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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 523 records · Page 29
All sourcesNASA NTRSDOE OSTI
NASA NTRS2008

Failures in Hybrid Microcircuits During Environmental Testing. History Cases

This purpose of this viewgraph presentation is to discuss failures in hermetic hybrids observed at the GSFC PA Lab during environmental stress testing. The cases discussed are: Case I. Substrate metallization failures during Thermal cycling (TC). Case II. Flex lid-induced failure. Case Ill. Hermeticity failures during TC. Case IV. Die metallization cracking during TC. and how many test cycles and parts is necessary? Case V. Wire Bond failures after life test. Case VI. Failures caused by Au/In IMC growth.

Teverovsky, Alexander↗
NASA NTRS2014

Evaluation of Polymer Hermetically Sealed Tantalum Capacitors

Polymer cathode tantalum capacitors have lower ESR (equivalent series resistance) compared to other types of tantalum capacitors and for this reason have gained popularity in the electronics design community. Their use allows improved performance of power supply systems along with substantial reduction of size and weight of the components used. However, these parts have poor thermal stability and can degrade in humid environments. Polymer hermetically sealed (PHS) capacitors avoid problems related to environmental degradation of molded case parts and can potentially replace current wet and solid hermetically sealed capacitors. In this work, PHS capacitors manufactured per DLA LAM DWG#13030 are evaluated for space applications. Several lots of capacitors manufactured over period from 2010 to 2014 were tested for the consistency of performance, electrical and thermal characteristics, highly accelerated life testing, and robustness under reverse bias and random vibration conditions. Special attention was given to analysis of leakage currents and the effect of long-term high temperature storage on capacitors in as is condition and after hermeticity loss. The results show that PHS capacitors might be especially effective for low-temperature applications or for system requiring a cold start-up. Additional screening and qualification testing have been recommended to assure the necessary quality of capacitors for space projects.

ferrite beads↗
NASA NTRSDate not supplied

Summary of NASA Progress on the Development and Qualification of a 12-kW Hall-Effect, Solar Electric Propulsion Thruster

Beginning in 2014, the National Aeronautics and Space Administration (NASA) Space Technology Mission Directorate (STMD) began a project to increase the state of the art for the Hall-Effect Solar Electric Propulsion (SEP) technology. The Technology Demonstration Missions (TDM) Program Office provides programmatic oversight of SEP with the project being led by Glenn Research Center, supported by the Jet Propulsion Laboratory and development, qualification & flight hardware all provided by Aerojet Rocketdyne (AR). This technology was pursued as the propulsion system for the Asteroid Redirect and Robotic Mission (ARRM). While the concept was originally slated for ARRM, it was realigned to Gateway to support future Moon to Mars objectives. The Gateway lunar station was established and will play a key role in NASA’s Artemis Program which utilizes collaboration with the Canadian Space Agency (CSA), the European Space Agency (ESA) and the Japanese Space Agency (JAXA). The 12-kW hardware will be the primary propulsion for the Gateway element, Power & Propulsion Element (PPE), from Low Earth Orbit to a Near Rectilinear Halo Orbit around the Moon. Initial efforts began with utilizing Technology Development Units (TDU) built by NASA as the predecessor to the contract activity with AR. Over the past few years, AR has built Engineering Test Units (ETU), Engineering Development Units (EDU) and qualification & flight models (QM and FM, respectively). With requirement changes from the AARM mission to PPE, the joint team has modified the design and has started qualification activities for environment testing (shock, vibe) at multiple facilities in the US leading to eventual life testing. This paper will explore the various design changes, system modeling and the latest status for qualification testing.

Joel Robinson↗
NASA NTRSDate not supplied

Summary of NASA Progress on the Development and Qualification of a 12 kW Hall Effect, Solar Electric Propulsion Thruster

Beginning in 2014, the National Aeronautics and Space Administration (NASA) Space Technology Mission Directorate (STMD) began a project to increase the state of the art for the Hall-Effect Solar Electric Propulsion (SEP) technology. The Technology Demonstration Missions (TDM) Program Office provides programmatic oversight of SEP with the project being led by Glenn Research Center, supported by the Jet Propulsion Laboratory and development, qualification & flight hardware all provided by Aerojet Rocketdyne (AR). This technology was pursued as the propulsion system for the Asteroid Redirect and Robotic Mission (ARRM). While the concept was originally slated for ARRM, it was realigned to Gateway to support future Moon to Mars objectives. The Gateway lunar station was established and will play a key role in NASA’s Artemis Program which utilizes collaboration with the Canadian Space Agency (CSA), the European Space Agency (ESA) and the Japanese Space Agency (JAXA). The 12-kW hardware will be the primary propulsion for the Gateway element, Power & Propulsion Element (PPE), from Low Earth Orbit to a Near Rectilinear Halo Orbit around the Moon. Initial efforts began with utilizing Technology Development Units (TDU) built by NASA as the predecessor to the contract activity with AR. Over the past few years, AR has built Engineering Test Units (ETU), Engineering Development Units (EDU) and qualification & flight models (QM and FM, respectively). With requirement changes from the AARM mission to PPE, the joint team has modified the design and has started qualification activities for environment testing (shock, vibe) at multiple facilities in the US leading to eventual life testing. This paper will explore the various design changes, system modeling and the latest status for qualification testing.

