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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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All sourcesNASA NTRSDOE OSTI
NASA NTRS2011

Failure Modes in Capacitors When Tested Under a Time-Varying Stress

Power-on failure has been the prevalent failure mechanism for solid tantalum capacitors in decoupling applications. A surge step stress test (SSST) has been previously applied to identify the critical stress level of a capacitor batch to give some predictability to the power-on failure mechanism [1]. But SSST can also be viewed as an electrically destructive test under a time-varying stress (voltage). It consists of rapidly charging the capacitor with incremental voltage increases, through a low resistance in series, until the capacitor under test is electrically shorted. When the reliability of capacitors is evaluated, a highly accelerated life test (HALT) is usually adopted since it is a time-efficient method of determining the failure mechanism; however, a destructive test under a time-varying stress such as SSST is even more time efficient. It usually takes days or weeks to complete a HALT test, but it only takes minutes for a time-varying stress test to produce failures. The advantage of incorporating a specific time-varying stress profile into a statistical model is significant in providing an alternative life test method for quickly revealing the failure mechanism in capacitors. In this paper, a time-varying stress that mimics a typical SSST has been incorporated into the Weibull model to characterize the failure mechanism in different types of capacitors. The SSST circuit and transient conditions for correctly surge testing capacitors are discussed. Finally, the SSST was applied for testing Ta capacitors, polymer aluminum capacitors (PA capacitors), and multi-layer ceramic (MLC) capacitors with both precious metal electrodes (PME) and base metal electrodes (BME). The test results are found to be directly associated with the dielectric layer breakdown in Ta and PA capacitors and are independent of the capacitor values, the way the capacitors were built, and the capacitors manufacturers. The test results also show that MLC capacitors exhibit surge breakdown voltages much higher than the rated voltage and that the breakdown field is inversely proportional to the dielectric layer thickness. The SSST data can also be used to comparatively evaluate the voltage robustness of capacitors for decoupling applications.

Liu, David (Donhang)↗
NASA NTRS2011

Failure Modes in Capacitors When Tested Under a Time-Varying Stress

Steady step surge testing (SSST) is widely applied to screen out potential power-on failures in solid tantalum capacitors. The test simulates the power supply's on and off characteristics. Power-on failure has been the prevalent failure mechanism for solid tantalum capacitors for decoupling applications. On the other hand, the SSST can also be reviewed as an electrically destructive test under a time-varying stress. It consists of rapidly charging the capacitor with incremental voltage increases, through a low resistance in series, until the capacitor under test is electrically shorted. Highly accelerated life testing (HALT) is usually a time-efficient method for determining the failure mechanism in capacitors; however, a destructive test under a time-varying stress like SSST is even more effective. It normally takes days to complete a HALT test, but it only takes minutes for a time-varying stress test to produce failures. The advantage of incorporating specific time-varying stress into a statistical model is significant in providing an alternative life test method for quickly revealing the failure modes in capacitors. In this paper, a time-varying stress has been incorporated into the Weibull model to characterize the failure modes. The SSST circuit and transient conditions to correctly test the capacitors is discussed. Finally, the SSST was applied for testing polymer aluminum capacitors (PA capacitors), Ta capacitors, and multi-layer ceramic capacitors with both precious metal electrode (PME) and base-metal-electrodes (BME). It appears that testing results are directly associated to the dielectric layer breakdown in PA and Ta capacitors and are independent on the capacitor values, the way the capacitors being built, and the manufactures. The testing results also reveal that ceramic capacitors exhibit breakdown voltages more than 20 times the rated voltage, and the breakdown voltages are inverse proportional to the dielectric layer thickness. The possibility of ceramic capacitors in front-end decoupling applications to block the surge noise from a power supply is also discussed.

