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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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The meeting focused on progress made in establishing performance and lifetime expectations of magnetoplasmadynamic (MPD) thrusters as functions of power, propellant, and design; models for the plasma flow and electrode components; viability and transportability of quasi-steady thruster testing; engineering requirements for high power, long life thrusters; and facilities and their requirements for performance and life testing.
Eagle-Picher currently has several advanced nickel-hydrogen (NiH2) cell component and battery designs under development including common pressure vessel (CPV), single pressure vessel (SPV), and dependent pressure vessel (DPV) designs. A CPV NiH2 battery, utilizing low-cost 64 mm (2.5 in.) cell diameter technology, has been designed and built for multiple smallsat programs, including the TUBSAT B spacecraft which is currently scheduled (24 Nov. 93) for launch aboard a Russian Proton rocket. An advanced 90 mm (3.5 in.) NiH2 cell design is currently being manufactured for the Space Station Freedom program. Prototype 254 mm (10 in.) diameter SPV batteries are currently under construction and initial boilerplate testing has shown excellent results. NiH2 cycle life testing is being continued at Eagle-Picher and IPV cells have currently completed more than 89,000 accelerated LEO cycles at 15% DOD, 49,000 real-time LEO cycles at 30 percent DOD, 37,800 cycles under a real-time LEO profile, 30 eclipse seasons in accelerated GEO, and 6 eclipse seasons in real-time GEO testing at 75 percent DOD maximum. Nickel-metal hydride battery development is continuing for both aerospace and electric vehicle applications. Eagle-Picher has also developed an extensive range of battery evaluation, test, and analysis (BETA) measurement and control equipment and software, based on Hewlett-Packard computerized data acquisition/control hardware.
This paper contains summaries of testing procedures and analysis of stress rupture life testing for two stress rupture test programs, one for Kevlar COPVs performed at Lawrence Livermore National Laboratory, and the other a joint study between NASA JSC White Sands Test Facility and the Jet Propulsion Laboratory. These will be discussed in detail including test setup and issues encountered during testing. Lessons learned from testing in these two programs will be discussed.
The EcoTurn Class K production prototypes have passed all AAR qualification tests and received conditional approval. The accelerated life test on the second set of seals is in progress. Due to the performance of the first set, no problems are expected.The seal has demonstrated superior performance over the HDL seal in the test lab with virtually zero torque and excellent contamination exclusion and grease retention.
The International Space Station (ISS) is a result of international collaboration in building a sophisticated laboratory of an unprecedented scale in Low Earth Orbit. After a complex assembly sequence spanning over a decade, some of the early modules launched at the beginning of the program would reach the end of their certified lives, while the newer modules were just being commissioned into operation. To maximize the return on global investments in this one-of-a-kind orbiting platform that was initially conceived for a service life until 2016, it is essential for the cutting edge research on ISS to continue as long as the station can be sustained safely in orbit. ISS Program is assessing individual modules in detail to extend the service life of the ISS to 2024, and possibly to 2028. Without life extension, Functional Cargo Block (known by its Russian acronym as FGB) and the Service Module (SM), two of the early modules on the Russian Segment, would reach the end of their certified lives in 2013 and 2015 respectively. Both FGB and SM are critical for the propulsive function of the ISS. This paper describes the approach used for the service life extension of the FGB propulsion system. Also presented is an overview of the system description along with the process adopted for developing the life test plans based on considerations of system failure modes, fault tolerance and safety provisions. Tests and analyses performed, important findings and life estimates are summarized. Based on the life extension data, FGB propulsion system, in general, is considered ready for a service life until 2028.
The reliability of photovoltaic (PV) inverters is critical for long-term solar system performance, with cooling fan failures frequently leading to costly downtime. While much research exists on general cooling fan reliability, little attention has been given to fans operating within PV inverters and their unique environmental challenges. Here, this article proposes a comprehensive methodology to address this gap. First, a failure mode and effects analysis is performed on fans to identify the key failure mechanisms in PV applications, their corresponding stressors, and the models necessary for lifetime prediction. Second, an accelerated life test is designed and conducted to collect valuable experimental data for PV inverter fans in a reasonable amount of time. Third, a mathematical conversion of dynamic mission profiles into effective constant stress levels is derived. Fourth, case studies are given, showcasing lifetime estimates that account for geographic variations in mission profile data. The results demonstrate that this integrated approach leads to an accurate reliability assessment for PV inverter cooling fans.
