Development of life-test methodology for long-life mechanical components. Phase 1: Development of methodology
Explore the source record for details and available documents.
Hamilton, D. B.↗
SEARCH · Search NASA
Results for “life testing”
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.
Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.
Accelerated life testing of spacecraft subsystems
The rationale and requirements for conducting accelerated life tests on electronic subsystems of spacecraft are presented. A method for applying data on the reliability and temperature sensitivity of the parts contained in a sybsystem to the selection of accelerated life test parameters is described. Additional considerations affecting the formulation of test requirements are identified, and practical limitations of accelerated aging are described.
Wiksten, D.↗
Intermediate Temperature Fluids Life Tests - Experiments
There are a number of different applications that could use heat pipes or loop heat pipes (LHPs) in the intermediate temperature range of 450 to 725 K (170 to 450 C), including space nuclear power system radiators, fuel cells, and high temperature electronics cooling. Historically, water has been used in heat pipes at temperatures up to about 425 K (150 C). Recent life tests, updated below, demonstrate that titanium/water and Monel/water heat pipes can be used at temperatures up to 550 K (277 C), due to water's favorable transport properties. At temperatures above roughly 570 K (300 C), water is no longer a suitable fluid, due to high vapor pressure and low surface tension as the critical point is approached. At higher temperatures, another working fluid/envelope combination is required, either an organic or halide working fluid. An electromotive force method was used to predict the compatibility of halide working fluids with envelope materials. This procedure was used to reject aluminum and aluminum alloys as envelope materials, due to their high decomposition potential. Titanium and three corrosion resistant superalloys were chosen as envelope materials. Life tests were conducted with these envelopes and six different working fluids: AlBr3, GaCl3, SnCl4, TiCl4, TiBr4, and eutectic diphenyl/diphenyl oxide (Therminol VP-1/Dowtherm A). All of the life tests except for the GaCl3 are ongoing; the GaCl3 was incompatible. As the temperature approaches 725 K (450 C), cesium is a potential heat pipe working fluid. Life tests results are also presented for cesium/Monel 400 and cesium/70-30 copper/nickel heat pipes operating near 750 K (477 C). These materials are not suitable for long term operation, due to copper transport from the condenser to the evaporator.
Anderson, William G.↗
Life test of six high temperature resistojets.
Life test of high temperature /2400 K/ 10 millipound resistojet thrustors, comparing results to theoretical predictions
Halbach, C. R.↗
Thermionic converter life-test program
Solar energy thermionic converter life test program and equipment, noting failure due to loss of intraelectrode Cs
Stapfer, G.↗
Advanced Failure Determination Measurement Techniques Used in Thermal Fatigue Life Testing of Electronic Packaging
Thermal fatigue life testing of various electronic packaging technologies is being performed by the Reliability Technology Group at the Jet Propulsion Laboratory. These testing efforts are in progress to improve uderstanding of the reliability issues associated with low volume packaging technologies for space applications and to develop qualification and acceptance approaches for these technologies. The work described here outlines the electrical failure detection techniques used during testing by documenting the circuits and components used to make these measurements, the sensitivity of the measurements, and the applicability of each specific measurement.
fatigue surface mount measurement testing thermal ↗
The 50Ah NiH2 cell life test results
Information is given in viewgraph form for the 50 AhNiH2 cell life test results. Information is given on pressure vessel design, electrochemical/stack design, cell electrical characteristics, and cell life test results.
Jamin, Thierry↗
Performance Characterization of a Microchannel Liquid/Liquid Heat Exchanger Throughout an Extended Duration Life Test
Liquid/Liquid Heat Exchangers (L/L HX) are an integral portion of any spacecraft active thermal control system. For this study the X-38 L/L HX was used as a baseline. As detailed in a previous ICES manuscript, NASA paired with Pacific Northwest National Laboratory to develop a Microchannel L/L HX (MHX). This microchannel HX was designed to meet the same performance characteristics as the aforementioned X-38 HX. The as designed Microchannel HX has a 26% and 60% reduction in mass and volume, respectively. Due to the inherently smaller flow passages the design team was concerned about fouling affecting performance during extended missions. To address this concern, NASA has developed a test stand and is currently performing an 18 month life test on the MHX. This report will detail the up-to-date performance of the MHX during life testing.