Liu, David (Donhang)↗
NASA NTRS1992

Profiling System

A non-destructive testing system, originally developed for Langley Research Center, is sold commercially. The DyLASP Profilometer locates defects in composite and metallic materials and assemblies. It operates in real time and displays results as a contour map of the assembly with defects indicated by size and location. Applications are in non-destructive testing and evaluation, and the company will customize to user requirements.

Source record↗
DOE OSTI2024

SSTDR and FDR Detection of Un-Energized and Energized Cable Anomalies Including Thermal Degradation Using Machine Learning

Historically, cables are initially qualified for nuclear power plant use for 40 years. As plants extend their operating license to 60 and 80 years, continued use of these cables must shift to a performance-based approach since it is cost prohibitive to completely replace cables that are likely still capable of performing their design function. A variety of cable tests are available and are commonly applied during outages when the cables can be taken out of service. Frequency domain reflectometry (FDR) is one of these test methods that is being more broadly accepted and used because it not only detects anomalies along the cable with a low-voltage signal that does not stress the cable insulation, but the technique also locates the anomalies. This supports follow-up local inspection and local repair or partial replacement of a damaged cable segment. Currently, FDR testing is only applied to cables that are taken out of service since the test instrument would be damaged by operational voltages. A related technology that has found some acceptance in the aircraft and rail industry is spread spectrum time domain reflectometry (SSTDR). This technology has been implemented with a custom commercial instrument by LiveWire Innovation that is designed to operate on live cables up to 1000 volts and with a bandwidth of 48 MHz. Initial evaluation by the Pacific Northwest National Laboratory (PNNL) of the Live Wire system indicated that a broader bandwidth (BW) SSTDR may be better for many kinds of flaws. This led PNNL to develop an SSTDR laboratory instrument suitable for tests up to 500 MHz bandwidth. Testing on energized cables is also desirable for online monitoring systems so an inductive clamshell coupler was developed that allows energized cables to be tested up to at least 5 kV and likely higher voltage levels. Dielectric spectroscopy and tan delta testing plus various laboratory destructive tests were included in this data acquisition campaign directed to feed a machine learning (ML) study. With these kinds of developments, online energized cable tests may be possible with industrial adoption of such hardware advances but it will be completely impractical to have highly skilled data analysts continually examine these complex signals for indications of damage or compromised conditions. If online testing is to be implemented in new test hardware, it must be accompanied by software that can interpret the signals and alert plant operators of changing or degraded conditions. The thermally aged, shielded cable investigated here was separately treated for ML analysis. Visual analysis of electrical data showed generally increasing peaks where the cable entered and exited the oven. These peaks were not exactly aligned with expected locations, but these differences were attributed to velocity of propagation calibration errors. Only supervised ML was applied to the thermally aged data as this data was only available shortly before the committed publication date of this report. The supervised ML was structured to divide the 0 to 70-day responses as ‘normal’ from 0 to 35 days or ‘anomalous’ from 36 to 70 days, based on cable tensile elongation at break (EAB) insulation characterization. Using 80% of the data for training and 20% for testing, the supervised ML predicted normal versus anomalous was 70% accurate. Important conclusions include: • Accuracy to predict the presence of cable damage is improved from the 2023 effort by more training data. Weighted accuracies for comparisons among the instruments ranged from 67 to 89 % for unsupervised ML and 71 to 99% for supervised ML. • Based on the synthetic data tests, the unsupervised models are more generalizable to unseen anomalies. The Multi-Layer Perceptron classifier (MLP) model reported as high as 99.7% accuracy on the test data, but this dropped to 58.3% when tested on the synthetic data. In contrast, the unsupervised Pointwise model only achieved 89.7% accuracy on the experimental data but reported 78.3% accuracy on the synthetic data. • The best anomaly indicators are higher frequency (400 MHz BW) FDR data. Other tests may be interesting but for this study, this was the best predicter.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2023

Comparison of Elastic Moduli of LPBF 316H Material Using RUS Measurements and Destructive Mechanical Testing

Preliminary results are presented on performing Resonance Ultrasound Spectroscopy (RUS) measurements on stainless steel 316 H fabricated using Laser Powder Bed Fusion (LPBF) additive manufacturing methods. The elastic constants determined using RUS measurements are compared to tensile tests and RUS measurements on wrought stainless steel 316 L. Good agreement is found between the RUS measurements and the mechanical testing results.