The International Space Station (ISS) primary Electric Power System (EPS) currently uses Nickel-Hydrogen (Ni-H2) batteries to store electrical energy. The electricity for the space station is generated by its solar arrays, which charge batteries during insolation for subsequent discharge during eclipse. The Ni-H2 batteries are designed to operate at a 35 depth of discharge (DOD) maximum during normal operation in a Low Earth Orbit. Since the oldest of the 48 Ni-H2 battery Orbital Replacement Units (ORUs) has been cycling since September 2006, these batteries are now approaching their end of useful life. In 2010, the ISS Program began the development of Lithium-Ion (Li-Ion) batteries to replace the Ni-H2 batteries and concurrently funded a Li-Ion ORU and cell life testing project. When deployed, they will be the largest Li-Ion batteries ever utilized for a human-rated spacecraft. This paper will include an overview of the ISS Li-Ion battery system architecture, the Li-Ion battery design and development, controls to limit potential hazards from the batteries, and the status of the Li-Ion cell and ORU life cycle testing.
Evaluation of the long term effects on aerospace nickel cadmium cells is described. A number of 6Ah and 12Ah capacity cells which were stored in shorted condition for 9 to 11 years at the Goddard Space Flight Center were selected for the study. Of the three tests which were initiated (initial and final destruction analyses of the test cells, electrical characterization tests, and life cycling tests) only the electrical characterization tests are completed; the other tests are scheduled to be completed by February 1987. The preliminary electrial performance data from the life cycling test and chemical composition data from the destructive testing indicate no anomalous behavior.
The critical mechanical components of the scan mirror mechanism are described and their evaluation and screening procedures are discussed. A bumper/damper unit is used in the design to reverse motion of the mirror and effect scan and retrace cycles. A wear evaluation was conducted on the bumper impact surfaces that established nylon 6-10 as an acceptable material. The elastomeric dampers were subjected to thermal vacuum tests for condensables and outgassing as well as parametric life tests. The flexure pivots that support the mirror were tested to establish a curve of stress plotted as a function of cycles to failure for rotational operation. The pivots met the life requirement of 150,000,000 cycles at a + or - 2.9 deg amplitude during fatigue testing. Screening procedures were established for dampers and flexure pivots to obtain flight quality components.
A major reliability issue for all advanced nonvolatile memory (NVM) technology devices including FRAMs is the data retention characteristics over extended period of time, under environmental stresses and exposure to total ionizing dose (TID) radiation effects. For this testing, 256 Kb FRAMs in 28-pin plastic DIPS, rated for industrial grade temperature range of -40 C to +85 C, were procured. These are two-transistor, two-capacitor (2T-2C) design FRAMs. In addition to data retention characteristics, the parts were also evaluated for imprint failures, which are defined as the failure of cells to change from a "preferred" state, where it has been for a significant period of time to an opposite state (e.g., from 1 to 0, or 0 to 1). These 256 K FRAMs were subjected to scanning acoustic microscopy (C-SAM); 1,000 temperature cycles from -65 C to +150 C; high temperature aging at 150 C, 175 C, and 200 C for 1,000 hours; highly accelerated stress test (HAST) for 500 hours; 1,000 hours of operational life test at 125 C; and total ionizing dose radiation testing. As a preconditioning, 10 K read/write cycles were performed on all devices. Interim electrical measurements were performed throughout this characterization, including special imprint testing and final electrical testing. Some failures were observed during high temperature aging test at 200 C, during HAST testing, and during 1,000 hours of operational life at 125 C. The parts passed 10 Krad exposure, but began showing power supply current increases during the dose increment from 10 Krad to 30 Krad, and at 40 Krad severe data retention and parametric failures were observed. Failures from various environmental group testing are currently being analyzed.
A major reliability issue for all advanced nonvolatile memory (NVM) technology devices including FRAMs (Ferroelectric random access memories) is the data retention characteristics over extended period of time, under environmental stresses and exposure to total ionizing dose (TID) radiation effects. For this testing, 256 Kb FRAMs in 28-pin plastic DIPS, rated for industrial grade temperature range of -40 C to +85 C, were procured. These are two-transistor, two-capacitor (2T-2C) design FRAMs. In addition to data retention characteristics, the parts were also evaluated for imprint failures, which are defined as the failure of cells to change from a "preferred" state, where it has been for a significant period of time to an opposite state (e.g., from 1 to 0, or 0 to 1). These 256 K FRAMs were subjected to scanning acoustic microscopy (C-SAM); 1,000 temperature cycles from -65 C to +150 C; high temperature aging at 150 C, 175 C, and 200 C for 1,000 hours; highly accelerated stress test (HAST) for 500 hours; 1,000 hours of operational life test at 125 C; and total ionizing dose radiation testing. As a preconditioning, 10 K read/write cycles were performed on all devices. Interim electrical measurements were performed throughout this characterization, including special imprint testing and final electrical testing. Some failures were observed during high temperature aging test at 200 C, during HAST testing, and during 1,000 hours of operational life at 125 C. The parts passed 10 Krad exposure, but began showing power supply current increases during the dose increment from 10 Krad to 30 Krad, and at 40 Krad severe data retention and parametric failures were observed. Failures from various environmental group testing are currently being analyzed.