Joel W Robinson↗
NASA NTRS1977

Methodology for designing accelerated aging tests for predicting life of photovoltaic arrays

A methodology for designing aging tests in which life prediction was paramount was developed. The methodology builds upon experience with regard to aging behavior in those material classes which are expected to be utilized as encapsulant elements, viz., glasses and polymers, and upon experience with the design of aging tests. The experiences were reviewed, and results are discussed in detail.

Gaines, G. B.↗
NASA NTRS1988

Thermal barrier coating life prediction model development

This report describes work performed to determine the predominat modes of degradation of a plasma sprayed thermal barrier coating system and to develop and verify life prediction models accounting for these degradation modes. The primary TBC system consisted of a low pressure plasma sprayed NiCrAlY bond coat, an air plasma sprayed ZrO2-Y2O3 top coat, and a Rene' 80 substrate. The work was divided into 3 technical tasks. The primary failure mode to be addressed was loss of the zirconia layer through spalling. Experiments showed that oxidation of the bond coat is a significant contributor to coating failure. It was evident from the test results that the species of oxide scale initially formed on the bond coat plays a role in coating degradation and failure. It was also shown that elevated temperature creep of the bond coat plays a role in coating failure. An empirical model was developed for predicting the test life of specimens with selected coating, specimen, and test condition variations. In the second task, a coating life prediction model was developed based on the data from Task 1 experiments, results from thermomechanical experiments performed as part of Task 2, and finite element analyses of the TBC system during thermal cycles. The third and final task attempted to verify the validity of the model developed in Task 2. This was done by using the model to predict the test lives of several coating variations and specimen geometries, then comparing these predicted lives to experimentally determined test lives. It was found that the model correctly predicts trends, but that additional refinement is needed to accurately predict coating life.

Hillery, R. V.↗
NASA NTRS1995

Progress towards computer simulation of NiH2 battery performance over life

The long-term performance of rechargeable battery cells has traditionally been verified through life-testing, a procedure that generally requires significant commitments of funding and test resources. In the situation of nickel hydrogen battery cells, which have the capability of providing extremely long cycle life, the time and cost required to conduct even accelerated testing has become a serious impediment to transitioning technology improvements into spacecraft applications. The utilization of computer simulations to indicate the changes in performance to be expected in response to design or operating changes in nickel hydrogen cells is therefore a particularly attractive tool in advanced battery development, as well as for verifying performance in different applications. Computer-based simulations of the long-term performance of rechargeable battery cells have typically had very limited success in the past. There are a number of reasons for the lack in progress in this area. First, and probably most important, all battery cells are relatively complex electrochemical systems, in which performance is dictated by a large number of interacting physical and chemical processes. While the complexity alone is a significant part of the problem, in many instances the fundamental chemical and physical processes underlying long-term degradation and its effects on performance have not even been understood. Second, while specific chemical and physical changes within cell components have been associated with degradation, there has been no generalized simulation architecture that enables the chemical and physical structure (and changes therein) to be translated into cell performance. For the nickel hydrogen battery cell, our knowledge of the underlying reactions that control the performance of this cell has progressed to where it clearly is possible to model them. The recent development of a relative generalized cell modelling approach provides the framework for translating the chemical and physical structure of the components inside a cell into its performance characteristics over its entire cycle life. This report describes our approach to this task in terms of defining those processes deemed critical in controlling performance over life, and the model architecture required to translate the fundamental cell processes into performance profiles.

Zimmerman, Albert H.↗
NASA NTRS1972

Development, integration, and testing of a 30 cm thruster/power conditioning and control system.

The 30 cm thruster/power conditioning and control system discussed represents a significant milestone in the evolution of prime ion propulsion systems. The effort described covers three distinct electronic hardware implementation, integration and testing phases; development of a flight-type power conditioner for laboratory testing, development of a thruster control system to control the power conditioning for demonstrating continuously variable automatic thruster throttling from a single control over a range in excess of 5:1, and finally development of an automated endurance test system incorporating many of the above designs for a 6000 hour thruster life test.

