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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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NASA NTRS1998

JPL Global GPS Network

The research described in this viewgraph was carried out by the Jet Propulsion Laboratory (JPL), California Institute of Technology, under a contract with the National Aeronautics and Space Administration (NASA). JPL currently operates more than 55 permanent, continuously operating GPS ground stations for NASA many in conjunction with international and regional agencies. The data are automatically uploaded from the remote stations, processed, and distributed, with a high degree of reliability.

Moore, A. W.↗

NASA NTRS2000

A Boundary Scan Test Vehicle for Direct Chip Attach Testing

To facilitate the new faster, better and cheaper spacecraft designs, smaller more mass efficient avionics and instruments are using higher density electronic packaging technologies such as direct chip attach (DCA). For space flight applications, these technologies need to have demonstrated reliability and reasonably well defined fabrication and assembly processes before they will be accepted as baseline designs in new missions. As electronics shrink in size, not only can repair be more difficult, but 49 probing" circuitry can be very risky and it becomes increasingly more difficult to identify the specific source of a problem. To test and monitor these new technologies, the Direct Chip Attach Task, under NASA's Electronic Parts and Packaging Program (NEPP), chose the test methodology of boundary scan testing. The boundary scan methodology was developed for interconnect integrity and functional testing at hard to access electrical nodes. With boundary scan testing, active devices are used and failures can be identified to the specific device and lead. This technology permits the incorporation of "built in test" into almost any circuit and thus gives detailed test access to the highly integrated electronic assemblies. This presentation will describe boundary scan, discuss the development of the boundary scan test vehicle for DCA and current plans for testing of direct chip attach configurations.

Parsons, Heather A.↗

NASA NTRS2001

UNIPASS for AvSP? A Broader View

UNIPASS is a general-purpose probabilistic computer program consisting of three major modules, including preprocessor, solver and postprocessor. UNIPASS contains a user-friendly Graphical User Interface (GUI), numerous state-of-the-art probabilistic analysis techniques, a large library of statistical distributions and a function module with a large library of support functions that can easily define any complex limit-state function in a scripting FORTRAN-like syntax format. Its inverse probability analysis and sensitivities analysis capabilities make it a powerful design aid in any product cycle. Its precise numerical analysis engine is accurate enough to push the failure probabilities of a design to well below 10 (exp -50). UNIPASS is equipped with advanced artificial intelligence that is designed to handle systems with an essentially unlimited number of random variables with ease and efficiency. Its modular arrangement allows you to tailor an analysis to the desired level of accuracy and efficiency. The depth and comprehensiveness of UNIPASS are built upon the decades of experience and expertise of industry leaders including Boeing Aircraft, NASA and the DoD. Its rich content also makes UNIPASS a valuable instructional tool for random processes and probabilistic mechanics. The topics include: 1) Reliability in AvSP; 2) Role of UNIPASS in AvSP; and 3) Examples. This paper is in viewgraph form.

Wu, N. Eva↗

NASA NTRS1999

Design Tool Developed for Probabilistic Modeling of Ceramic Matrix Composite Strength

Ceramic matrix composites are being evaluated as candidate materials for many high temperature applications such as engine combustor liners for the High-Speed Civil Transport (HSCT). They are required to have an assured life of several thousand hours. Estimating the reliability of these components is quite a complex process and requires knowledge of the uncertainties that occur at various scales. The properties of ceramic matrix composites (CMC) are known to display a considerable amount of scatter due to variations in fiber/matrix properties, interphase/coating properties, bonding, amount of matrix voids, and many geometry- and fabrication-related parameters such as ply thickness and ply orientations. The objective of this research effort is to account for these uncertainties in a formal way by probabilistically analyzing both the stiffness- and strength related properties of CMC's. In current deterministic approaches, uncertainties are usually accounted for by safety factors. This approach often yields overly conservative designs, thereby reducing the potential of many advanced composite materials.