Sheth, Rubik B.↗
Long Life Nickel Electrodes for a Nickel-hydrogen Cell: Cycle Life Tests
In order to develop a long life nickel electrode for a Ni/H2 cell, cycle life tests of nickel electrodes were carried out in Hi/H2 boiler plate cells. A 19 test cell matrix was made of various nickel electrode designs including three levels each of plaque mechanical strength, median pore size of the plaque, and active material loading. Test cells were cycled to the end of their life (0.5v) in a 45-minute low earth orbit cycle regime at 80% depth-of-discharge. The results show that the active material loading level affects the cycle life the most with the optimum loading at 1.6 g/cc void. Mechanical strength did not affect the cycle life noticeably in the bend strength range of 400 to 700 psi. The best plaque type appears to be one which is made of INCO nickel powder type 287 and has a median pore size of 13 micron.
Lim, H. S.↗
AUSSAT battery life test program
AUSSAT Pty. Ltd., the Australian National Satellite organization, has contracted with the Hughes Aircraft Company (HAC) for the construction of 3 satellites based on the now familiar HS-376 product line. As part of the AUSSAT contract, HAC is conducting an extensive NiCd battery life test program. The life test program, objectives and test results to date are described. Particular emphasis is given to the evaluation of the FS2117 separator as a future replacement for the Pellon 2505 separator of which only a very limited quantity remains.
Gorian, P. W.↗
Halogen Occultation Experiment (HALOE) gas cell life test program
The Halogen Occultation Experiment (HALOE) will use gas filter correlation radiometry to measure the atmospheric concentration profiles of HCl, HF, NO, and CH4 from the Upper Atmosphere Research Satellite. The need to contain the gases for the gas filter measurements has resulted in the development of gas cells and the need for a life test program to demonstrate that the gas cells will perform their functions for extended periods (several years) of time. This report describes the tests in the life test program, the test apparatus used, and the analysis techniques developed. The report also presents data obtained during the first 14 months of the test program.
Sullivan, E. M.↗
The Advanced Microwave Sounding Unit-A: Antenna Number 2 Bearing Assembly Life Test
Four bearing assemblies, lubricated with Apiezon C oil with 5% lead naphthenate (PbNp), were life tested in support of the Advanced Microwave Sounding Unit-A (AMSU-A). These assemblies were tested continuously for five to six years using the scanning pattern of the flight instrument. A post-life-test analysis was performed on two of the assemblies to evaluate the lubricant behavior and wear in the bearings.
Powers, Charles E.↗
Design of Refractory Metal Life Test Heat Pipe and Calorimeter
Heat pipe life tests have seldom been conducted on a systematic basis. Typically, one or more heat pipes are built and tested for an extended period at a single temperature with simple condenser loading. Results are often reported describing the wall material, working fluid, test temperature, test duration, and occasionally the nature of any failure. Important information such as design details, processing procedures, material assay, power throughput, and radial power density are usually not mentioned. We propose to develop methods to generate carefully controlled data that conclusively establish heat pipe operating life with material-fluid combinations capable of extended operation. The test approach detailed in this Technical Publication will use 16 Mo-44.5%Re alloy/sodium heat pipe units that have an approximate12-in length and 5/8-in diameter. Two specific test series have been identified: (1) Long-term corrosion rates based on ASTM-G-68-80 (G-series) and (2) corrosion trends in a cross-correlation sequence at various temperatures and mass fluences based on a Fisher multifactor design (F-series). Evaluation of the heat pipe hardware will be performed in test chambers purged with an inert purified gas (helium or helium/argon mixture) at low pressure (10-100 torr) to provide thermal coupling between the heat pipe condenser and calorimeter. The final pressure will be selected to minimize the potential for voltage breakdown between the heat pipe and radio frequency (RF) induction coil (RF heating is currently the planned method of powering the heat pipes). The proposed calorimeter is constructed from a copper alloy and relies on a laminar flow water-coolant channel design to absorb and transport energy
Martin, J. J.↗
NSTAR Extended Life Test Discharge Chamber Flake Analysis
The Extended Life Test (ELT) of the NASA Solar Electric Propulsion Technology Readiness (NSTAR) ion thruster was concluded after 30,352 hours of operation. The ELT was conducted using the Deep Space 1 (DS1) back-up flight engine, a 30 cm diameter xenon ion thruster. Post-test inspection of the ELT engine revealed numerous contaminant flakes distributed over the bottom of the cylindrical section of the anode within the discharge chamber (DC). Extensive analyses were conducted to determine the source of the particles, which is critical to the understanding of degradation mechanisms of long life ion thruster operation. Analyses included: optical microscopy (OM) and particle length histograms, field emission scanning electron microscopy (FESEM) combined with energy dispersive spectroscopy (EDS), and atomic oxygen plasma exposure tests. Analyses of the particles indicate that the majority of the DC flakes consist of a layered structure, typically with either two or three layers. The flakes comprising two layers were typically found to have a molybdenum-rich (Mo-rich) layer on one side and a carbon-rich (C-rich) layer on the other side. The flakes comprising three layers were found to be sandwich-like structures with Mo-rich exterior layers and a C-rich interior layer. The presence of the C-rich layers indicates that these particles were produced by sputter deposition build-up on a surface external to the discharge chamber from ion sputter erosion of the graphite target in the test chamber. This contaminant layer became thick enough that particles spalled off, and then were electro-statically attracted into the ion thruster interior, where they were coated with Mo from internal sputter erosion of the screen grid and cathode components. Atomic oxygen tests provided evidence that the DC chamber flakes are composed of a significant fraction of carbon. Particle size histograms further indicated that the source of the particles was spalling of carbon flakes from downstream surfaces. Analyses of flakes taken from the downstream surface of the accelerator grid provided additional supportive information. The production of the downstream carbon flakes, and hence the potential problems associated with the flake particles in the ELT ion thruster engine is a facility induced effect and would not occur in the space environment.
