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PCB Quality Metrics that Drive Reliability

Risk-based technology infusion is a deliberate and systematic process that defines the analysis and communication methodology by which new technology is applied and integrated into existing and new designs, identifies technology development needs based on trends analysis and facilitates the identification of shortfalls against performance objectives. This presentation at IPC Works Asia Aerospace 2021 Events provides the audience a snapshot of quality variations in printed-wiring-board quality, as assessed, using experiences in processing and risk analysis of PWB structural integrity coupons. The presentation will focus on printed-wiring-board quality metrics used, the relative type and number of non-conformances observed and trend analysis using statistical methods. Trend analysis shows the top five non-conformances observed across PWB suppliers, the root cause(s) behind these non-conformance and suggestions of mitigation plans. The trends are then matched with the current state of the PWB supplier base and its challenges and opportunities. The presentation further discusses the risk-based SMA approaches and methods being applied at GSFC for evaluating candidate printed wiring board technologies that promote the adoption of higher throughput and faster processing technology for GSFC missions.

Printed circuit boards↗
NASA NTRS1985

Develop and demonstrate manufacturing processes for fabricating graphite filament reinforced polymide (Gr/PI) composite structural elements

A study was conducted to assess the merits of using graphite/polyimide, NR-150B2 resin, for structural applications on advanced space launch vehicles. The program was divided into two phases: (1) Fabrication Process Development; and (2) Demonstration Components. The first phase of the program involved the selection of a graphite fiber, quality assurance of the NR-150B2 polyimide resin, and the quality assurance of the graphite/polyimide prepreg. In the second phase of the program, a limited number of components were fabricated before the NR-150B2 resin system was removed from the market by the supplier, Du Pont. The advancement of the NR-150B2 polyimide resin binder was found to vary significantly based on previous time and temperature history during the prepregging operation. Strength retention at 316C (600F) was found to be 50% that of room temperature strength. However, the composite would retain its initial strength after 200 hours exposure at 316C (600F). Basic chemistry studies are required for determining NR-150B2 resin binder quality assurance parameters. Graphite fibers are available that can withstand high temperature cure and postcure cycles.

Chase, V. A.↗
NASA NTRS2018

Impact of Powder Variability on the Microstructure and Mechanical Behavior of Selective Laser Melted (SLM) Alloy 718

Nickel Alloy 718 has found wide use in high-temperature aerospace applications (up to 700°C), due to a combination of good mechanical properties, environmental resistance, and workability at moderate cost. These properties have led Alloy 718 to early adoption by selective laser melting (SLM) additive manufacturing. This presentation will share results from a comprehensive industry survey of 718 powder feedstock for SLM. The survey focuses on the impact of variability in powder characteristics on build quality, microstructure, tensile and high cycle fatigue in the as-fabricated and machined surface conditions. The investigation includes sixteen powder lots from eight suppliers that are produced by gas atomization or rotary atomization in argon or nitrogen. This research was previously presented and published at the 9th International Symposium on Superalloy 718 & Derivatives and was funded by NASA Space Launch System Liquid Engine Office with the Human Exploration Operations Mission Directorate.

Sudbrack, Chantal↗
NASA NTRS2010

Using SCOR as a Supply Chain Management Framework for Government Agency Contract Requirements

Enterprise Supply Chain Management consists of: Specifying suppliers to support inter-program and inter-agency efforts. Optimizing inventory levels and locations throughout the supply chain. Executing corrective actions to improve quality and lead time issues throughout the supply chain. Processing reported data to calculate and make visible supply chain performance (provide information for decisions and actions). Ensuring the right hardware and information is provided at the right time and in the right place. Monitoring the industrial base while developing, producing, operating and retiring a system. Seeing performance deep in the supply chain that could indicate issues affecting system availability and readiness.