Murthy, Pappu L. N.↗

NASA NTRS2009

Measurement Variability of Vertical Scanning Interferometry Tool Used for Orbiter Window Defect Assessment

The ability to sufficiently measure orbiter window defects to allow for window recertification has been an ongoing challenge for the orbiter vehicle program. The recent Columbia accident has forced even tighter constraints on the criteria that must be met in order to recertify windows for flight. As a result, new techniques are being investigated to improve the reliability, accuracy and resolution of the defect detection process. The methodology devised in this work, which is based on the utilization of a vertical scanning interferometric (VSI) tool, shows great promise for meeting the ever increasing requirements for defect detection. This methodology has the potential of a 10-100 fold greater resolution of the true defect depth than can be obtained from the currently employed micrometer based methodology. An added benefit is that it also produces a digital elevation map of the defect, thereby providing information about the defect morphology which can be utilized to ascertain the type of debris that induced the damage. However, in order to successfully implement such a tool, a greater understanding of the resolution capability and measurement repeatability must be obtained. This work focused on assessing the variability of the VSI-based measurement methodology and revealed that the VSI measurement tool was more repeatable and more precise than the current micrometer based approach, even in situations where operator variation could affect the measurement. The analysis also showed that the VSI technique was relatively insensitive to the hardware and software settings employed, making the technique extremely robust and desirable

Padula, Santo, II↗

NASA NTRS2010

Space Shuttle Reusable Solid Rocket Motor

RSRM is a highly reliable human-rated Solid Rocket Motor: a) Largest diameter SRM to achieve flight status; b) Only human-rated SRM. RSRM reliability achieved by: a)Applying special attention to Process Control, Testing, and Postflight; b) Communicating often; c) Identifying and addressing issues in a disciplined approach; d) Identifying and fully dispositioning "out-of-family" conditions; e) Addressing minority opinions; and f) Learning our lessons.

Moore, Dennis↗

NASA NTRS2014

Facility Systems, Ground Support Systems, and Ground Support Equipment General Design Requirements

This standard establishes requirements and guidance for design and fabrication of ground systems (GS) that includes: ground support equipment (GSE), ground support systems (GSS), and facility ground support systems (F GSS) to provide uniform methods and processes for design and development of robust, safe, reliable, maintainable, supportable, and cost-effective GS in support of space flight and institutional programs and projects.

Ground Support Equipment↗

NASA NTRS2014

Additive Manufacturing: Ensuring Quality for Spacecraft Applications

Reliable manufacturing requires that material properties and fabrication processes be well defined in order to insure that the manufactured parts meet specified requirements. While this issue is now relatively straightforward for traditional processes such as subtractive manufacturing and injection molding, this capability is still evolving for AM products. Hence, one of the principal challenges within AM is in qualifying and verifying source material properties and process control. This issue is particularly critical for applications in harsh environments and demanding applications, such as spacecraft.

Additive Manufacturing↗

NASA NTRS2015

Infusing Reliability Techniques into Software Safety Analysis

Software safety analysis for a large software intensive system is always a challenge. Software safety practitioners need to ensure that software related hazards are completely identified, controlled, and tracked. This paper discusses in detail how to incorporate the traditional reliability techniques into the entire software safety analysis process. In addition, this paper addresses how information can be effectively shared between the various practitioners involved in the software safety analyses. The author has successfully applied the approach to several aerospace applications. Examples are provided to illustrate the key steps of the proposed approach.

FTA↗

NASA NTRS2018

Upgrades to the International Space Station Water Processor Assembly

The International Space Station Water Processor Assembly provides contaminant control and deionization to the Water Recovery System. The Water Processor Assembly presently utilizes sorbent-based Multifiltration Beds and a downstream Catalytic Reactor for these operations. Upgrades and process improvements are desired to improve performance, increase reliability, and decrease consumable resupply. To this end, reverse osmosis membrane separation technologies were evaluated to reduce influent contaminant loads, candidate additives to inhibit wastewater biofilm formation were studied, and life stability testing was completed for a recently developed high-activity catalyst. Evaluation of an adsorption media integration concept was also completed. The performance and applicability of these new technologies within the Water Processor Assembly, as well as their suitability for exploration missions, are discussed herein.

