TRUST-AM: Trust and Reliability through Unified Simulation and Testing for Additive Manufacturing
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Qualification↗
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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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Evaluation of Life Testing Schemes
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Qualification↗
Thermal cycling testing to failure of a ceramic column grid array package for space applications
Ceramic column grid array (CCGA) packages have been used increasingly in logic and microprocessor functions, telecommunications, flight avionics boards, payload electronics boards, engineering navigational and science cameras, electronic assemblies, and other applications, because of their inherent advantages such as high electrical interconnect density, very good thermal and electrical performance, and compatibility with standard surface-mount technology (SMT) packaging assembly processes. Because these advanced electronic packages tend to have less solder-joint strain-relief than do leaded flat-pack electronic packages, the reliability of CCGA packages in challenging thermal environments is a very important consideration for their short- and long-term use in JPL-NASA space missions. In this study, we assembled daisy chains of polyimide printed wiring boards from CCGA-interconnect packages, inspected the boards nondestructively, and then subjected them to thermal cycling to assess their reliability in thermal environments from +125°C to -40°C±25°C. The test hardware consists of a CCGA 1752 package (CN version). The package was divided into four daisy-chained sections that were electrically monitored for their continuity during thermal cycling. The CCGA 1752 package is roughly 45 mm × 45 mm with a 42-mm × 42-mm array of 80%/20% Pb/Sn columns on a 1.00-mm pitch. The resistance of the daisy-chained CCGA interconnects was continuously monitored during thermal cycling in a gaseous nitrogen environment. Electrical continuity resistance measurements as a function of thermal cycling are reported here; tests to date have shown significant change to an open circuit in daisy-chain resistance as a function of thermal cycling. The change in interconnect resistance becomes increasingly noticeable with increasing number of thermal cycles. This paper describes the experimental thermal-cycling test results of CCGA 1752 package reliability testing under an extremely wide temperature range. The first failure was observed at 1479th thermal cycle. We report the thermal-cycle reliability test data for ~2500 thermal cycles.
Ramesham, Rajeshuni↗
NEPP DDR Device Reliability FY13 Report
This document reports the status of the NEPP Double Data Rate (DDR) Device Reliability effort for FY2013. The task targeted general reliability of > 100 DDR2 devices from Hynix, Samsung, and Micron. Detailed characterization of some devices when stressed by several data storage patterns was studied, targeting ability of the data cells to store the different data patterns without refresh, highlighting the weakest bits. DDR2, Reliability, Data Retention, Temperature Stress, Test System Evaluation, General Reliability, IDD measurements, electronic parts, parts testing, microcircuits
Guertin, Steven M.↗
Fan Acoustic Flight Effects on the PAA & ASN Flight Test
Accurate and reliable prediction of noise emitted from turbofan aircraft engines is an ongoing challenge. For continued progress, it is necessary to assess the performance of the most recent prediction methods in the NASA Aircraft NOise Prediction Program (ANOPP), and to examine the effects of flight condition on fan noise. The assessment is based on an extensive acoustic dataset acquired as part of the Propulsion Airframe Aeroacoustics and Aircraft System Noise (PAA&ASN) Flight Test conducted on a Boeing 787-10 aircraft. Engine operating condition was varied to study the characteristics of fan noise in flight. In a subset of the flight test matrix, the influence of the aft duct acoustic liner was studied by covering the lined area with aluminum tape to simulate a hardwall duct. The combination of test data at different flight conditions, along with rigorous predictions of jet noise, is used in this paper to extract fan noise from the measured total aircraft noise levels. The measured fan noise levels are compared with those predicted using the latest methods for fan source noise, liner attenuation, and PAA effect prediction. Detailed analyses are undertaken to understand agreement between data and various aspects of the prediction models, including spectral shape, directivity, and response to throttle setting. An additional investigation was undertaken to study the effect of aircraft speed on fan noise, as current models do not directly account for this parameter.