Paxton, Joe↗
NASA NTRS2010

Facilitating NASA's Use of GEIA-STD-0005-1, Performance Standard for Aerospace and High Performance Electronic Systems Containing Lead-Free Solder

GEIA-STD-0005-1 defines the objectives of, and requirements for, documenting processes that assure customers and regulatory agencies that AHP electronic systems containing lead-free solder, piece parts, and boards will satisfy the applicable requirements for performance, reliability, airworthiness, safety, and certify-ability throughout the specified life of performance. It communicates requirements for a Lead-Free Control Plan (LFCP) to assist suppliers in the development of their own Plans. The Plan documents the Plan Owner's (supplier's) processes, that assure their customer, and all other stakeholders that the Plan owner's products will continue to meet their requirements. The presentation reviews quality assurance requirements traceability and LFCP template instructions.

Plante, Jeannete↗
NASA NTRS2010

Comparison of Autoclave and Out-of-Autoclave Composites

The National Aeronautics and Space Administration (NASA) Exploration Systems Mission Directorate initiated an Advanced Composite Technology Project through the Exploration Technology Development Program in order to support the polymer composite needs for future heavy lift launch architectures. As an example, the large composite dry structural applications on Ares V inspired the evaluation of autoclave and out-of-autoclave (OOA) composite materials. A NASA and industry team selected the most appropriate materials based on component requirements for a heavy lift launch vehicle. Autoclaved and OOA composites were fabricated and results will highlight differences in processing conditions, laminate quality, as well as initial room temperature thermal and mechanical performance. Results from this study compare solid laminates that were both fiber-placed and hand-laid. Due to the large size of heavy-lift launch vehicle composite structures, there is significant potential that the uncured composite material or prepreg will experience significant out-life during component fabrication. Therefore, prepreg out-life was a critical factor examined in this comparison. In order to rigorously test material suppliers recommended out-life, the NASA/Industry team extended the out-time of the uncured composite prepreg to values that were approximately 50% beyond the manufacturers out-time limits. Early results indicate that the OOA prepreg composite materials suffered in both composite quality and mechanical property performance from their extended out-time. However, the OOA materials performed similarly to the autoclaved composites when processed within a few days of exposure to ambient "shop" floor handling. Follow on studies evaluating autoclave and OOA aluminum honeycomb core sandwich composites are planned.

Sutter, James K.↗
NASA NTRS2000

Diagnostic Techniques Used to Study Chemical-Vapor-Deposited Diamond Films

The advantages and utility of chemical-vapor-deposited (CVD) diamond as an industrial ceramic can only be realized if the price and quality are right. Until recently, this technology was of interest only to the academic and basic research community. However, interest has grown because of advances made by leading CVD diamond suppliers: 1) Reduction of the cost of CVD polycrystalline diamond deposition below $5/carat ($8/sq cm); 2) Installation of production capacity; 3) Epitaxial growth of CVD single-crystal diamond. Thus, CVD diamond applications and business are an industrial reality. At present, CVD diamond is produced in the form of coatings or wafers. CVD diamond film technology offers a broader technological potential than do natural and high-pressure synthetic diamonds because size, geometry, and eventually cost will not be as limiting. Now that they are cost effective, diamond coatings - with their extreme properties - can be used in a variety of applications. Diamond coatings can improve many of the surface properties of engineering substrate materials, including erosion, corrosion, and wear resistance. Examples of actual and potential applications, from microelectromechanical systems to the wear parts of diamond coatings and related superhard coatings are described. For example, diamond coatings can be used as a chemical and mechanical barrier for the space shuttles check valves, particularly on the guide pins and seat assemblies.