36 MATERIALS SCIENCE↗
NASA NTRS2009

Vibro-Acoustic Analysis of NASA's Space Shuttle Launch Pad 39A Flame Trench Wall

A vital element to NASA's manned space flight launch operations is the Kennedy Space Center Launch Complex 39's launch pads A and B. Originally designed and constructed In the 1960s for the Saturn V rockets used for the Apollo missions, these pads were modified above grade to support Space Shuttle missions. But below grade, each of the pad's original walls (including a 42 feet deep, 58 feet wide, and 450 feet long tunnel designed to deflect flames and exhaust gases, the flame trench) remained unchanged. On May 31, 2008 during the launch of STS-124, over 3500 of the. 22000 interlocking refractory bricks that lined east wall of the flame trench, protecting the pad structure were liberated from pad 39A. The STS-124 launch anomaly spawned an agency-wide initiative to determine the failure root cause, to assess the impact of debris on vehicle and ground support equipment safety, and to prescribe corrective action. The investigation encompassed radar imaging, infrared video review, debris transport mechanism analysis using computational fluid dynamics, destructive testing, and non-destructive evaluation, including vibroacoustic analysis, in order to validate the corrective action. The primary focus of this paper is on the analytic approach, including static, modal, and vibro-acoustic analysis, required to certify the corrective action, and ensure Integrity and operational reliability for future launches. Due to the absence of instrumentation (including pressure transducers, acoustic pressure sensors, and accelerometers) in the flame trench, defining an accurate acoustic signature of the launch environment during shuttle main engine/solid rocket booster Ignition and vehicle ascent posed a significant challenge. Details of the analysis, including the derivation of launch environments, the finite element approach taken, and analysistest/ launch data correlation are discussed. Data obtained from the recent launch of STS-126 from Pad 39A was instrumental in validating the design analysis philosophies outlined in this paper.

Margasahayam, Ravi N.↗
DOE OSTI2025

Automated Non-Destructive Mechanical Testing of Fine Pitch Wirebond Arrays

This is the required paper summarizing the poster presentation material to be presented at The 25th European Microelectronics & Packaging Conference (EMPC 2025) (16 – 18 September 2025). The paper will be associated with the conference presentation in the conference proceedings

Menk, Lyle Alexander [Sandia National Laboratories↗
NASA NTRS1974

Dissimilar metals joint evaluation

Dissimilar metals tubular joints between 2219-T851 aluminum alloy and 304L stainless steel were fabricated and tested to evaluate bonding processes. Joints were fabricated by four processes: (1) inertia (friction) weldings, where the metals are spun and forced together to create the weld; (2) explosive welding, where the metals are impacted together at high velocity; (3) co-extrusion, where the metals are extruded in contact at high temperature to promote diffusion; and (4) swaging, where residual stresses in the metals after a stretching operation maintain forced contact in mutual shear areas. Fifteen joints of each type were prepared and evaluated in a 6.35 cm (2.50 in.) O.D. size, with 0.32 cm (0.13 in.) wall thickness, and 7.6 cm (3.0 in) total length. The joints were tested to evaluate their ability to withstand pressure cycle, thermal cycle, galvanic corrosion and burst tests. Leakage tests and other non-destructive test techniques were used to evaluate the behavior of the joints, and the microstructure of the bond areas was analyzed.