Kayatin, Matthew J.↗

NASA NTRS1994

Status of Hollow Cathode Heater Development for the Space Station Plasma Contactor

A hollow cathode-based plasma contactor has been selected for use on the Space Station. During the operation of the plasma contactor, the hollow cathode heater will endure approximately 12000 thermal cycles. Since a hollow cathode heater failure would result in a plasma contactor failure, a hollow cathode heater development program was established to produce a reliable heater. The development program includes the heater design, process documents for both heater fabrication and assembly, and heater testing. The heater design was a modification of a sheathed ion thruster cathode heater. Heater tests included testing of the heater unit alone and plasma contactor and ion thruster testing. To date, eight heaters have been or are being processed through heater unit testing, two through plasma contactor testing and three through ion thruster testing, all using direct current power supplies. Comparisons of data from heater unit performance tests before cyclic testing, plasma contactor tests, and ion thruster tests at the ignition input current level show the average deviation of input power and tube temperature near the cathode tip to be +/-0.9 W and +/- 21 C, respectively. Heater unit testing included cyclic testing to evaluate reliability under thermal cycling. The first heater, although damaged during assembly, completed 5985 ignition cycles before failing. Four additional heaters successfully completed 6300, 6300, 700, and 700 cycles. Heater unit testing is currently ongoing for three heaters which have to date accumulated greater than 7250, greater than 5500, and greater than 5500 cycles, respectively.

Soulas, George C.↗

NASA NTRS1972

Survey of current component reliability problems and methods for prevention.

The current reliability problems related to electronic components and microcircuits are presented in this paper. Specific process controls, design, materials, application constraints, destructive testing, electrical tests, and procedures for implementation are recommended to improve the reliability of selected electronic components.

Hamiter, L.↗

NASA NTRS2011

Solid Rocket Booster (SRB) - Evolution and Lessons Learned During the Shuttle Program

The Solid Rocket Booster (SRB) element integrates all the subsystems needed for ascent flight, entry, and recovery of the combined Booster and Motor system. These include the structures, avionics, thrust vector control, pyrotechnic, range safety, deceleration, thermal protection, and retrieval systems. This represents the only human-rated, recoverable and refurbishable solid rocket ever developed and flown. Challenges included subsystem integration, thermal environments and severe loads (including water impact), sometimes resulting in hardware attrition. Several of the subsystems evolved during the program through design changes. These included the thermal protection system, range safety system, parachute/recovery system, and others. Obsolescence issues occasionally required component recertification. Because the system was recovered, the SRB was ideal for data and imagery acquisition, which proved essential for understanding loads and system response. The three main parachutes that lower the SRBs to the ocean are the largest parachutes ever designed, and the SRBs are the largest structures ever to be lowered by parachutes. SRB recovery from the ocean was a unique process and represented a significant operational challenge; requiring personnel, facilities, transportation, and ground support equipment. The SRB element achieved reliability via extensive system testing and checkout, redundancy management, and a thorough postflight assessment process. Assembly and integration of the booster subsystems was a unique process and acceptance testing of reused hardware components was required for each build. Extensive testing was done to assure hardware functionality at each level of stage integration. Because the booster element is recoverable, subsystems were available for inspection and testing postflight, unique to the Shuttle launch vehicle. Problems were noted and corrective actions were implemented as needed. The postflight assessment process was quite detailed and a significant portion of flight operations. The SRBs provided fully redundant critical systems including thrust vector control, mission critical pyrotechnics, avionics, and parachute recovery system. The design intent was to lift off with full redundancy. On occasion, the redundancy management scheme was needed during flight operations. This paper describes some of the design challenges, how the design evolved with time, and key areas where hardware reusability contributed to improved system level understanding.