Miyoshi, Kazuhisa↗
NASA NTRS2020

PCB Quality Metrics that Drive Reliability (PD 18)

Risk based technology infusion is a deliberate and systematic process which defines the analysis and communication methodology by which new technology is applied and integrated into existing and new designs, identifies technology development needs based on trends analysis and facilitates the identification of shortfalls against performance objectives. This presentation at IPC Works Asia Aerospace 2019 Events provides the audience a snapshot of quality variations in printed wiring board quality, as assessed, using experiences in processing and risk analysis of PWB structural integrity coupons. The presentation will focus on printed wiring board quality metrics used, the relative type and number of non-conformances observed and trend analysis using statistical methods. Trend analysis shows the top five non-conformances observed across PWB suppliers, the root cause(s) behind these non-conformance and suggestions of mitigation plans. The trends will then be matched with the current state of the PWB supplier base and its challenges and opportunities. The presentation further discusses the risk based SMA approaches and methods being applied at GSFC for evaluating candidate printed wiring board technologies which promote the adoption of higher throughput and faster processing technology for GSFC missions.

Sood, Bhanu↗
NASA NTRS1994

Phytochrome-mediated responses: Implications for controlled environment research facilities

Light is undoubtedly the most important environmental variable for plant growth and development; plants not only use radiant energy in photosynthesis, they also respond to the quantity, quality, direction and timing of incident radiation through photomorphogenic response that can have huge effects on the rate of growth and the pattern of development. It is surprising, therefore, that the manufacturers and suppliers of controlled environment facilities have been singularly uninventive in the design of the lighting assemblies they provide. The consumer has one choice only - a lighting assembly that provides irradiance levels usually only a fraction of sunlight, and a control system that is limited to regulating the timing of the on-off switch. The reasons for these limitations are partly technological, but in the main they result from ignorance on the part of both the consumer and the manufacturer. A specific and powerful example of this ignorance relates to the importance of the so-called far-red wavelengths (FR = 700-800 nm). Because the human eye can hardly detect wavelengths above 700 nm, and photosynthesis also cuts off at about 700 nm, the majority of plant and crop physiologists are still almost completely unaware that FR radiation can have massive effects on growth rate and development. In consequence, most growth cabinets have light sources based on fluorescent tubes, and provide very little FR apart from that emitted by a token number of small incandescent bulbs. Larger growth facilities often use broader spectrum light sources, but growth facilities that provide the capability to vary the FR incident upon the plants are about as abundant as seals in the Sahara. This article sets the background of the significance of FR radiation in the natural environment and its importance for plant growth and development in the hope that it might inform intelligently those concerned with improving the design of plant growth facilities.

Smith, Harry↗
NASA NTRS1995

Evaluation of Pd-Cr Wires for Strain Gage Application

A newly developed alloy, palladium-13 weight percent chromium (Pd13Cr), was identified by United Technologies Research Center under a NASA contract to be the best material for high temperature strain gage applications. An electrical resistance strain gage that can provide accurate static strain measurement to a temperature higher than that of a commercially available gage is urgently needed in aerospace and aeronautics research. A strain gage made of a 25.4 micron (1 mil) diameter Pd13Cr wire has been recently demonstrated to be usable for static strain measurements to 800 C. This compares to the 400 C temperature limit of the commercially available strain gages. The performance of the Pd-Cr gage, however, strongly depends on the quality of the Pd13Cr wire. Four batches of Pd-Cr wires purchased from three different manufacturers were therefore evaluated to determine the best source of the wire for strain gage applications. The three suppliers were Precious Metal Institute in China, Sigmund Cohn Co., and G & S Titanium, Inc. in the United States. Two batches of wires obtained from Previous Metal Institute in 1987 and 1992, respectively are referred to herein as China87 and China92 wires. The mechanical, chemical and electrical properties of these wires, both as-received and after high temperature exposures at 800 C for 50 hours were analyzed. The elastic modulus and the failure strength of the wires were evaluated using a tensile test machine equipped with a laser speckle strain measurement system. The chemical and microstructural properties of the wires were inspected using a plasma atomic emission spectrometer and a scanning electron microscope (SEM) equipped with an energy dispersive X-ray spectroscope (EDS). The electrical stability and repeatability of the wires were determined by measuring the electrical resistance of the wires during three thermal cycles to 1000 C and a ten-hour soak at 1000 C. As a result of this study, the wire which has the highest strength, the least impurities content, the best oxidation resistance and the best electrical stability will be selected for upcoming strain gage applications.

