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International Space Station Acoustics - A Status Report

It is important to control acoustic noise aboard the International Space Station (ISS) to provide a satisfactory environment for voice communications, crew productivity, and restful sleep, and to minimize the risk for temporary and permanent hearing loss. Acoustic monitoring is an important part of the noise control process on ISS, providing critical data for trend analysis, noise exposure analysis, validation of acoustic analysis and predictions, and to provide strong evidence for ensuring crew health and safety, thus allowing Flight Certification. To this purpose, sound level meter (SLM) measurements and acoustic noise dosimetry are routinely performed. And since the primary noise sources on ISS include the environmental control and life support system (fans and airflow) and active thermal control system (pumps and water flow), acoustic monitoring will indicate changes in hardware noise emissions that may indicate system degradation or performance issues. This paper provides the current acoustic levels in the ISS modules and sleep stations, and is an update to the status presented in 20031. Many new modules, and sleep stations have been added to the ISS since that time. In addition, noise mitigation efforts have reduced noise levels in some areas. As a result, the acoustic levels on the ISS have improved.

Allen, Christopher S.↗

Generic, Extensible, Configurable Push-Pull Framework for Large-Scale Science Missions

The push-pull framework was developed in hopes that an infrastructure would be created that could literally connect to any given remote site, and (given a set of restrictions) download files from that remote site based on those restrictions. The Cataloging and Archiving Service (CAS) has recently been re-architected and re-factored in its canonical services, including file management, workflow management, and resource management. Additionally, a generic CAS Crawling Framework was built based on motivation from Apache s open-source search engine project called Nutch. Nutch is an Apache effort to provide search engine services (akin to Google), including crawling, parsing, content analysis, and indexing. It has produced several stable software releases, and is currently used in production services at companies such as Yahoo, and at NASA's Planetary Data System. The CAS Crawling Framework supports many of the Nutch Crawler's generic services, including metadata extraction, crawling, and ingestion. However, one service that was not ported over from Nutch is a generic protocol layer service that allows the Nutch crawler to obtain content using protocol plug-ins that download content using implementations of remote protocols, such as HTTP, FTP, WinNT file system, HTTPS, etc. Such a generic protocol layer would greatly aid in the CAS Crawling Framework, as the layer would allow the framework to generically obtain content (i.e., data products) from remote sites using protocols such as FTP and others. Augmented with this capability, the Orbiting Carbon Observatory (OCO) and NPP (NPOESS Preparatory Project) Sounder PEATE (Product Evaluation and Analysis Tools Elements) would be provided with an infrastructure to support generic FTP-based pull access to remote data products, obviating the need for any specialized software outside of the context of their existing process control systems. This extensible configurable framework was created in Java, and allows the use of different underlying communication middleware (at present, both XMLRPC, and RMI). In addition, the framework is entirely suitable in a multi-mission environment and is supporting both NPP Sounder PEATE and the OCO Mission. Both systems involve tasks such as high-throughput job processing, terabyte-scale data management, and science computing facilities. NPP Sounder PEATE is already using the push-pull framework to accept hundreds of gigabytes of IASI (infrared atmospheric sounding interferometer) data, and is in preparation to accept CRIMS (Cross-track Infrared Microwave Sounding Suite) data. OCO will leverage the framework to download MODIS, CloudSat, and other ancillary data products for use in the high-performance Level 2 Science Algorithm. The National Cancer Institute is also evaluating the framework for use in sharing and disseminating cancer research data through its Early Detection Research Network (EDRN).

Foster, Brian M.↗

International Space Station Acoustics - A Status Report

It is important to control acoustic noise aboard the International Space Station (ISS) to provide a satisfactory environment for voice communications, crew productivity, alarm audibility, and restful sleep, and to minimize the risk for temporary and permanent hearing loss. Acoustic monitoring is an important part of the noise control process on ISS, providing critical data for trend analysis, noise exposure analysis, validation of acoustic analyses and predictions, and to provide strong evidence for ensuring crew health and safety, thus allowing Flight Certification. To this purpose, sound level meter (SLM) measurements and acoustic noise dosimetry are routinely performed. And since the primary noise sources on ISS include the environmental control and life support system (fans and airflow) and active thermal control system (pumps and water flow), acoustic monitoring will reveal changes in hardware noise emissions that may indicate system degradation or performance issues. This paper provides the current acoustic levels in the ISS modules and sleep stations and is an update to the status presented in 2011. Since this last status report, many payloads (science experiment hardware) have been added and a significant number of quiet ventilation fans have replaced noisier fans in the Russian Segment. Also, noise mitigation efforts are planned to reduce the noise levels of the T2 treadmill and levels in Node 3, in general. As a result, the acoustic levels on the ISS continue to improve.