Kanner, Howard S.↗

NASA NTRS2011

Solid Rocket Booster (SRB) Flight System Integration at Its Best

The Solid Rocket Booster (SRB) element integrates all the subsystems needed for ascent flight, entry, and recovery of the combined Booster and Motor system. These include the structures, avionics, thrust vector control, pyrotechnic, range safety, deceleration, thermal protection, and retrieval systems. This represents the only human-rated, recoverable and refurbishable solid rocket ever developed and flown. Challenges included subsystem integration, thermal environments and severe loads (including water impact), sometimes resulting in hardware attrition. Several of the subsystems evolved during the program through design changes. These included the thermal protection system, range safety system, parachute/recovery system, and others. Because the system was recovered, the SRB was ideal for data and imagery acquisition, which proved essential for understanding loads, environments and system response. The three main parachutes that lower the SRBs to the ocean are the largest parachutes ever designed, and the SRBs are the largest structures ever to be lowered by parachutes. SRB recovery from the ocean was a unique process and represented a significant operational challenge; requiring personnel, facilities, transportation, and ground support equipment. The SRB element achieved reliability via extensive system testing and checkout, redundancy management, and a thorough postflight assessment process. However, the in-flight data and postflight assessment process revealed the hardware was affected much more strongly than originally anticipated. Assembly and integration of the booster subsystems required acceptance testing of reused hardware components for each build. Extensive testing was done to assure hardware functionality at each level of stage integration. Because the booster element is recoverable, subsystems were available for inspection and testing postflight, unique to the Shuttle launch vehicle. Problems were noted and corrective actions were implemented as needed. The postflight assessment process was quite detailed and a significant portion of flight operations. The SRBs provided fully redundant critical systems including thrust vector control, mission critical pyrotechnics, avionics, and parachute recovery system. The design intent was to lift off with full redundancy. On occasion, the redundancy management scheme was needed during flight operations. This paper describes some of the design challenges and technical issues, how the design evolved with time, and key areas where hardware reusability contributed to improved system level understanding.

Wood, T. David↗

NASA NTRS1994

Advances in polycrystalline thin-film photovoltaics for space applications

Polycrystalline, thin-film photovoltaics represent one of the few (if not the only) renewable power sources which has the potential to satisfy the demanding technical requirements for future space applications. The demand in space is for deployable, flexible arrays with high power-to-weight ratios and long-term stability (15-20 years). In addition, there is also the demand that these arrays be produced by scalable, low-cost, high yield, processes. An approach to significantly reduce costs and increase reliability is to interconnect individual cells series via monolithic integration. Both CIS and CdTe semiconductor films are optimum absorber materials for thin-film n-p heterojunction solar cells, having band gaps between 0.9-1.5 ev and demonstrated small area efficiencies, with cadmium sulfide window layers, above 16.5 percent. Both CIS and CdTe polycrystalline thin-film cells have been produced on a laboratory scale by a variety of physical and chemical deposition methods, including evaporation, sputtering, and electrodeposition. Translating laboratory processes which yield these high efficiency, small area cells into the design of a manufacturing process capable of producing 1-sq ft modules, however, requires a quantitative understanding of each individual step in the process and its (each step) effect on overall module performance. With a proper quantification and understanding of material transport and reactivity for each individual step, manufacturing process can be designed that is not 'reactor-specific' and can be controlled intelligently with the design parameters of the process. The objective of this paper is to present an overview of the current efforts at MMC to develop large-scale manufacturing processes for both CIS and CdTe thin-film polycrystalline modules. CIS cells/modules are fabricated in a 'substrate configuration' by physical vapor deposition techniques and CdTe cells/modules are fabricated in a 'superstrate configuration' by wet chemical methods. Both laser and mechanical scribing operations are used to monolithically integrate (series interconnect) the individual cells into modules. Results will be presented at the cell and module development levels with a brief description of the test methods used to qualify these devices for space applications. The approach and development efforts are directed towards large-scale manufacturability of established thin-film, polycrystalline processing methods for large area modules with less emphasis on maximizing small area efficiencies.

