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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 415 records · Page 23
All sourcesNASA NTRSDOE OSTI
NASA NTRS2018

Lessons Learned in the Flight Qualification of the S-NPP and NOAA-20 Solar Array Mechanisms

Deployable solar arrays are the energy source used on almost all Earth orbiting spacecraft and their release and deployment are mission-critical; fully testing them on the ground is a challenging endeavor. The 8 meter long deployable arrays flown on two sequential NASA weather satellites were each comprised of three rigid panels almost 2 meters wide. These large panels were deployed by hinges comprised of stacked constant force springs, eddy current dampers, and were restrained through launch by a set of four releasable hold-downs using shape memory alloy release devices. The ground qualification testing of such unwieldy deployable solar arrays, whose design was optimized for orbital operations, proved to be quite challenging and provides numerous lessons learned. A paperwork review and follow-up inspection after hardware storage determined that there were negative torque margins and missing lubricant, this paper will explain how these unexpected issues were overcome. The paper will also provide details on how the hinge subassemblies, the fully-assembled array, and mechanical ground support equipment were subsequently improved and qualified for a follow-on flight with considerably less difficulty. The solar arrays built by Ball Aerospace Corp. for the Suomi National Polar Partnership (S-NPP) satellite and the Joint Polar Satellite System (JPSS-1) satellite (now NOAA-20) were both successfully deployed on-obit and are performing well.

Helfrich, Daniel↗
NASA NTRS2018

Lessons Learned in the Flight Qualification of the S-NPP and NOAA-20 Solar Array Mechanisms

Deployable solar arrays are the energy source used on almost all Earth orbiting spacecraft and their release and deployment are mission-critical; fully testing them on the ground is a challenging endeavor. The 8 meter long deployable arrays flown on two sequential NASA weather satellites were each comprised of three rigid panels almost 2 meters wide. These large panels were deployed by hinges comprised of stacked constant force springs, eddy current dampers, and were restrained through launch by a set of four releasable hold-downs using shape memory alloy release devices. The ground qualification testing of such unwieldy deployable solar arrays, whose design was optimized for orbital operations, proved to be quite challenging and provides numerous lessons learned. A paperwork review and follow-up inspection after hardware storage determined that there were negative torque margins and missing lubricant, this paper will explain how these unexpected issues were overcome. The paper will also provide details on how the hinge subassemblies, the fully-assembled array, and mechanical ground support equipment were subsequently improved and qualified for a follow-on flight with considerably less difficulty. The solar arrays built by Ball Aerospace Corp. for the Suomi National Polar Partnership (SNPP) satellite and the Joint Polar Satellite System (JPSS-1) satellite (now NOAA-20) were both successfully deployed on-obit and are performing well.

Sexton, Adam↗
NASA NTRS2019

Textile Material Lessons Learned During the Design and Qualification of the NASA Orion Capsule Parachute Assembly System

The NASA Orion Capsule Parachute Assembly System (CPAS) development and qualification testing was completed in September 2018. Over the course of the airdrop and ground testing campaign, the team benefited from the ability to design, test, and adjust the design based on observations and inspection results. While the design team used the best knowledge available and attempted to utilize best practices, a number of lessons were learned that should be documented for consideration by future designers. This paper describes these lessons learned including the use of textile reefing loops, the importance of performing joint tests, the impact of using bight sleeves on parachute deployment, and a surprising number of design changes required in the CPAS system after the decision was made to change the suspension line braid to save system mass.

Anderson, Brian P.↗
NASA NTRS2019

Space Flight Optoelectronics and Photonics Qualification

The Photonics group top level processes regarding development and qualification of space flight hardware for optoelectronic components along with our contributions and successes with LIDAR systems, space flight reliability heritage, and our testing capabilities are conveyed with this power point presentation.

Optical Systems↗
NASA NTRSDate not supplied

Flexible Solar Array Qualification Protocols (FSAP-ACO)

This poster highlights the Game Changing Development Program task, Space Act Agreement between Maxar Technologies and NASA to test 5-junction solar cells on roll out compatible blankets through qualification protocols similar to AIAA Standards S-111/112. A description of the planned work and current status is included.

Jeremiah Mcnatt↗
NASA NTRS2009

Mitigation selection and qualification recommendations for Xilinx Virtex, Virtex-II, and Virtex-4 field programmable gate arrays

This work discusses mitigation selection and qualification techniques for Xilinx reconfigurable field programmable gate arrays (FPGAs). The aim of the paper is to provide readers with a better understanding of the engineering/reliability/project cost relationship that occurs when developing a mitigation strategy for static random access memory (SRAM)-based FPGAs.