Allen, Christopher S.↗

A Review of Diagnostic Techniques for ISHM Applications

System diagnosis is an integral part of any Integrated System Health Management application. Diagnostic applications make use of system information from the design phase, such as safety and mission assurance analysis, failure modes and effects analysis, hazards analysis, functional models, fault propagation models, and testability analysis. In modern process control and equipment monitoring systems, topological and analytic , models of the nominal system, derived from design documents, are also employed for fault isolation and identification. Depending on the complexity of the monitored signals from the physical system, diagnostic applications may involve straightforward trending and feature extraction techniques to retrieve the parameters of importance from the sensor streams. They also may involve very complex analysis routines, such as signal processing, learning or classification methods to derive the parameters of importance to diagnosis. The process that is used to diagnose anomalous conditions from monitored system signals varies widely across the different approaches to system diagnosis. Rule-based expert systems, case-based reasoning systems, model-based reasoning systems, learning systems, and probabilistic reasoning systems are examples of the many diverse approaches ta diagnostic reasoning. Many engineering disciplines have specific approaches to modeling, monitoring and diagnosing anomalous conditions. Therefore, there is no "one-size-fits-all" approach to building diagnostic and health monitoring capabilities for a system. For instance, the conventional approaches to diagnosing failures in rotorcraft applications are very different from those used in communications systems. Further, online and offline automated diagnostic applications are integrated into an operations framework with flight crews, flight controllers and maintenance teams. While the emphasis of this paper is automation of health management functions, striking the correct balance between automated and human-performed tasks is a vital concern.

Patterson-Hine, Ann↗

What Went Wrong: A Survey of Wildfire UAS Mishaps through Named Entity Recognition

Increasingly, unmanned aircraft systems (UAS) are being applied to wildfire incidents for tasks such as mapping, aerial ignition, and delivery. As a result, incident reporting systems for wildfires are beginning to accumulate data related to UAS mishaps in wildfire response. In this research, we apply state-of-the-art natural language processing (NLP) techniques to develop a custom Named Entity Recognition (NER) model which extracts a Failure Modes and Effects Analysis (FMEA)-style survey of wildfire UAS mishaps reported in SAFECOM. The custom NER model is built by fine-tuning an existing (BERT) model, resulting in a generalizable NER model that can extract engineering relevant entities including failure modes, causes, effects, control processes, and recommendations from any failure-relevant text. Similar mishaps are clustered and reported as single rows within the FMEA. For each cluster, frequency, severity, and overall risk are computed. The methodology can be applied as part of a broader safety management system to track trends in mishaps and discover knowledge that can be utilized to improve safety outcomes and system performance.

Machine Learning↗

What Went Wrong: A Survey of Wildfire UAS Mishaps through Named Entity Recognition

Increasingly, unmanned aircraft systems (UAS) are being applied to wildfire incidents for tasks such as mapping, aerial ignition, and delivery. As a result, incident reporting systems for wildfires are beginning to accumulate data related to UAS mishaps in wildfire response. In this research, we apply state-of-the-art natural language processing (NLP) techniques to develop a custom Named Entity Recognition (NER) model which extracts a Failure Modes and Effects Analysis (FMEA)-style survey of wildfire UAS mishaps reported in SAFECOM. The custom NER model is built by fine-tuning an existing (BERT) model, resulting in a generalizable NER model that can extract engineering relevant entities including failure modes, causes, effects, control processes, and recommendations from any failure-relevant text. Similar mishaps are clustered and reported as single rows within the FMEA. For each cluster, frequency, severity, and overall risk are computed. The methodology can be applied as part of a broader safety management system to track trends in mishaps and discover knowledge that can be utilized to improve safety outcomes and system performance.