Aircraft System Noise↗
Reliability generalization: a viable key for establishing validity generalization
Even with radical restriction of range, reliability coefficients from 10 studies gave an average interstudy value of .74, suggesting constancy of reliability over diverse experiments. A value from a new test can help index reliability of tests not previously studied.
NASA Program Space Physiology and Countermeasures↗
Preliminary evaluation of a micro-based repeated measures testing system
A need exists for an automated performance test system to study the effects of various treatments which are of interest to the aerospace medical community, i.e., the effects of drugs and environmental stress. The ethics and pragmatics of such assessment demand that repeated measures in small groups of subjects be the customary research paradigm. Test stability, reliability-efficiency and factor structure take on extreme significance; in a program of study by the U.S. Navy, 80 percent of 150 tests failed to meet minimum metric requirements. The best is being programmed on a portable microprocessor and administered along with tests in their original formats in order to examine their metric properties in the computerized mode. Twenty subjects have been tested over four replications on a 6.0 minute computerized battery (six tests) and which compared with five paper and pencil marker tests. All tests achieved stability within the four test sessions, reliability-efficiencies were high (r greater than .707 for three minutes testing), and the computerized tests were largely comparable to the paper and pencil version from which they were derived. This computerized performance test system is portable, inexpensive and rugged.
Kennedy, Robert S.↗
Psychology of computer use: IX. A menu of self-administered microcomputer-based neurotoxicology tests
This study examined the feasibility of repeated self-administration of a newly developed battery of mental acuity tests which may have application in screening for fitness-for-duty or for persons who may be exposed to environmental stress, toxic agents, or disease. 16 subjects self-administered 18 microcomputer-based tests (13 new, 5 "core"), without proctors, over 10 sessions. The hardware performed well throughout the study and the tests appeared to be easily self-administered. Stabilities and reliabilities of the tests from the "core" battery were comparable to those obtained previously under more controlled experimental conditions. Eight of the new tests exceeded minimum criteria for metric and practical requirements and can be recommended as additions to the menu. Although the average retest reliability was high, cross-correlations between tests were low, implying factorial diversity. The menu can be used to form batteries with flexible total testing time which are likely to tap different mental processes and functions.
NASA Discipline Neuroscience↗
Helium-uranium dating of corals.
Fanale and Schaeffer (1965) determined He/U ages of corals and other aragonitic fossils, and found that the results generally agreed with independent age estimates. As a more extensive and rigorous test of the reliability of He/U ages of fossil corals, I have determined He/U ages of forty-five independently dated Cenozoic corals. Uranium and thorium isotope compositions and Rn-222 retentivities were also determined as consistency checks. The results indicate that reliable ages are obtained when certain consistency tests are met and specified corrections are made.
Bender, M. L.↗
Reliability-based econometrics of aerospace structural systems: Design criteria and test options
The design criteria and test options for aerospace structural reliability were investigated. A decision methodology was developed for selecting a combination of structural tests and structural design factors. The decision method involves the use of Bayesian statistics and statistical decision theory. Procedures are discussed for obtaining and updating data-based probabilistic strength distributions for aerospace structures when test information is available and for obtaining subjective distributions when data are not available. The techniques used in developing the distributions are explained.
Thomas, J. M.↗
Space station software reliability analysis based on failures observed during testing at the multisystem integration facility
Quality of software not only is vital to the successful operation of the space station, it is also an important factor in establishing testing requirements, time needed for software verification and integration as well as launching schedules for the space station. Defense of management decisions can be greatly strengthened by combining engineering judgments with statistical analysis. Unlike hardware, software has the characteristics of no wearout and costly redundancies, thus making traditional statistical analysis not suitable in evaluating reliability of software. A statistical model was developed to provide a representation of the number as well as types of failures occur during software testing and verification. From this model, quantitative measure of software reliability based on failure history during testing are derived. Criteria to terminate testing based on reliability objectives and methods to estimate the expected number of fixings required are also presented.