Lei, Jih-Fen↗
NASA NTRS2019

UAS Service Supplier Checkout: How UTM Confirmed Readiness of Flight Tests with UAS Service Suppliers

NASA collaborated with industry partners to develop and test the small Unmanned Aircraft System (sUAS) Traffic Management (UTM) research platform, a software prototype used for developing airspace integration requirements for sUAS operations. The lessons learned from these activities will help inform the Federal Aviation Administration (FAA) on what is needed to safely manage sUAS operations. A core component of the UTM platform is the UAS Service Supplier (USS), which acts as a communications bridge to meet the regulatory and operational requirements. As the UTM partners began USS flight tests, NASA found that it was difficult to get all USSs functioning at comparable quality levels to ensure successful flight tests. Also, NASA anticipated that the FAA would encounter similar challenges when they begin to register USSs for operational use. These realizations led to the development of USS Checkout, a set of processes and tools designed to increase flight test efficiency. We learned that a good USS Checkout process is balanced for simplicity versus test coverage, and is amenable to automation. We also learned that when USS Checkout is a USS prerequisite for flight tests, flight tests were more efficient and effective.

Smith, Irene Skupniewicz↗
NASA NTRS2018

Qualifying Bulk Metallic Glass Gear Materials for Spacecraft Applications

NASA is evaluating bulk metallic glass (BMG) gears for extreme environment (cryogenic) applications; e.g., Europa Lander. The main purpose of this report is to recommend a quality assurance (QA) protocol for the production of consistent and reliable gear castings. Currently, there are two, separate manufacturers involved; Materion Corporation produces re-melt stock and Visser Precision Cast, Inc. produces BMG castings. Division of the existing alloy specifications document into material supplier-specific documents is proposed. Until a composition-based specification is established, processability- and performance-based methodologies may be an option during manufacturing development. It is recommended that each of the documents has a distinct focus; the processing behavior of crystalline feedstock, and the mechanical behavior of amorphous castings. The report addresses the “gray area” in QA testing between these materials suppliers by outlining an equitable division of responsibilities. The use of a number of dedicated reference dies to produce witness materials for physical and mechanical property evaluation is strongly recommended. Allocation of QA tests between screen testing of gear castings, and formal testing of witness materials, including cryogenic properties, is also proposed. The most effective suite of tests for both physical and mechanical property determination are down-selected from available national and international standards. The contents of this report create a solid basis for selection of QA tests, thereby setting the stage for negotiations between the materials suppliers and the customer.This technical paper:a) provides recommendations to advance materials specifications document JPL D-56223,Rev. A from “draft” to “preliminary” status;b) proposes division of the current document into two supplier-specific documents;c) separates testing methods by “ingots/castings” and “witness materials”;d) classifies test methodology based on “processability” and “performance”;e) assembles candidate ASTM specifications for “screen testing” and “formal testing”;f) identifies standard tests compatible with evaluation of BMG flexspline gears;g) suggests division of responsibilities for processability and performance testing; andh) addresses the QA “gray area” between production of ingots and castings.The report recommends that:a) processability- and performance-based QA methods might be used in lieu ofcompositional specifications during manufacturing development only;b) reference dies be designed for “acceptance” and “qualification” castings;c) witness materials provide physical and mechanical property data;d) formal testing be conducted at ambient and cryogenic temperatures; ande) processing/properties be correlated with compositional variations.