Machine Learning↗

High pressure turbomachinery ground test facility

Turbomachinery test facilities are at present scarce to non-existent world-wide. The turbomachinery test facility at Stennis Space Center will provide for advanced development and research and development capabilities for liquid hydrogen/liquid oxygen propellant rocket engine components. The facility will provide ultra-high pressure via gas generators to deliver the needed turbine drive on various turbomachinery. State of the art process control systems will provide the vital pressure, temperature and flow requirements during tests. These systems will better control adverse transient conditions during start-up and shutdown, and by using advanced control theory, as well as incorporate test article health monitoring. Also, digital data acquisition systems will obtain high frequency (up to 20 KHz) and low frequency (up to 1 KHz) data during the test. Pressures of up to 15,000 psi will be generated to pressurize high pressure tanks supplying cryogens to various test article inlets thus pushing turbopump materials and manufacturing processes to their limits. By planning for future projects the test facility will be easily adaptable to multi-program test configurations over a range of thermodynamic positions.

Scheuermann, Patrick E.↗

Leveraging CSPP: Building a cloud based direct broadcast processing system

Reducing the time that it takes to have useful satellite information is very important because timely access allows for more informed decision making. This is especially true in time critical situations like disaster response and financial market analysis. One way to achieve reductions in the overall time between information capture and delivery to use the direct broadcast from weather satellites. In this work, we describe a state driven satellite information system that captures a satellite’s direct broadcast signal and uses cloud-based resources to provide end-user controlled processing. The system takes advantage of the reliability and customizability of Amazon Web Services to provide fast and reliable access to a system that takes the direct broadcast signal and leverages the CSPP software as well as dynamically supplied end-user processing modules to produce a user desired information product. Finally, we describe the development process and how a flexible design allowed for changes as the capabilities of the processing platform evolved and the lessons we learned from the process.

CSPP↗

Center for Space Power, Texas A and M University

Johnson Controls is a 106 year old company employing 42,000 people worldwide with $4.7 billion annual sales. Though we are new to the aerospace industry we are a world leader in automobile battery manufacturing, automotive seating, plastic bottling, and facilities environment controls. The battery division produces over 24,000,000 batteries annually under private label for the new car manufacturers and the replacement market. We are entering the aerospace market with the nickel hydrogen battery with the help of NASA's Center for Space Power at Texas A&M. Unlike traditional nickel hydrogen battery manufacturers, we are reaching beyond the space applications to the higher volume markets of aircraft starting and utility load leveling. Though space applications alone will not provide sufficient volume to support the economies of scale and opportunities for statistical process control, these additional terrestrial applications will. For example, nickel hydrogen batteries do not have the environmental problems of nickel cadmium or lead acid and may someday start your car or power your electric vehicle. However you envision the future, keep in mind that no manufacturer moves into a large volume market without fine tuning their process. The Center for Space Power at Texas A&M is providing indepth technical analysis of all of the materials and fabricated parts of our battery as well as thermal and mechanical design computer modeling. Several examples of what we are doing with nickel hydrogen chemistry to lead to these production efficiencies are presented.

Jones, Ken↗

Metal Additive Manufacturing for Rocket Engines: Successes and Failures

NASA has been developing additive manufacturing (AM) for various technical and programmatic advantages for complex rocket engine and aerospace components. This maturation has focused on various AM processes, new alloys, characterizing material properties, developing standards, producing demonstrator parts, and integrating AM hardware in liquid rocket engines through test-fail-fix cycles, as well as application and dissemination of lessons learned of the AM lifecycle. The importance of proper AM processing was made evident in the failure of a Laser Powder Bed Fusion (L-PBF) copper-alloy combustion chamber during a hot-fire test due to a degraded material quality. The hot-fire test aimed to demonstrate high duty cycle under a risk-tolerant development project, where consequences of component failure would be minimal. However, the unintentional component failure emphasized the necessity of robust material characterization and rigorous process control procedures for the safe use of AM components in critical applications. This presentation provides an overview of the development failure, a discussion on the evaluation of the failed chamber and supplemental chambers produced at the same time, a representative material samples that included intentional build witness lines, and a summary of the key results and recommendations from the evaluations. NASA continues to approach AM processes and designs with a level of risk and acceptance of failures that is appropriate for the project objectives, with the overall goal of safe implementation of AM technology and transferring AM technology into commercial space applications. This presentation with provide critical awareness to the community lessons learned on proper implementation of AM.