Tamayo, Tak Chai↗
Development and in-flight performance of the Mariner 9 spacecraft propulsion system
On November 14, 1971, Mariner 9 was decelerated into orbit about Mars by a 1334-newton (300-lbf) liquid bipropellant propulsion system. The development and in-flight performance are described and summarized of this pressure-fed, nitrogen tetroxide/monomethyl hydrazine bipropellant system. The design of all Mariner propulsion subsystems has been predicated upon the premise that simplicity of approach, coupled with thorough qualification and margin-limits testing, is the key to cost-effective reliability. The qualification test program and analytical modeling of the Mariner 9 subsystem are discussed. Since the propulsion subsystem is modular in nature, it was completely checked, serviced, and tested independent of the spacecraft. Proper prediction of in-flight performance required the development of three significant modeling tools to predict and account for nitrogen saturation of the propellant during the six-month coast period and to predict and statistically analyze in-flight data. The flight performance of the subsystem was excellent, as were the performance prediction correlations. These correlations are presented.
Evans, D. D.↗
Development and in-flight performance of the Mariner 9 spacecraft propulsion system
On November 14, 1971, Mariner 9 was decelerated into orbit about Mars by a 1334 N (300 lbf) liquid bipropellant propulsion system. This paper describes and summarizes the development and in-flight performance of this pressure-fed, nitrogen tetroxide/monomethyl hydrazine bipropellant system. The design of all Mariner propulsion subsystems has been predicted upon the premise that simplicity of approach, coupled with thorough qualification and margin-limits testing, is the key to cost-effective reliability. The qualification test program and analytical modeling are also discussed. Since the propulsion subsystem is modular in nature, it was completely checked, serviced, and tested independent of the spacecraft. Proper prediction of in-flight performance required the development of three significant modeling tools to predict and account for nitrogen saturation of the propellant during the six-month coast period and to predict and statistically analyze in-flight data.
Evans, D. D.↗
Nondestructive testing of electro thermal devices
This paper describes the results of a recent investigation into 'thermal time constant' nondestructive testing of high reliability electrical fuses. The use of established nondestructive test technology for examining the quality and firing characteristics of electro-explosive devices has been successfully applied to the inspection and prediction of the functional performance of electrical fuses. The technique requires application of a low level current pulse to the electrical fuse with an oscilloscope display of the curve as generated by the temperature coefficient of resistance feedback. The heating curve of temperature vs time is composed of one predominant thermal time constant, which is the product of the test unit's thermal capacity and thermal resistance. It has been found that the quality of the individual electrical fuse, for instance, the relative condition of the critical internal weld or solder joint, can be examined nondestructively.
Earnest, J. E., Jr.↗
Dynamic Visual Acuity and Landing Sickness in Crewmembers Returning from Long-Duration Spaceflight
Long-term exposure to microgravity causes sensorimotor adaptations that result in functional deficits upon returning to a gravitational environment. At landing the vestibular system and the central nervous system, responsible for coordinating head and eye movements, are adapted to microgravity and must re-adapt to the gravitational environment. This re-adaptation causes decrements in gaze control and dynamic visual acuity, with astronauts reporting oscillopsia and blurred vision. Dynamic visual acuity (DVA) is assessed using an oscillating chair developed in the Neuroscience Laboratory at JSC. This chair is lightweight and easily portable for quick deployment in the field. The base of the chair is spring-loaded and allows for manual oscillation of the subject. Using a metronome, the chair is vertically oscillated plus or minus 2 cm at 2 Hz by an operator, to simulate walking. While the subject is being oscillated, they are asked to discern the direction of Landolt-C optotypes of varying sizes and record their direction using a gamepad. The visual acuity thresholds are determined using an algorithm that alters the size of the optotype based on the previous response of the subject using a forced-choice best parameter estimation that is able to rapidly converge on the threshold value. Visual acuity thresholds were determined both for static (seated) and dynamic (oscillating) conditions. Dynamic visual acuity is defined as the difference between the dynamic and static conditions. Dynamic visual acuity measures will be taken prior to flight (typically L-180, L-90, and L-60) and up to eight times after landing, including up to 3 times on R plus 0. Follow up measurements will be taken at R plus 1 (approximately 36 hours after landing). Long-duration International Space Station crewmembers will be tested once at the refueling stop in Europe and once again upon return to Johnson Space Center. In addition to DVA, subjective ratings of motion sickness will be recorded throughout the testing. Using the chair as a portable and reliable way to test DVA, we aim to test returning astronauts to assess the amount of retinal slip that they experience. By comparing these measurements to their motion sickness scores (using a scale of 1 to 20 where 20 is vomiting), we will correlate the amount of retinal slip to the level of motion sickness experienced. In addition to testing this in returning astronauts, we will perform ground-based studies to determine the effectiveness of stroboscopic goggles in reducing retinal slip and improving DVA. Finally, we will employ stroboscopic goggles in the field to astronauts experiencing high levels of motion sickness to minimize retinal slip and reduce their symptoms.