Herron, B. G.↗
NASA NTRS1978

Advanced very high resolution radiometer

The program covered the design, construction, and test of a Breadboard Model, Engineering Model, Protoflight Model, Mechanical/Structural Model, and a Life Test Model. Special bench test and calibration equipment was also developed for use on the program. Initially, the instrument was to operate from a 906 n.mi. orbit and be thermally isolated from the spacecraft. The Breadboard Model and the Mechanical/Structural Model were designed and built to these requirements. The spacecraft altitude was changed to 450 n.mi., IFOVs and spectral characteristics were modified, and spacecraft interfaces were changed. The final spacecraft design provided a temperature-controlled Instrument Mounting Platform (IMP) to carry the AVHRR and other instruments. The design of the AVHRR was modified to these new requirements and the modifications were incorporated in the Engineering Model. The Protoflight Model and the Flight Models conform to this design.

Source record↗
NASA NTRS1979

AVHRR/1-FM Advanced Very High Resolution Radiometer

The advanced very high resolution radiometer is discussed. The program covers design, construction, and test of a breadboard model, engineering model, protoflight model, mechanical/structural model, and a life test model. Special bench test and calibration equipment was developed for use on the program. The flight model program objectives were to fabricate, assemble and test four of the advanced very high resolution radiometers along with a bench cooler and collimator.

Source record↗
NASA NTRS1990

Characterization testing of a 40 ampere hour bipolar nickel-hydrogen battery

Extensive characterization testing has been done on a second 40-ampere hour (A h), 10-cell, bipolar nickel-hydrogen (Ni-H2) battery, to study the effects of operating parameters such as charge and discharge rates, temperature, and pressure on capacity, A h and watt hour (W h) efficiencies, and end-of-charge and midpoint discharge voltages. Testing to date has produced many interesting results, with the battery performing well throughout the test matrix except during the high-rate (5 C and 10 C) discharges, where poorer than expected results were observed. The exact cause of this poor performance is, as yet, unknown. Small scale 2 in. x 2 in. battery tests are to be used in studying this problem. Low earth orbit cycle life testing at a 40-percent depth of discharge and 10 C is scheduled to follow the characterization testing.

Brewer, Jeffrey C.↗
NASA NTRS1989

Hubble Space Telescope six-battery nickel-cadmium mission simulation test

A simulation test of the six-battery nickel-cadmium mission to determine battery life and electrical power system (EPS) performance characteristics for the Hubble Space Telescope (HST) program, is described. The basic HST power system requirements are to provide power generation, energy storage, and EPS control and distribution for 2.5 years with the nickel-cadmium (NiCd) batteries at an end of life solar array of 2 years. Mission simulation life testing begain in April of 1986, and the batteries have completed their 2.5 year mission requirement. Conditions as close as practical to the actual predicted mission profiles were used. These included solar array degradation, load variations, beta angle changes, temperature changes (with excursions to 10 C), battery reconditioning, safemode simulations, and off-normal roll activities. Discounting system cycling interruptions caused by hardware, software, human error, and periodic updates and revisions, the HST EPS breadboard hardware operated continuously for 30 months and demonstrated the power system's ability to meet the HST requirement.

Jackson, Lorna G.↗
NASA NTRS1990

Manufacture and evaluation of Li/BCX DD cells

This project is divided into four main tasks: cell manufacture, acceptance, and lot certification of cells, performance testing of cells, and abuse testing of cells. Lithium/bromine chloride in thionyl chloride (Li/BCX) 149 DD cells (PN 3B2085-XA) were built according to the provisions of Electrochem Industries Quality Plan 17096. Acceptance and lot certification testing was performed according to NASA JSC Document EP5-83-025, Revision B. Acceptance testing included open circuit and load voltage check, visual examination, size and weight measurements, and high temperature exposure. Lot certification tests were performed for capacity performance and for performance under conditions of thermal and electrical abuse. These tests included 149 C exposure, capacity discharge, fuse check, high temperature exposure, high rate discharge, short circuit, vibration, and overdischarge testing. A quantity of 200 cells was delivered to Johnson Space Center for life test evaluation. A parametric evaluation of the capacity discharge of Li/BCX DD cells was performed over a variety of temperatures and discharge rates. This testing served to map the performance capability of the cell. Tests were also performed over a variety of electrical and thermal abuse conditions. Abuse tests included short circuit, charging, overdischarge, high temperature exposure, shock, and vibration.