L-PBF↗

Successes and Failures of Metal Additive Manufacturing for Rocket Engines

NASA has been developing additive manufacturing (AM) for various technical and programmatic advantages for complex rocket engine and aerospace components. This maturation has focused on various AM processes, new alloys, characterizing material properties, developing standards, producing demonstrator parts, and integrating AM hardware in liquid rocket engines through test-fail-fix cycles, as well as application and dissemination of lessons learned of the AM lifecycle. The importance of proper AM processing was made evident in the failure of a Laser Powder Bed Fusion (L-PBF) copper-alloy combustion chamber during a hot-fire test due to a degraded material quality. The hot-fire test aimed to demonstrate high duty cycle under a risk-tolerant development project, where consequences of component failure would be minimal. However, the unintentional component failure emphasized the necessity of robust material characterization and rigorous process control procedures for the safe use of AM components in critical applications. This presentation provides an overview of the development failure, a discussion on the evaluation of the failed chamber and supplemental chambers produced at the same time, a representative material samples that included intentional build witness lines, and a summary of the key results and recommendations from the evaluations. NASA continues to approach AM processes and designs with a level of risk and acceptance of failures that is appropriate for the project objectives, with the overall goal of safe implementation of AM technology and transferring AM technology into commercial space applications. This presentation with provide critical awareness to the community lessons learned on proper implementation of AM.

Additive Manufacturing↗

System Acquires And Displays Signal-Propagation Data

Electronic system acquires, controls processing of, and displays data from experiments on propagation of phase-coherent radio signals at frequencies of 12, 20, and 30 GHz. Acquisition equipment coordinates flow of data from multiple input channels to computer. Software provides for multi-tasking and for interactive graphical displays, including easy-to-use windows and pulldown menus with mouse input. Offers outstanding accuracy; acquires and displays data and controls associated equipment, all in real time.

Mckeeman, John C.↗

Electromagnetically Clean Solar Arrays

The term 'electromagnetically clean solar array' ('EMCSA') refers to a panel that contains a planar array of solar photovoltaic cells and that, in comparison with a functionally equivalent solar-array panel of a type heretofore used on spacecraft, (1) exhibits less electromagnetic interferences to and from other nearby electrical and electronic equipment and (2) can be manufactured at lower cost. The reduction of electromagnetic interferences is effected through a combination of (1) electrically conductive, electrically grounded shielding and (2) reduction of areas of current loops (in order to reduce magnetic moments). The reduction of cost is effected by designing the array to be fabricated as a more nearly unitary structure, using fewer components and fewer process steps. Although EMCSAs were conceived primarily for use on spacecraft they are also potentially advantageous for terrestrial applications in which there are requirements to limit electromagnetic interference. In a conventional solar panel of the type meant to be supplanted by an EMCSA panel, the wiring is normally located on the back side, separated from the cells, thereby giving rise to current loops having significant areas and, consequently, significant magnetic moments. Current-loop geometries are chosen in an effort to balance opposing magnetic moments to limit far-0field magnetic interactions, but the relatively large distances separating current loops makes full cancellation of magnetic fields problematic. The panel is assembled from bare photovoltaic cells by means of multiple sensitive process steps that contribute significantly to cost, especially if electomagnetic cleanliness is desired. The steps include applying a cover glass and electrical-interconnect-cell (CIC) sub-assemble, connecting the CIC subassemblies into strings of series-connected cells, laying down and adhesively bonding the strings onto a panel structure that has been made in a separate multi-step process, and mounting the wiring on the back of the panel. Each step increases the potential for occurrence of latent defects, loss of process control, and attrition of components. An EMCSA panel includes an integral cover made from a transparent material. The silicone cover supplants the individual cover glasses on the cells and serves as an additional unitary structural support that offers the advantage, relative to glass, of the robust, forgiving nature of the silcone material. The cover contains pockets that hold the solar cells in place during the lamination process. The cover is coated with indium tin oxide to make its surface electrically conductive, so that it serves as a contiguous, electrically grounded shield over the entire panel surface. The cells are mounted in proximity to metallic printed wiring. The painted-wiring layer comprises metal-film traces on a sheet of Kapton (or equivalent) polyimide. The traces include contact pads on one side of the sheet for interconnecting the cells. Return leads are on the opposite side of the sheet, positioned to form the return currents substantially as mirror images of, and in proximity to, the cell sheet currents, thereby minimizing magnetic moments. The printed-wiring arrangement mimics the back-wiring arrangement of conventional solar arrays, but the current-loop areas and the resulting magnetic moments are much smaller because the return-current paths are much closer to the solar-cell sheet currents. The contact pads are prepared with solder fo electrical and mechanical bonding to the cells. The pocketed cover/shield, the solar cells, the printed-wiring layer, an electrical bonding agent, a mechanical-bonding agent, a composite structural front-side face sheet, an aluminum honeycomb core, and a composite back-side face sheet are all assembled, then contact pads are soldered to the cells and the agents are cured in a single lamination process.

