the required operational lifetime of space-based coherent Doppler lidars. The leading causes of sudden failure and premature degradation of LDAs are intrinsic semiconductor defects, optical facet breakdown resulting from excessive localized heating, and thermo-mechanical stresses due to the extreme thermal cycling of the laser active regions1-2. Long pulse operation grossly amplifies the impact of these failure/degradation causes, particularly the thermo-mechanical stresses due to pulse-to-pulse thermal cycling. Therefore, several experimental setups have been developed to investigate each of the failure mechanisms and causes of premature degradation in order to evaluate various package designs, define the best operating parameters, and to guide the technology advancement, leading to highly reliable and very long lifetime LDAs5. Several areas of improvement in the packaging and fabrication process of laser diodes have already been identified and efforts towards implementing these improvements are well underway. These efforts include the use of advanced high thermal conductivity materials for packaging of laser diode arrays and new fabrication techniques for mechanically attaching laser diode bars and submounts. But even using the existing LDAs, it may be possible to increase the lifetime by careful selection of the package type, number of bars per package and their pitch, operational temperature, and operating parameters such repetition rate, pulsewidth, and applied current. Obviously, the LDA specification and operational parameters will involve a system level trade analysis to ensure that the lidar instrument meets its performance objectives. One goal of this work is to enable such trade analysis by evaluating LDAs from different suppliers in different package types and quantifying their performance as a function of their operational parameters.
Amzajerdian, Farzin↗
B-52 stability augmentation system reliability
The B-52 SAS (Stability Augmentation System) was developed and retrofitted to nearly 300 aircraft. It actively controls B-52 structural bending, provides improved yaw and pitch damping through sensors and electronic control channels, and puts complete reliance on hydraulic control power for rudder and elevators. The system has experienced over 300,000 flight hours and has exhibited service reliability comparable to the results of the reliability test program. Development experience points out numerous lessons with potential application in the mechanization and development of advanced technology control systems of high reliability.
Bowling, T. C.↗
Engineering planetary lasers for interstellar communication
Transmitting large amounts of data efficiently among neighboring stars will vitally support any eventual contact with extrasolar intelligence, whether alien or human. Laser carriers are particularly suitable for high-quality, targeted links. Space laser transmitter systems designed by this work, based on both demonstrated and imminent advanced space technology, could achieve reliable data transfer rates as high as 1 kb/s to matched receivers as far away as 25 pc, a distance including over 700 approximately solar-type stars. The centerpiece of this demonstration study is a fleet of automated spacecraft incorporating adaptive neural-net optical processing active structures, nuclear electric power plants, annular momentum control devices, and ion propulsion. Together the craft sustain, condition, modulate, and direct to stellar targets an infrared laser beam extracted from the natural mesospheric, solar-pumped, stimulated CO2 emission recently discovered at Venus. For a culture already supported by mature interplanetary industry, the cost of building planetary or high-power space laser systems for interstellar communication would be marginal, making such projects relevant for the next human century. Links using high-power lasers might support data transfer rates as high as optical frequencies could ever allow. A nanotechnological society such as we might become would inevitably use 10 to the 20th power b/yr transmission to promote its own evolutionary expansion out of the galaxy.
Sherwood, Brent↗
Determining Surface Roughness in Urban Areas Using Lidar Data
An automated procedure has been developed to derive relevant factors, which can increase the ability to produce objective, repeatable methods for determining aerodynamic surface roughness. Aerodynamic surface roughness is used for many applications, like atmospheric dispersive models and wind-damage models. For this technique, existing lidar data was used that was originally collected for terrain analysis, and demonstrated that surface roughness values can be automatically derived, and then subsequently utilized in disaster-management and homeland security models. The developed lidar-processing algorithm effectively distinguishes buildings from trees and characterizes their size, density, orientation, and spacing (see figure); all of these variables are parameters that are required to calculate the estimated surface roughness for a specified area. By using this algorithm, aerodynamic surface roughness values in urban areas can then be extracted automatically. The user can also adjust the algorithm for local conditions and lidar characteristics, like summer/winter vegetation and dense/sparse lidar point spacing. Additionally, the user can also survey variations in surface roughness that occurs due to wind direction; for example, during a hurricane, when wind direction can change dramatically, this variable can be extremely significant. In its current state, the algorithm calculates an estimated surface roughness for a square kilometer area; techniques using the lidar data to calculate the surface roughness for a point, whereby only roughness elements that are upstream from the point of interest are used and the wind direction is a vital concern, are being investigated. This technological advancement will improve the reliability and accuracy of models that use and incorporate surface roughness.