Allen, Gregory↗
NASA NTRS2021

Lessons Learned from Screening and Qualification of COTS Capacitors

A traditional approach to screening and qualification of hi-rel COTS capacitors and its limitations are analyzed. Results of testing of four types of COTS capacitors for L2 projects are summarized. The types include DLA drawing tantalum MnO2 capacitors, high-voltage hermetically sealed polymer tantalum capacitors, multianode COTS+ capacitors, and feedthrough BME ceramic capacitors. Lessons learned from this experience might accelerate processes and reduce risks of inclusion of COTS components in space projects.

reliability↗
NASA NTRS2021

Screening and Qualification of BME Feedthrough Capacitors for a Space Project

Surface mount technology feedthrough ceramic capacitors are gaining popularity in Hi-Rel systems due to small size and great filtering characteristics. In this work, BME feedthrough capacitors compliant with AEC-Q200 requirements have been evaluated, screened and qualified for a space project. Evaluation included analysis of the effect of post-soldering thermal shocks, temperature dependencies of leakage currents, distribution of breakdown voltages, assessments of high-current capability, and thermal resistance of the parts. The parts have been screened and qualified at conditions close to the military requirements for ceramic capacitors. No failures were detected during screening including burning-in, but two samples failed during monitored 2000 hour life testing at 125C and two times rated voltage. Failure analysis revealed manufacturing defects that required additional analysis of screening and qualification test conditions. Highly accelerated life testing (HALT) has been carried out to assess reliability acceleration factors and the probability of failure at the use conditions. An approach to selection of adequate burning-in and life test conditions is discussed.

Alexander Teverovsky↗
NASA NTRS2021

Screening and Qualification of BME Feedthrough Capacitors for a Space Project

Surface mount technology feedthrough ceramic capacitors are gaining popularity in Hi-Rel systems due to small size and great filtering characteristics. In this work, BME feedthrough capacitors compliant with AEC-Q200 requirements have been evaluated, screened and qualified for a space project. Evaluation included analysis of the effect of post-soldering thermal shocks, temperature dependencies of leakage currents, distribution of breakdown voltages, assessments of high-current capability, and thermal resistance of the parts. The parts have been screened and qualified at conditions close to the military requirements for ceramic capacitors. No failures were detected during screening including burning-in, but two samples failed during monitored 2000 hour life testing at 125C and two times rated voltage. Failure analysis revealed manufacturing defects that required additional analysis of screening and qualification test conditions. Highly accelerated life testing (HALT) has been carried out to assess reliability acceleration factors and the probability of failure at the use conditions. An approach to selection of adequate burning-in and life test conditions is discussed.

Alexander Teverovsky↗
NASA NTRSDate not supplied

Process Qualification Concepts in NASA-STD-6030

- Terminology - Definition and role of QMP in the NASA-STD-6030 framework - Qualification checklist for evaluating a candidate AM material process - Types of data needed to evaluate the metrics for a QMP - Advocacy for a singular, contained data entity that enables QMP evaluation and other aspects of the AM ecosystem - Material Engineering Equivalence Baseline - Discussion of Material Engineering Equivalence concepts - Summary

Doug Wells↗
NASA NTRSDate not supplied

NASA's Certification and Qualification Challenges for Additively Manufactured Hardware: What Is Next?

In 2021, NASA released NASA-STD-6030 “Additive Manufacturing Requirements for Spaceflight Systems” to create qualification and certification strategies for mature metallic and non-metallic AM materials and technologies. While these standards have had an immediate impact on the additive manufacturing (AM) industry, there remain many challenges that have yet to be overcome. NASA and its partners in academia and industry are working together to proactively address these issues. One of the most critical needs is a Probabilistic Damage Tolerance Assessment (PDTA) approach, which includes the development of computational modeling, understanding the “effect of defects”, and the implementation of in-situ process monitoring and inspection techniques.

Will Tilson↗
NASA NTRSDate not supplied

Powder Bed Fusion Laser Beam Metals Additive Manufacturing: Process Monitoring Approaches for Qualification and Certification

The use of in-situ process monitoring is of interest to lower the cost of inspection for the qualification of powder bed fusion laser beam metal (PBF-LB/M) additively manufactured (AM) parts. Precise monitoring of the PBF-LB/M AM build process constitutes a multi-scale and multi-discipline task. There are several significant challenges to the in-situ approach: the synchronization of sensor signals to process steps; the physical interpretation and classification of sensor signals; managing very large datasets; and comparing the inputs with the observed monitoring signals. At NASA Langley Research Center, a configurable architecture additive testbed has been developed to monitor the build process with synchronized sensors. The philosophy and method adopted for the synchronization of the cameras with laser power and position throughout a complex PBF-LB/M AM build will be described. The synchronized in-situ monitoring signals are compared with ex-situ nondestructive inspection, x-ray computed tomography (XCT). Such comparisons permit a better understanding of how the sequential process actions of LPBF-AM can affect build quality. The multi-scale and complex process of printing additively manufactured (AM) parts can have unexpected, but predictable, build conditions that result in material microstructure variability. This presentation will describe an additive manufacturing model-based process metric (AM-PM) computational method that is a fully parallel reduced order modeling approach developed to evaluate the evolution of AM processes. This method couples the known sequence of the AM process with a physically informed nearest neighbors’ calculation to map the conditions of a part-scale build. The result is a map of the build that is derived directly from build files or in-situ process monitoring sensors. The methodology of the approach will be described and mapped to the porosity observed from XCT for a complex PBF-LB/M build. Such comparative results develop understanding of how the sequential process actions can affect the PBF-LB/M AM build quality and microstructure variability.