Metallized polymer film capacitors (MPFC) manufactured by NanoLam technology have a better volumetric efficiency and performance that may exceed the reliability of conventional MPFCs typically used in power and high voltage systems that require high insulation resistance and low power losses. These capacitors can be also an effective replacement for electrolytic and stacked ceramic capacitors currently used in space applications looking to save significant volume and mass. This report evaluates the effects of environmental conditions including radiation and storage at room and high temperatures on the characteristics of NanoLam elements used in the production of MPFCs. Assessments of the reliability acceleration factors and predictions for the useful life are made based on highly accelerated life tests (HALT) using distributions of times to parametric failures at different stress conditions. It has been shown that even a relatively small amount of moisture absorbed at room environments in the dielectric layers may substantially change the probability of failure. In the presence of moisture, degradation processes that started after voltage application continue with time during storage.
The Deep Space 1 (DSl) spare flight thruster (FT2) was operated for 30,352 hours during the extended life test (ELT). The test was performed to validate the service life of the thruster, study known and identify unknown life limiting modes. Several of the known life limiting modes involve the ion optics system. These include loss of structural integrity for either the screen grid or accelerator grid due to sputter erosion from energetic ions striking the grid, sputter erosion enlargement of the accelerator grid apertures to the point where the accelerator grid power supply can no longer prevent electron backstreaming, unclearable shorting between the grids causes by flakes of sputtered material, and rouge hole formation due to flakes of material defocusing the ion beam. Grid gap decrease, which increases the probability of electron backstreaming and of arcing between the grids, was identified as an additional life limiting mechanism after the test. A combination of accelerator grid aperture enlargement and grid gap decrease resulted in the inability to prevent electron backstreaming at full power at 26,000 hours of the ELT. Through pits had eroded through the accelerator grid webbing and grooves had penetrated through 45% of the grid thickness in the center of the grid. The upstream surface of the screen grid eroded in a chamfered pattern around the holes in the central portion of the grid. Sputter deposited material, from the accelerator grid, adhered to the downstream surface of the screen grid and did not spall to form flakes. Although a small amount of sputter deposited material protruded into the screen grid apertures, no rouge holes were found after the ELT.
Batteries for use in the Defense Communications Satellite System were life tested. Charge current is assessed in terms of eclipse periods.
Development of polyimide two-stage hydraulic actuator rod seals for application in high-performance aircraft was accomplished. The significant portion of the effort was concentrated on optimization of the chevron and K-section second-stage seal geometries to satisfy the requirements for operation at 450 K (350 F) with dynamic pressure loads varying between 200 psig steady-state and 1500 psig impulse cycling. Particular significance was placed on reducing seal gland dimension by efficiently utilizing the fatigue allowables of polyimide materials. Other objectives included investigation of pressure balancing techniques for first-stage polyimide rod seals for 4000 psig 450 K(350 F) environment and fabrication of a modular retainer for the two-stage combination. Seals were fabricated in 0.0254 m (1.0in.) and 0.0635 m (2.5in.) sizes and tested for structural integrity, frictional resistance, and endurance life. Test results showed that carefully designed second stages using polyimides could be made to satisfy the dynamic return pressure requirements of applications in high-performance aircraft. High wear under full system pressure indicated that further research is necessary to obtain an acceptable first-stage design. The modular retainer was successfully tested and showed potential for new actuator applications.
High temperature barrier metallizations were assessed and tested for I(2)L and CMOS applications. Life tests were accelerated to 375 C in view of the -55 C to +300 C temperature range established for engine-located electronics without fuel cooling. The gold-refractory metallizations evaluated were Au-TiW-PtSi, Au-TiW/TiO2/TiW-PtSi and Au-TiW(N)-PtSi. These metallization systems were thermally annealed to at least 375 C for up to 250 hours. The critical requirement for stable diffusion barrier is the TiW grain size. Small grain (250A-500A) films were observed to be stable up to 375 C. Deposition to TiW diffusion barrier in the presence of oxygen and nitrogen also results in an effective diffusion barrier. Auger electron spectroscopy profiles of the PtSi indicates some penetration by the TiW. In the case of PtSi/TiW interface, the redistribution of oxygen further passivates the system by forming a TiO2 layer at the interface.
The development plans for a new separator for nickel cadmium (NiCd) cells is described. Research includes acceptance testing, operation in a charge/discharge characterization matrix, and life testing in low earth orbit (LEO) and geosynchronous (GEO) orbit under real time and accelerated conditions.
Activities performed at NASA/GSFC (Goddard Space Flight Center) related to direct detection optical communications for space applications are discussed. The following subject areas are covered: (1) requirements for optical communication systems (data rates and channel quality; spatial acquisition; fine tracking and pointing; and transmit point-ahead correction); (2) component testing and development (laser diodes performance characterization and life testing; and laser diode power combining); (3) system development and simulations (The GSFC pointing, acquisition and tracking system; hardware description; preliminary performance analysis; and high data rate transmitter/receiver systems); and (4) proposed flight demonstration of optical communications.