Rosenberg, M.J.F↗
A study of the reliability of electronic components in a nuclear radiation environment. Volume II - The revised test procedure
Test procedures for program to determine reliability of electronic components in nuclear radiation environment
ENVIRONMENTAL TESTING↗
Test Hardware Design for Flight-Like Operation of Advanced Stirling Convertors
NASA Glenn Research Center (GRC) has been supporting development of the Advanced Stirling Radioisotope Generator (ASRG) since 2006. A key element of the ASRG project is providing life, reliability, and performance testing of the Advanced Stirling Convertor (ASC). For this purpose, the Thermal Energy Conversion branch at GRC has been conducting extended operation of a multitude of free-piston Stirling convertors. The goal of this effort is to generate long-term performance data (tens of thousands of hours) simultaneously on multiple units to build a life and reliability database. The test hardware for operation of these convertors was designed to permit in-air investigative testing, such as performance mapping over a range of environmental conditions. With this, there was no requirement to accurately emulate the flight hardware. For the upcoming ASC-E3 units, the decision has been made to assemble the convertors into a flight-like configuration. This means the convertors will be arranged in the dual-opposed configuration in a housing that represents the fit, form, and thermal function of the ASRG. The goal of this effort is to enable system level tests that could not be performed with the traditional test hardware at GRC. This offers the opportunity to perform these system-level tests much earlier in the ASRG flight development, as they would normally not be performed until fabrication of the qualification unit. This paper discusses the requirements, process, and results of this flight-like hardware design activity.
Oriti, Salvatore M.↗
Test Hardware Design for Flightlike Operation of Advanced Stirling Convertors (ASC-E3)
NASA Glenn Research Center (GRC) has been supporting development of the Advanced Stirling Radioisotope Generator (ASRG) since 2006. A key element of the ASRG project is providing life, reliability, and performance testing of the Advanced Stirling Convertor (ASC). For this purpose, the Thermal Energy Conversion branch at GRC has been conducting extended operation of a multitude of free-piston Stirling convertors. The goal of this effort is to generate long-term performance data (tens of thousands of hours) simultaneously on multiple units to build a life and reliability database. The test hardware for operation of these convertors was designed to permit in-air investigative testing, such as performance mapping over a range of environmental conditions. With this, there was no requirement to accurately emulate the flight hardware. For the upcoming ASC-E3 units, the decision has been made to assemble the convertors into a flight-like configuration. This means the convertors will be arranged in the dual-opposed configuration in a housing that represents the fit, form, and thermal function of the ASRG. The goal of this effort is to enable system level tests that could not be performed with the traditional test hardware at GRC. This offers the opportunity to perform these system-level tests much earlier in the ASRG flight development, as they would normally not be performed until fabrication of the qualification unit. This paper discusses the requirements, process, and results of this flight-like hardware design activity.
Oriti, Salvatore M.↗