Meyer, S.↗
NASA NTRS1993

Plasma contactor technology for Space Station Freedom

Hollow cathode plasma contactors were baselined for Space Station Freedom (SSF) to control the electrical potentials of surfaces to eliminate/mitigate damaging interactions with the space environment. The system represents a dual-use technology which is a direct outgrowth of the NASA electric propulsion program and in particular the technology development effort on ion thruster systems. Specific efforts include optimizing the design and configuration of the contactor, validating its required lifetime, and characterizing the contactor plume and electromagnetic interference. The plasma contact or subsystems include the plasma contact or unit, a power electronics unit, and an expellant management unit. Under this program these will all be brought to breadboard and engineering model development status. New test facilities were developed, and existing facilities were augmented, to support characterizations and life testing of contactor components and systems. The magnitude, scope, and status of the plasma contactor hardware development program now underway and preliminary test results on system components are discussed.

Patterson, Michael J.↗
NASA NTRS2003

Increased Surface Fatigue Lives of Spur Gears by Application of a Coating

Hard coatings have potential for increasing gear surface fatigue lives. Experiments were conducted using gears both with and without a metal-containing, carbonbased coating. The gears were case-carburized AISI 9310 steel spur gears. Some gears were provided with the coating by magnetron sputtering. Lives were evaluated by accelerated life tests. For uncoated gears, all of fifteen tests resulted in fatigue failure before completing 275 million revolutions. For coated gears, eleven of the fourteen tests were suspended with no fatigue failure after 275 million revolutions. The improved life owing to the coating, approximately a six-fold increase, was a statistically significant result.

Krantz, Timothy L.↗
NASA NTRS2012

NASA Advanced Life Support Technology Testing and Development

Prior to 2010, NASA's advanced life support research and development was carried out primarily under the Exploration Life Support Project of NASA's Exploration Systems Mission Directorate. In 2011, the Exploration Life Support Project was merged with other projects covering Fire Prevention/Suppression, Radiation Protection, Advanced Environmental Monitoring and Control, and Thermal Control Systems. This consolidated project was called Life Support and Habitation Systems, which was managed under the Exploration Systems Mission Directorate. In 2012, NASA re-organized major directorates within the agency, which eliminated the Exploration Systems Mission Directorate and created the Office of the Chief Technologist (OCT). Life support research and development is currently conducted within the Office of the Chief Technologist, under the Next Generation Life Support Project, and within the Human Exploration Operation Missions Directorate under several Advanced Exploration System projects. These Advanced Exploration Systems projects include various themes of life support technology testing, including atmospheric management, water management, logistics and waste management, and habitation systems. Food crop testing is currently conducted as part of the Deep Space Habitation (DSH) project within the Advanced Exploration Systems Program. This testing is focused on growing salad crops that could supplement the crew's diet during near term missions.

Wheeler, Raymond M.↗
NASA NTRS2001

Bioregenerative Life Support Systems Test Complex (Bio-Plex) Food Processing System: A Dual System

A Bioregenerative Life Support Test Complex, BIO-Plex, is currently being constructed at the Johnson Space Center (JSC) in Houston, TX. This facility will attempt to answer the questions involved in developing a lunar or planetary base. The Food Processing System (FPS) of the BIO-Plex is responsible for supplying food to the crew in coordination with the chosen mission scenario. Long duration space missions require development of both a Transit Food System and of a Lunar or Planetary Food System. These two systems are intrinsically different since the first one will be utilized in the transit vehicle in microgravity conditions with mostly resupplied foods, while the second will be used in conditions of partial gravity (hypogravity) to process foods from crops grown in the facility. The Transit Food System will consist of prepackaged food of extended shelf life. It will be supplemented with salad crops that will be consumed fresh. Microgravity imposes significant limitation on the ability to handle food and allows only for minimal processing. The challenge is to develop food systems similar to the International Space Station or Shuttle Food Systems but with a shelf life of 3 - 5 years. The Lunar or Planetary Food System will allow for food processing of crops due to the presence of some gravitational force (1/6 to 1/3 that of Earth). Crops such as wheat, soybean, rice, potato, peanut, and salad crops, will be processed to final products to provide a nutritious and acceptable diet for the crew. Not only are constraints imposed on the FPS from the crops (e.g., crop variation, availability, storage and shelf-life) but also significant requirements are present for the crew meals (e.g., RDA, high quality, safety, variety). The FPS becomes a fulcrum creating the right connection from crops to crew meals while dealing with issues of integration within a closed self-regenerative system (e.g., safe processing, waste production, volumes, air contaminations, water usage, etc.). Options for the first test, for duration of 120 days, currently scheduled for late 2003 are outlined.

Perchonok, Michele↗