Wakefield, M. E.↗
NASA NTRS1982

Recognizing defects in carbon-fiber reinforced plastics

The damage tolerance of structures made of carbon-fiber-reinforced plastic is tested under various loads. Test laminate (73/1/1, 24/9/1, 1465 A) specimens of thickness 1.5-3.2 mm with various defects were subjected to static and dynamic loads. Special attention was given to delamination, and ultrasonic C-scans were made on the specimens. It was shown that cracks from even small defects are detected with great accuracy. The same probes were also X rayed; defects that could not be detected under ordinary X rays were bored and studied under vacuum by a contrast technique. The nondestructive ultrasonic and X ray tests were controlled by partially destructive tests, and good agreement was observed.

Schuetze, R.↗
DOE OSTI2023

AGC-2 Specimen Post Irradiation Data Package Report

This report documents results of the post-irradiation examination material property testing of the creep, control, and piggyback specimens from the irradiation creep capsule Advanced Graphite Creep (AGC)-2 are reported. This is the second of a series of six irradiation test trains planned as part of the AGC experiment to fully characterize the neutron irradiation effects and radiation creep behavior of current nuclear graphite grades. The AGC-2 capsule was irradiated in the Idaho National Laboratory Advanced Test Reactor at a nominal temperature of 600°C and to a peak dose of 5 dpa (displacements per atom). One half of the creep specimens were subjected to mechanical stresses (an applied stress of either 13.8, 17.2, or 20.7 MPa) to induce irradiation creep. All post-irradiation testing and measurement results are reported with the exception of the irradiation mechanical strength testing, which is the last destructive testing stage of the irradiation testing program. Material property tests were conducted on specimens from 15 nuclear graphite grades using a similar loading configuration as the first AGC capsule (AGC-1) to provide easy comparison between the two capsules. However, AGC-2 contained an increased number of specimens (i.e., 487 total specimens irradiated) and replaced specimens of the minor grade 2020 with the newer grade 2114. The data reported include specimen dimensions for both stressed and unstressed specimens to establish the irradiation creep rates, mass and volume data necessary to derive density, elastic constants (Young’s modulus, shear modulus, and Poisson’s ratio) from ultrasonic time of flight velocity measurements, Young’s modulus from the fundamental frequency of vibration, electrical resistivity, and thermal diffusivity and thermal expansion data from 100–500°C. No data outliers were determined after all measurements were completed. A brief statistical analysis was performed on the irradiated data and a limited comparison between pre- and post-irradiation properties is presented. A more complete evaluation of trends in the material property changes, as well as irradiation-induced creep due to irradiation, temperature, and applied load on specimens will be discussed in later AGC-2 post-irradiation examination analysis reports.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
NASA NTRS1983

Hermetic edge sealing of photovoltaic modules

The edge sealing technique is accomplished by a combination of a chemical bond between glass and aluminum, formed by electrostatic bonding, and a metallurgical bond between aluminum and aluminum, formed by ultrasonic welding. Such a glass to metal seal promises to provide a low cost, long lifetime, highly effective hermetic seal which can protect module components from severe environments. Development of the sealing techniques and demonstration of their effectiveness by fabricating a small number of dummy modules, up to eight inches square in size, and testing them for hermeticity using helium leak testing methods are reviewed. Non-destructive test methods are investigated.

Source record↗
NASA NTRS2013

Commercial Parts Technology Qualification Processes

Many high-reliability systems, including space systems, use selected commercial parts (including Plastic Encapsulated Microelectronics or PEMs) for unique functionality, small size, low weight, high mechanical shock resistance, and other factors. Predominantly this usage is subjected to certain 100% tests (typically called screens) and certain destructive tests usually (but not always) performed on the flight lot (typically called qualification tests). Frequently used approaches include those documented in EEE-INST-002 and JPL DocID62212 (which are sometimes modified by the particular aerospace space systems manufacturer). In this study, approaches from these documents and several space systems manufacturers are compared to approaches from a launch systems manufacturer (SpaceX), an implantable medical electronics manufacturer (Medtronics), and a high-reliability transport system process (automotive systems). In the conclusions section, these processes are outlined for all of these cases and presented in tabular form. Then some simple comparisons are made. In this introduction section, the PEM technology qualification process is described, as documented in EEE-INST-002 (written by the Goddard Space Flight Center, GSFC), as well as the somewhat modified approach employed at the Jet Propulsion Laboratory (JPL). Approaches used at several major NASA contractors are also described