Lanning, Bruce R.↗

NASA NTRS2002

3-D Flow Field Diagnostics and Validation Studies using Stereoscopic Tracking Velocimetry

The measurement of 3-D three-component velocity fields is of great importance in both ground and space experiments for understanding materials processing and fluid physics. Here, we present the investigation results of stereoscopic tracking velocimetry (STV) for measuring 3-D velocity fields. The effort includes diagnostic technology development, experimental velocity measurement, and comparison with analytical and numerical computation. The advantages of STV stems from the system simplicity for building compact hardware and in software efficiency for continual near-real-time process monitoring. It also has illumination flexibility for observing volumetric flow fields from arbitrary directions. STV is based on stereoscopic CCD observations of particles seeded in a flow. Neural networks are used for data analysis. The developed diagnostic tool is tested with a simple directional solidification apparatus using Succinonitrile. The 3-D velocity field in the liquid phase is measured and compared with results from detailed numerical computations. Our theoretical, numerical, and experimental effort has shown STV to be a viable candidate for reliably quantifying the 3-D flow field in materials processing and fluids experiments.

Cha, Soyoung Stephen↗

NASA NTRS2015

Reliability and Probabilistic Risk Assessment - How They Play Together

Since the Space Shuttle Challenger accident in 1986, NASA has extensively used probabilistic analysis methods to assess, understand, and communicate the risk of space launch vehicles. Probabilistic Risk Assessment (PRA), used in the nuclear industry, is one of the probabilistic analysis methods NASA utilizes to assess Loss of Mission (LOM) and Loss of Crew (LOC) risk for launch vehicles. PRA is a system scenario based risk assessment that uses a combination of fault trees, event trees, event sequence diagrams, and probability distributions to analyze the risk of a system, a process, or an activity. It is a process designed to answer three basic questions: 1) what can go wrong that would lead to loss or degraded performance (i.e., scenarios involving undesired consequences of interest), 2) how likely is it (probabilities), and 3) what is the severity of the degradation (consequences). Since the Challenger accident, PRA has been used in supporting decisions regarding safety upgrades for launch vehicles. Another area that was given a lot of emphasis at NASA after the Challenger accident is reliability engineering. Reliability engineering has been a critical design function at NASA since the early Apollo days. However, after the Challenger accident, quantitative reliability analysis and reliability predictions were given more scrutiny because of their importance in understanding failure mechanism and quantifying the probability of failure, which are key elements in resolving technical issues, performing design trades, and implementing design improvements. Although PRA and reliability are both probabilistic in nature and, in some cases, use the same tools, they are two different activities. Specifically, reliability engineering is a broad design discipline that deals with loss of function and helps understand failure mechanism and improve component and system design. PRA is a system scenario based risk assessment process intended to assess the risk scenarios that could lead to a major/top undesirable system event, and to identify those scenarios that are high-risk drivers. PRA output is critical to support risk informed decisions concerning system design. This paper describes the PRA process and the reliability engineering discipline in detail. It discusses their differences and similarities and how they work together as complementary analyses to support the design and risk assessment processes. Lessons learned, applications, and case studies in both areas are also discussed in the paper to demonstrate and explain these differences and similarities.

Safie, Fayssal↗

NASA NTRS2004

Reliability Quantification of the Flexure: A Critical Stirling Convertor Component

Uncertainties in the manufacturing, fabrication process, material behavior, loads, and boundary conditions results in the variation of the stresses and strains induced in the flexures and its fatigue life. Past experience and the test data at material coupon levels revealed a significant amount of scatter of the fatigue life. Owing to these facts, the design of the flexure, using conventional approaches based on safety factor or traditional reliability based on similar equipment considerations does not provide a direct measure of reliability. Additionally, it may not be feasible to run actual long term fatigue tests due to cost and time constraints. Therefore it is difficult to ascertain material fatigue strength limit. The objective of the paper is to present a methodology and quantified results of numerical simulation for the reliability of flexures used in the Stirling convertor for their structural performance. The proposed approach is based on application of finite element analysis method in combination with the random fatigue limit model, which includes uncertainties in material fatigue life. Additionally, sensitivity of fatigue life reliability to the design variables is quantified and its use to develop guidelines to improve design, manufacturing, quality control and inspection design process is described.

Shah, Ashwin R.↗