deGroh, Kim K.↗
Accelerated life testing effects on CMOS microcircuit characteristics
The 250 C, 200C and 125C accelerated tests are described. The wear-out distributions from the 250 and 200 C tests were used to estimate the activation energy between the two test temperatures. The duration of the 125 C test was not sufficient to bring the test devices into the wear-out region. It was estimated that, for the most complex of the three devices types, the activation energy between 200 C and 125 C should be at least as high as that between 250 C and 200 C. The practicality of the use of high temperature for the accelerated life tests from the point of view of durability of equipment is assessed. Guidlines for the development of accelerated life-test conditions are proposed. The use of the silicon nitride overcoat to improve the high temperature accelerated life-test characteristics of CMOS microcircuits is described.
Source record↗
Accelerated life testing effects on CMOS microcircuit characteristics
This report covers the time period from May 1976 to December 1979 and encompasses the three phases of accelerated testing: Phase 1, the 250 C testing; Phase 2, the 200 C testing; and Phase 3, the 125 C testing. The duration of the test in Phase 1 and Phase 2 was sufficient to take the devices into the wear out region. The wear out distributions were used to estimate the activation energy between the 250 C and the 200 C test temperatures. The duration of the 125 C test, 20,000 hours, was not sufficient to bring the test devices into the wear out region; consequently the third data point at 125 C for determining the consistency of activation energy could not be obtained. It was estimated that, for the most complex of the three device types, the activation energy between 200 C and 125 C should be at least as high as that between 250 C and 200 C. The practicality of the use of high temperature for the accelerated life tests from the point of view of durability of equipment was assessed. Guidelines for the development of accelerated life test conditions were proposed. The use of the silicon nitride overcoat to improve the high temperature accelerated life test characteristics of CMOS microcircuits was explored in Phase 4 of this study and is attached as an appendix to this report.
Source record↗
Life testing of secondary silver-zinc cells
Testing on a variety of secondary silver-zinc (Ag-Zn) cells has been in progress at the Marshall Space Flight Center (MSFC) for over six years. The latest test involves a 350-Ah cell design that has been cycled at 10 C for 16 months. This design has achieved over 7200 low-earth-orbit (LEO) cycles as well as 17 deep discharges at an 85 percent depth of discharge. This test not only is a life test on these cells but also addresses different methods of storing these cells between the deep discharges. As the test is approaching completion, some interesting results are being seen. In particular, two of the four packs currently on test have failed to meet the 35-h (295-Ah) deep discharge requirement that was arbitrarily set at the beginning of the test. This capacity loss failure is likely a result of the storage method used on these two packs between deep discharges. The two packs are LEO cycled in such a way as to minimize overcharge in an attempt to prolong life.
Brewer, Jeffrey C.↗
Destructive Evaluation of a Xenon Hollow Cathode after a 28,000 Hour Life Test
International Space Station (ISS) plasma contactor system requires a hollow cathode assembly (HCA) with a lifetime of at least 18,000 hours. In order to demonstrate the lifetime capability of the HCA, a series of hollow cathode wear tests was performed which included a life test operated at the maximum current of the HCA. This test sought to verify hollow cathode lifetime capability and contamination control protocols. This hollow cathode accumulated 27,800 hours of operation before it failed during a restart attempt. The cathode was subsequently destructively analyzed in order to determine the failure mechanism. Microscopic examination of the cathode interior determined that relatively small changes in the cathode physical geometry had occurred and barium tungstates, which are known to limit the emission process, had formed over a majority of the electron emitter surface. Because the final state of the insert was consistent with expected impregnate chemistry, the hollow cathode was believed to have reached the end of its usable life under the test conditions.
Sarver-Verhey, Timothy R.↗