Stem, Theodore G.↗

Investigate zero-stress replicated optics

The contracted activities for the procurement of 'Investigate Zero-Stress Replicated Optics' to support the AXAF-S x-ray spectrometer mirrors has been completed. To date four large Wolter I grazing incidence x-ray optical shells have been electroformed from nickel. The mirrors were fabricated utilizing each of two nickel alloy plated aluminum substrates twice. A wide variety of testing has been completed by NASA MSFC and UAH. This testing includes heat treatment control tests, subscale plating and fixture testing, alloy control of the electroless nickel, adhesion and release testing of the gold to electroless nickel, electroforming instrumentation and software and fabrication of subscale models. The full scale shells are one millimeter thick nickel electrodeposited over a thin gold layer which in turn has the optical surface on the inside. The optical surface is the replicate of the surface prepared on the substrate. Appendix I briefly outlines the fabrication process. Major objectives which were shared by UAH and MSFC include the design of facilities, equipment and tooling and procurement of materials and equipment. Process development followed with the fabrication of small scale pilot units. Procurement commenced immediately and equipment and materials were ordered to implement the fabrication of first surface full scale substrates (mandrels) and the second surface electroformed optical components. All principal objectives have been achieved. Inspection of the mirrors in visible and x-ray modes validates that the required performance and the quality can be achieved by an electroforming replication process. A very distinct progressive improvement has been achieved with each of the four mirrors produced. The final mirror exceeded the original goals and set an improved standard for flight hardware. The future goal of a 30 arc second resolution at 8 KEV x-ray appears to be achievable by this process when proper cleanliness and process control is utilized.

Engelhaupt, Darell↗

Cryogenic Behavior of the High Temperature Crystal Oscillator PX-570

Microprocessors, data-acquisition systems, and electronic controllers usually require timing signals for proper and accurate operation. These signals are, in most cases, provided by circuits that utilize crystal oscillators due to availability, cost, ease of operation, and accuracy. Stability of these oscillators, i.e. crystal characteristics, is usually governed, amongst other things, by the ambient temperature. Operation of these devices under extreme temperatures requires, therefore, the implementation of some temperature-compensation mechanism either through the manufacturing process of the oscillator part or in the design of the circuit to maintain stability as well as accuracy. NASA future missions into deep space and planetary exploration necessitate operation of electronic instruments and systems in environments where extreme temperatures along with wide-range thermal swings are countered. Most of the commercial devices are very limited in terms of their specified operational temperature while very few custom-made and military-grade parts have the ability to operate in a slightly wider range of temperature. Thus, it is becomes mandatory to design and develop circuits that are capable of operation efficiently and reliably under the space harsh conditions. This report presents the results obtained on the evaluation of a new (COTS) commercial-off-the-shelf crystal oscillator under extreme temperatures. The device selected for evaluation comprised of a 10 MHz, PX-570-series crystal oscillator. This type of device was recently introduced by Vectron International and is designed as high temperature oscillator [1]. These parts are fabricated using proprietary manufacturing processes designed specifically for high temperature and harsh environment applications [1]. The oscillators have a wide continuous operating temperature range; making them ideal for use in military and aerospace industry, industrial process control, geophysical fields, avionics, and engine control. They exhibit low jitter and phase noise, consume little power, and are suited for high shock and vibration applications. The unique package design of these crystal oscillators offers a small ceramic package footprint, as well as providing both through-hole mounting and surface mount options.