Cooper, Mark S.↗
NASA NTRS2004

Research Performed within the Non-Destructive Evaluation Team at NASA Glenn Research Center

Non-destructive testing is essential in many fields of manufacturing and research in order to perform reliable examination of potentially damaged materials and parts without destroying the inherent structure of the materials. Thus, the Non-Destructive Evaluation (NDE) Team at NASA Glenn Research Center partakes in various projects to improve materials testing equipment as well as analyze materials, material defects, and material deficiencies. Due to the array of projects within the NDE Team at this time, five research aims were supplemental to some current projects. A literature survey of "DE and testing methodologies as related to rocks was performed. Also, Mars Expedition Rover technology was assessed to understand the requirements for instrumentation in harsh space environments (e.g. temperature). Potential instrumentation and technologies were also considered and documented. The literature survey provided background and potential sources for a proposal to acquire funding for ultrasonic instrumentation on board a future Mars expedition. The laboratory uses a Santec Systems AcousticScope AS200 acoustography system. Labview code was written within the current program in order to improve the current performance of the acoustography system. A sample of Reinforced Carbon/Carbon (RCC) material from the leading edge of the space shuttle underwent various non-destructive tests (guided wave scanning, thermography, computed tomography, real time x-ray, etc.) in order to characterize its structure and examine possible defects. Guided wave scan data of a ceramic matrix composite (CMC) panel was reanalyzed utilizing image correlations and signal processing variables. Additional guided wave scans and thermography were also performed on the CMC panel. These reevaluated data and images will be used in future presentations and publications. An additional axis for the guided wave scanner was designed, constructed, and implemented. This additional axis allowed incremental spacing of the previously fixed transducers for ultrasonic velocity measurements.

Burns, Erin A.↗
NASA NTRS2007

Nondestructive Methods and Special Test Instrumentation Supporting NASA Composite Overwrapped Pressure Vessel Assessments

Many aging composite overwrapped pressure vessels (COPVs), being used by the National Aeronautics and Space Administration (NASA) are currently under evaluation to better quantify their reliability and clarify their likelihood of failure due to stress rupture and age-dependent issues. As a result, some test and analysis programs have been successfully accomplished and other related programs are still in progress at the NASA Johnson Space Center (JSC) White Sands Test Facility (WSTF) and other NASA centers, with assistance from the commercial sector. To support this effort, a group of Nondestructive Evaluation (NDE) experts was assembled to provide NDE competence for pretest evaluation of test articles and for application of NDE technology to real-time testing. Techniques were required to provide assurance that the test article had adequate structural integrity and manufacturing consistency to be considered acceptable for testing and these techniques were successfully applied. Destructive testing is also being accomplished to better understand the physical and chemical property changes associated with progression toward "stress rupture" (SR) failure, and it is being associated with NDE response, so it can potentially be used to help with life prediction. Destructive work also includes the evaluation of residual stresses during dissection of the overwrap, laboratory evaluation of specimens extracted from the overwrap to evaluate physical property changes, and quantitative microscopy to inform the theoretical micromechanics.