Hales, Stephen J.↗
NASA NTRS2018

Use of Open Networks and Delay-Tolerant Protocol to Decrease WAN Latency of EOS near Real-Time Data

Since 1999, NASA's Earth Observing System Data Operations System (EDOS) project at Goddard Space Flight Center (GSFC) has provided high-rate data capture, level zero processing, and product distribution services for a majority of NASA's EOS (Earth Observing System) high-rate missions, including Terra, Aqua, Aura, ICESat, EO-1, SMAP, and OCO-2. EDOS high-rate science and engineering (150-300 Mbps) data-driven capture systems are deployed at 7 worldwide ground stations which are connected via both private (closed) and public (open) wide area networks (WANs) to the centralized EDOS Level Zero Processing Facility (LZPF) located at GSFC, where the data is processed and Level 0 products are distributed to users worldwide. All data transferred over the open networks to GSFC traverse an IPSec tunnel, providing the same level of security as a VPN connection. EDOS produces both time-based and near real-time products (session-based). Near real-time data products are produced from a single ground station contact; time-based products are produced from multiple ground station contacts. EDOS is the primary supplier of EOS Level 0 data to the NASA near real-time user community known as the Land, Atmosphere Near real-time Capability for EOS (LANCE). For the past few years, EDOS has streamlined its systems to reduce WAN latency for near real-time data delivery, including implementing Quality of Service (QoS), expanding closed network bandwidth, adding open network connections with more bandwidth, and implementing a delay-tolerant protocol to mitigate long round-trip times to remote ground stations.

Delay-Tolerant Protocol↗
NASA NTRS1980

Completion of evaluation of manufacturing processes for B/Al composites containing 0.2mm diameter boron fibers

Four fabricators produced a total of 54 B/1100 Al, B/6061 Al, and B/2024 Al panels for evaluation. The 8 ply unidirectional, 45 to 50 volume percent, panels were made using 0.20 mm diameter boron fibers which were obtained from a single supplier. Hot press consolidation was carried out in vacuum except for one set of dry woven tape panels which were hot pressed in air. A single testing contractor conducted nondestructive inspection, metallography, fractography and mechanical property tests. The mechanical property tests included 21 and 260 C tensile tests and 21 C shear tests. Panel quality, as measured by nondestructive evaluation, was generally good as were the 21 C tensile properties. The panels hot pressed in air delaminated in the shear tests. Shear strength values were lower in these panels. But tensile strengths were not affected by the delaminations because of the relation between the tensile loading direction and the delaminations. Composite tensile strength was found to be proportional to the volume percent boron and the aluminum matrix rather than to the tape used or fabrication technique. Suitability of these composites for 260 C service was confirmed by tensile tests.

Moore, T. J.↗
NASA NTRS1995

Requirements for effective use of CFD in aerospace design

This paper presents a perspective on the requirements that Computational Fluid Dynamics (CFD) technology must meet for its effective use in aerospace design. General observations are made on current aerospace design practices and deficiencies are noted that must be rectified for the U.S. aerospace industry to maintain its leadership position in the global marketplace. In order to rectify deficiencies, industry is transitioning to an integrated product and process development (IPPD) environment and design processes are undergoing radical changes. The role of CFD in producing data that design teams need to support flight vehicle development is briefly discussed. An overview of the current state of the art in CFD is given to provide an assessment of strengths and weaknesses of the variety of methods currently available, or under development, to produce aerodynamic data. Effectiveness requirements are examined from a customer/supplier view point with design team as customer and CFD practitioner as supplier. Partnership between the design team and CFD team is identified as an essential requirement for effective use of CFD. Rapid turnaround, reliable accuracy, and affordability are offered as three key requirements that CFD community must address if CFD is to play its rightful role in supporting the IPPD design environment needed to produce high quality yet affordable designs.

Raj, Pradeep↗
NASA NTRS1995

Exchange, interpretation, and database-search of ion mobility spectra supported by data format JCAMP-DX

To assist peak assignment in ion mobility spectrometry it is important to have quality reference data. The reference collection should be stored in a database system which is capable of being searched using spectral or substance information. We propose to build such a database customized for ion mobility spectra. To start off with it is important to quickly reach a critical mass of data in the collection. We wish to obtain as many spectra combined with their IMS parameters as possible. Spectra suppliers will be rewarded for their participation with access to the database. To make the data exchange between users and system administration possible, it is important to define a file format specially made for the requirements of ion mobility spectra. The format should be computer readable and flexible enough for extensive comments to be included. In this document we propose a data exchange format, and we would like you to give comments on it. For the international data exchange it is important, to have a standard data exchange format. We propose to base the definition of this format on the JCAMP-DX protocol, which was developed for the exchange of infrared spectra. This standard made by the Joint Committee on Atomic and Molecular Physical Data is of a flexible design. The aim of this paper is to adopt JCAMP-DX to the special requirements of ion mobility spectra.