Patterson, Richard↗

Characterization of the Vectron PX-570 Crystal Oscillator for Use in Harsh Environments

Computing hardware, data-acquisition systems, communications systems, and many electronic control systems require well-controlled timing signals for proper and accurate operation. These signals are, in most cases, provided by circuits that employ crystal oscillators due to availability, cost, ease of operation, and accuracy. In some cases, the electronic systems are expected to survive and operate under harsh conditions that include exposure to extreme temperatures. These applications exist in terrestrial systems as well as in aerospace products. Well-logging, geothermal systems, and industrial process control are examples of ground-based applications, while distributed jet engine control in aircraft, space-based observatories (such as the James Webb Space Telescope), satellites, and lunar and planetary landers are typical environments where electronics are exposed to harsh operating conditions. To ensure these devices produce reliable results, the digital heartbeat from the oscillator must deliver a stable signal that is not affected by external temperature or other conditions. One such solution is a recently introduced commercial-off-the-shelf (COTS) oscillator, the PX-570 series from Vectron International. The oscillator was designed for high-temperature applications and as proof, the crystal oscillator was subjected to a wide suite of tests to determine its ruggedness for operation in harsh environments. The tests performed by Vectron included electrical characterization under wide range of temperature, accelerated life test/aging, shock and vibration, internal moisture analysis, ESD threshold, and latch-up testing. The parametric evaluation was performed on the oscillator's frequency, output signal rise and fall times, duty cycle, and supply current over the temperature range of -125 C to +230 C. The evaluations also determined the effects of thermal cycling and the oscillator's re-start capability at extreme hot and cold temperatures. These thermal cycling and restart tests were performed at the NASA Glenn Research Center. Overall, the crystal oscillator performed well and demonstrated very good frequency stability. This paper will discuss the test procedures and present details of the performance results.

Li, Jacob↗

Packaging Technology for SiC High Temperature Circuits Operable up to 500 Degrees Centigrade

New high temperature low power 8-pin packages have been fabricated using commercial fabrication service. These packages are made of aluminum nitride and 96 percent alumina with Au metallization. The new design of these packages provides the chips inside with EM shielding. Wirebond geometry control has been achieved for precise mechanical tests. Au wirebond samples with 45 degree heel-angle have been tested using wireloop test module. The geometry control improves the consistency of measurement of the wireloop breaking point.Also reported on is a parametric study of the thermomechanical reliability of a Au thick-film based SiC die-attach assembly using nonlinear finite element analysis (FEA) was conducted to optimize the die-attach thermo-mechanical performance for operation at temperatures from room temperature to 500 degrees Centigrade. This parametric study centered on material selection, structure design and process control.

Chen, Lian-Yu↗

Spatial Scaling of Snow Observations and Microwave Emission Modeling During CLPX and Appropriate Satellite Sensor Resolution

Accurate estimates of snow water equivalent and other properties play an important role in weather, natural hazard, and hydrological forecasting and climate modeling over a range of scales in space and time. Remote sensing-derived estimates have traditionally been of the "snapshot" type, but techniques involving models with assimilation are also being explored. In both cases, forward emission models are useful to understand the observed passive microwave signatures and developing retrieval algorithms. However, mismatches between passive microwave sensor resolutions and the scales of processes controlling subpixel heterogeneity can affect the accuracy of the estimates. Improving the spatial resolution of new passive microwave satellite sensors is a major desire in order to (literally) resolve such subpixel heterogeneity, but limited spacecraft and mission resources impose severe constraints and tradeoffs. In order to maximize science return while mitigating risk for a satellite concept, it is essential to understand the scaling behavior of snow in terms of what the sensor sees (brightness temperature) as well as in terms of the actual variability of snow. NASA's Cold Land Processes Experiment-1 (CLPX-1: Colorado, 2002 and 2003) was designed to provide data to measure these scaling behaviors for varying snow conditions in areas with forested, alpine, and meadow/pasture land cover. We will use observations from CLPX-1 ground, airborne, and satellite passive microwave sensors to examine and evaluate the scaling behavior of observed and modeled brightness temperatures and observed and retrieved snow parameters across scales from meters to 10's of kilometers. The conclusions will provide direct examples of the appropriate spatial sampling scales of new sensors for snow remote sensing. The analyses will also illustrate the effects and spatial scales of the underlying phenomena (e.g., land cover) that control subpixel heterogeneity.

Kim, Edward J.↗