Saulsberry, Regor↗
DOE OSTI2025

Destructive PIE and Safety Testing of Six AGR-5/6/7 Capsule 2 Compacts

This study evaluates fission product retention and particle failure mechanisms in AGR-5/6/7 Capsule 2 uranium carbide and uranium oxide (UCO) tristructural isotropic (TRISO) fuel under high-temperature gas reactor accident-relevant conditions using high-temperature safety tests and destructive postirradiation examination. Three Capsule 2 compacts were held isothermally at 1600°C for approximately 300 hours and one compact at 1800°C for approximately 300 hours; two additional compacts were examined in the as-irradiated state. Post-test deconsolidation–leach–burn–leach (DLBL) quantified nuclide inventories in matrix and particles. Individual particles were surveyed for radioisotope inventories, and microanalytical approaches resolved microstructural evolution and fission product distributions within the coating layers. At 1600°C, no krypton was detected above the minimum detectable limit, and cesium releases were far below a single particle equivalent, indicating the absence of full TRISO failure or SiC failures. Silver releases were limited and primarily reflected depleted postirradiation inventories, consistent with prior compact-level exams indicating substantial in-pile 110mAg loss. At 1800°C, cumulative 134Cs release of approximately 2.5 particle equivalents and delayed 85Kr totaling approximately 0.53 particle equivalents were consistent with one full TRISO failure and two SiC failures. Europium and strontium releases were roughly one order of magnitude higher than at 1600°C and comparable to AGR-1/AGR-2 high-temperature tests, with sustained late-hold rates indicating diffusion through intact coatings coupled with matrix depletion. Overall, AGR-5/6/7 Capsule 2 UCO fuel demonstrated fission product retention during safety testing consistent with prior AGR campaigns, while distinctive in-pile 110mAg depletion and measurable 1600°C europium loss motivate targeted follow-on studies.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2025

Destructive PIE and Safety Testing of Six AGR-5/6/7 Capsule 2 Compacts

This study evaluates fission product retention and particle failure mechanisms in AGR-5/6/7 Capsule 2 uranium carbide and uranium oxide (UCO) tristructural isotropic (TRISO) fuel under high-temperature gas reactor accident-relevant conditions using high-temperature safety tests and destructive post-irradiation examination. Three Capsule 2 compacts were held isothermally at 1600°C for approximately 300 hours and one compact at 1800°C for approximately 300 hours; two additional compacts were examined in the as-irradiated state. Post-test deconsolidation–leach–burn–leach (DLBL) quantified nuclide inventories in matrix and particles. Individual particles were surveyed for radioisotope inventories, and microanalytical approaches resolved microstructural evolution and fission product distributions within the coating layers. At 1600°C, no krypton was detected above the minimum detectable limit, and cesium releases were far below a single particle equivalent, indicating the absence of full TRISO failure or SiC failures. Silver releases were limited and primarily reflected depleted post-irradiation inventories, consistent with prior compact-level exams indicating substantial in-pile 110m Ag loss. At 1800°C, cumulative 134 Cs release of approximately 2.5 particle equivalents and delayed 85 Kr totaling approximately 0.53 particle equivalents were consistent with one full TRISO failure and two SiC failures. Europium and strontium releases were roughly one order of magnitude higher than at 1600°C and comparable to AGR-1/AGR-2 high-temperature tests, with sustained late-hold rates indicating diffusion through intact coatings coupled with matrix depletion. Overall, AGR-5/6/7 Capsule 2 UCO fuel demonstrated fission product retention during safety testing consistent with prior AGR campaigns, while distinctive in-pile 110m Ag depletion and measurable 1600°C europium loss motivate targeted follow-on studies.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2025

Small scale electron linear accelerators for industrial applications

Linear accelerators (linacs), producing electron or X-ray radiation in the MeV range, are critical tools for industrial irradiation, medical device sterilization, food pasteurization, non-destructive testing, security, medical, and many other applications. Many of these applications require compact and flexible radiation sources. In this paper, we present new technologies for small-scale electron linear accelerators and examples of their practical implementations. Furthermore, these developments include low energy accelerators with self-shielding options and form factors, ranging from cabinet-size to hand-portable generators; medium-energy accelerators for novel radiotherapy and security applications; and high-energy 10 MeV linacs capable of reaching 20–35 kW beam power for emerging industrial and phytosanitary applications

43 PARTICLE ACCELERATORS↗