Laser Powder Bed Fusion↗
NASA NTRSDate not supplied

LOFTID (Low-Earth Orbit Flight Test of an Inflatable Decelerator) PASS (Payload Adapter Separation System) Design & Qualification

On November 10, 2022, NASA, in partnership with United Launch Alliance (ULA), launched Low-earth Orbit Flight Test of an Inflatable Decelerator (LOFTID) as a secondary payload on an Atlas V Centaur out of the Vandenburg Space Force Base (VSFB). After successfully delivering the primary payload, Joint Polar Satellite System-2 (JPSS-2), to a sun synchronous trajectory, the Centaur upper stage reoriented LOFTID onto the desired reentry trajectory. After conducting a de-orbit burn to enter the atmosphere the Payload Adaptor was ejected to expose the packed LOFTID vehicle. The LOFTID Hypersonic Inflatable Aerodynamic Decelerator (HIAD) was deployed and inflated. The Centaur pointed LOFTID to the desired entry attitude and spun the vehicle up to roughly three rpm before separating the reentry vehicle over the Middle East. The LOFTID vehicle flew freely before reentering the atmosphere over Alaska at >8km/sec and decelerating as designed. LOFTID demonstrated stable flight from hypersonic entry through subsonic parachute deployment. LOFTID was enabled by a mission-unique Payload Adapter Separation System (PASS) which separated the Payload Adapter prior to the start of the LOFTID flight demonstration, allowing the launch vehicle to accommodate a superstack of two independent, similarly sized payloads. This paper will discuss the design, development, and qualification effort of the LOFTID PASS.

Sean M Hancock↗
NASA NTRSDate not supplied

Design and Qualification or the Low-Earth Orbit Flight Test of an Inflatable Decelerator(LOFTID) Payload Adapter Separation System (PASS)

On November 10, 2022, NASA and United Launch Alliance (ULA) launched Low-Earth Orbit Flight Test of an Inflatable Decelerator (LOFTID) as a secondary payload on an Atlas V Centaur from Vandenburg Space Force Base (VSFB). After deploying the primary payload, JPSS-2, to a sun-synchronous orbit, the Centaur reoriented LOFTID for reentry, ejecting the Payload Adaptor to expose the stowed LOFTID reentry vehicle (RV). The Hypersonic Inflatable Aerodynamic Decelerator (HIAD) was then deployed and inflated, and the Centaur reoriented the RV to the desired entry attitude, spun the vehicle to roughly three rpm, and separated the reentry vehicle. After nearly half an orbit of free flight, LOFTID reentered the atmosphere at >8 km/sec, demonstrating stable flight from hypersonic entry through subsonic parachute deployment. A mission-unique Payload Adapter Separation System (PASS) enabled the successful LOFTID flight demonstration, allowing the launch vehicle to accommodate a superstack of two independent, similarly sized payloads. This paper discusses the design, development, and qualification of the LOFTID PASS along with lessons learned.

HIAD↗
NASA NTRSDate not supplied

12-kW Advanced Electric Propulsion System Hall Current Thruster Qualification and Production Status

The AEPS contract was awarded to AR in May of 2016 with the goal of developing a 12.5kW Hall Thruster System, including the Hall Current Thruster (HCT), Power Processor Unit (PPU) and Xenon Flow Controller (XFC). It was originally targeted to support the Asteroid Redirect Mission, which was cancelled early in the project. The project was subsequently restructured to support the Gateway PPE propulsion mission, with modified scope that consisted of the development, qualification and delivery of three 12kW flight thrusters. The PPU and XFC components were designed and development hardware fabricated with initial testing performed prior to being de-scoped from the contract. System level testing was performed by AR using these engineering components in early 2022 at the Aerospace Corporation’s EP-3 test facility.

Hall thruster↗
NASA NTRSDate not supplied

Additive Manufactured Hardware Qualification and Certification at NASA

Additive Manufacturing (AM) is certainly changing the space industry and providing new opportunities to travel to low earth orbit and explore our universe New design opportunities –not previously possible –for new high performance metal alloys, light-weighting, managing thermal, structural, and dynamic loads are being enabled by AM. Additively manufactured parts are already being inserted for complext system for NASA programs in critical applications –“ready to fly” Human exploration of space, especially deep space, requires extreme reliability Qualification of AM design/parts/process and Flight Certification

Alison Park↗