Holland, Donald↗
NASA Reference Motor Designs for Electric Vertical Takeoff and Landing Vehicles
Electric and hybrid electric vertical takeoff and landing vehicles require high performance and high reliability electric motor drivetrains. Failure analysis of NASA’s Revolutionary Vertical Lift Technologies’ reference vehicles pointed to current electric motor drivetrain reliability being below what is needed to meet the expected stringent reliability requirements for Urban Air Mobility vehicles. In this paper, design studies are carried out for UAM vehicle electric motors to produce reference designs. The primary intent of these reference motor designs is to provide guidance for UAM motor reliability model development and technology advancement. They additionally provide high fidelity motor sizing information for vehicle designers and references for different technologies or motor topologies to be traded against.
Electric Motor Urban Air Mobility↗
NASA Reference Motor Designs for Electric Vertical Takeoff and Landing Vehicles
Electric and hybrid electric vertical takeoff and landing vehicles require high performance and high reliability electric motor drivetrains. Failure analysis of NASA’s Revolutionary Vertical Lift Technologies’ reference vehicles pointed to current electric motor drivetrain reliability being below what is needed to meet the expected stringent reliability requirements for Urban Air Mobility vehicles [1]. In this paper, design studies are carried out for UAM vehicle electric motors to produce reference designs. The primary intent of these reference motor designs is to provide guidance for UAM motor reliability model development and technology advancement. They additionally provide high fidelity motor sizing information for vehicle designers and references for different technologies or motor topologies to be traded against.
Thomas Tallerico↗
Advanced Exploration of Reliable Operation at low Altitudes: meteorology, Simulation, and Technology (AEROcAST): Improving Weather Tolerant Operations for AAM
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Grady Koch↗
Reliability of BGA Packages for Highly Reliable Application and Chip Scale Package Board Level Reliability
Diffenent aspects of advanced surface mount package technology have been investigated for aerospace applications. Three key areas included understanding assembly reliability behavior of conventional surface Mount, Ball Grid Arrays (BGAs), and Chip Scale Packages.
BGA Package Chip Scale Reliability↗
CSP/BGA Board level Reliability
Different aspects of advanced surface mount package technology have been investigated for aerospace applications. Three key areas included the assembly reliability of conventional Surface Mount, Ball Grid Arrays (BGAs), and Chip Scale Packages.
package type board material surface finish solder ↗
Impact of Device Scaling on Deep Sub-micron Transistor Reliability: A Study of Reliability Trends using SRAM
As microelectronics are scaled in to the deep sub-micron regime, users of advanced technology CMOS, particularly in high-reliability applications, should reassess how scaling effects impact long-term reliability. An experimental based reliability study of industrial grade SRAMs, consisting of three different technology nodes, is proposed to substantiate current acceleration models for temperature and voltage life-stress relationships. This reliability study utilizes step-stress techniques to evaluate memory technologies (0.25mum, 0.15mum, and 0.13mum) embedded in many of today's high-reliability space/aerospace applications. Two acceleration modeling approaches are presented to relate experimental FIT calculations to Mfr's qualification data.
CMOS integrated circuits↗
3D X-ray CT for BGA/CGA Workmanship Defect Detection
Commercial-off-the-shelf (COTS) advanced microelectronic technologies in high-reliability versions are now being considered for use in a number of National Aeronautics and Space Administration (NASA) electronic systems. One of the key drawbacks of advanced electronic packages with hidden solder joint interconnections, such as the column grid array (CGA), is that inspection can be challenging—whether visually or using X-rays. In general, inspection for solder joint integrity is poor, except for identifying shorts. The new, advanced X-ray systems, especially the 3D computer tomography version, may be able to provide the three-dimensional features that are extremely difficult to resolve under the 2D systems.This report presents both 2D and 3D X-ray images along with their representative optical photomicrographs for a number of advanced electronics package assemblies including 3D stack and CGA assemblies before and after thermal cycling.
Ghaffarian, Reza↗