Baumback, J. I.↗
NASA NTRS2009

Modeling Guidelines for Code Generation in the Railway Signaling Context

Modeling guidelines constitute one of the fundamental cornerstones for Model Based Development. Their relevance is essential when dealing with code generation in the safety-critical domain. This article presents the experience of a railway signaling systems manufacturer on this issue. Introduction of Model-Based Development (MBD) and code generation in the industrial safety-critical sector created a crucial paradigm shift in the development process of dependable systems. While traditional software development focuses on the code, with MBD practices the focus shifts to model abstractions. The change has fundamental implications for safety-critical systems, which still need to guarantee a high degree of confidence also at code level. Usage of the Simulink/Stateflow platform for modeling, which is a de facto standard in control software development, does not ensure by itself production of high-quality dependable code. This issue has been addressed by companies through the definition of modeling rules imposing restrictions on the usage of design tools components, in order to enable production of qualified code. The MAAB Control Algorithm Modeling Guidelines (MathWorks Automotive Advisory Board)[3] is a well established set of publicly available rules for modeling with Simulink/Stateflow. This set of recommendations has been developed by a group of OEMs and suppliers of the automotive sector with the objective of enforcing and easing the usage of the MathWorks tools within the automotive industry. The guidelines have been published in 2001 and afterwords revisited in 2007 in order to integrate some additional rules developed by the Japanese division of MAAB [5]. The scope of the current edition of the guidelines ranges from model maintainability and readability to code generation issues. The rules are conceived as a reference baseline and therefore they need to be tailored to comply with the characteristics of each industrial context. Customization of these recommendations has been performed for the automotive control systems domain in order to enforce code generation [7]. The MAAB guidelines have been found profitable also in the aerospace/avionics sector [1] and they have been adopted by the MathWorks Aerospace Leadership Council (MALC). General Electric Transportation Systems (GETS) is a well known railway signaling systems manufacturer leading in Automatic Train Protection (ATP) systems technology. Inside an effort of adopting formal methods within its own development process, GETS decided to introduce system modeling by means of the MathWorks tools [2], and in 2008 chose to move to code generation. This article reports the experience performed by GETS in developing its own modeling standard through customizing the MAAB rules for the railway signaling domain and shows the result of this experience with a successful product development story.

Ferrari, Alessio↗
NASA NTRS2010

Comparison of Traditional and Innovative Techniques to Solve Technical Challenges

Although NASA has an adequate food system for current missions, research is required to accommodate new requirements for future NASA exploration missions. The Inadequate Food System risk reflects the need to develop requirements and technologies that will enable NASA to provide the crew with a safe, nutritious and acceptable food system while effectively balancing appropriate resources such as mass, volume, and crew time in exploratory missions. As we go deeper into space or spend more time on the International Space Station (ISS), there will be requirements for packaged food to be stored for 3 5 years. New food packaging technologies are needed that have adequate oxygen and water barrier properties to maintain the foods' quality over this extended shelf life. NASA has been unsuccessful in identify packaging materials that meet the necessary requirements when using several traditional routes including literature reviews, workshops, and internal shelf life studies on foods packaged in various packaging materials. Small Business Innovative Research grants were used for accelerating food packaging materials research with limited success. In order to accelerate the process, a theoretical challenge was submitted to InnoCentive resulting in a partial award. A similar food packaging challenge was submitted to Yet2.com and several potential commercial packaging material suppliers were identified that, at least partially, met the requirements. Comparisons and results of these challenges will be discussed.

Perchonok, Michele↗