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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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At least 631 records · Page 35
All sourcesNASA NTRSDOE OSTI
NASA NTRS2009

Reliability Centered Maintenance - Methodologies

Journal article about Reliability Centered Maintenance (RCM) methodologies used by United Space Alliance, LLC (USA) in support of the Space Shuttle Program at Kennedy Space Center. The USA Reliability Centered Maintenance program differs from traditional RCM programs because various methodologies are utilized to take advantage of their respective strengths for each application. Based on operational experience, USA has customized the traditional RCM methodology into a streamlined lean logic path and has implemented the use of statistical tools to drive the process. USA RCM has integrated many of the L6S tools into both RCM methodologies. The tools utilized in the Measure, Analyze, and Improve phases of a Lean Six Sigma project lend themselves to application in the RCM process. All USA RCM methodologies meet the requirements defined in SAE JA 1011, Evaluation Criteria for Reliability-Centered Maintenance (RCM) Processes. The proposed article explores these methodologies.

Kammerer, Catherine C.↗
DOE OSTI2024

High Temperature Copper Metallization: Demand, Hurdles and Reliability

As newer cells structures come online, the pressing need to replace silver in the metallization pastes has renewed interest in alternative technologies employing base metals. Copper typically leads the charge with its abundance and lower cost but has faced numerous obstacles from relatively higher oxidation and diffusion rates which can damage the lifetime of the devices. In this study, a low-cost alternative to silver metallization pastes has been shown on PERC cells. The screen printable copper paste can be fired in air at temperatures >500 degrees C, and the impact of processing conditions and equipment on the performance and reliability of 274 cm2 cells have been evaluated. Through damp heat testing of micro-modules using 16 cm2 cells, routes that can lead to both the failure and success of durable contacts have been demonstrated.

copper↗
NASA NTRSDate not supplied

A Novel RF Architecture for Simultaneous Communication, Navigation, and Remote Sensing with Software-Defined Radio

The rapid growth of SmallSat and CubeSat missions at NASA has necessitated a re-evaluation of communication and remote-sensing architectures. Novel designs for CubeSat-sized single-board computers can now include larger Field-Programmable Gate Arrays (FPGAs) and faster System-on-Chip (SoCs) devices. These components substantially improve onboard processing capabilities so that varying subsystems no longer require an independent processor. By replacing individual Radio Frequency (RF) systems with a single software-defined radio (SDR) and processor, mission designers have greater control over reliability, performance, and efficiency. The presented architecture combines individual processing systems into a single design and establishes a modular SDR architecture capable of both remote-sensing and communication applications. This new approach based on a multi-input multi-output (MIMO) SDR features a scalable architecture optimized for Size, Weight, Power, and Cost (SWaP-C), with sufficient noise performance and phase-coherence to enable both remote-sensing and navigation applications, while providing a communication solution for simultaneous S-band and X-band transmission. This SDR design is developed around the NASA CubeSat Card Standard (CS2) that provides the required modularity through simplified backplane and interchangeable options for multiple radiation-hardened/tolerant processors. This architecture provides missions with a single platform for high-rate communication and a future platform to develop cognitive radio systems.

Advanced Avionics, Hybrid Processing, Data Process↗
NASA NTRS1979

Analysis and Evaluation of Processes and Equipment in Tasks 2 and 4 of the Low-cost Solar Array Project

To facilitate the task of objectively comparing competing process options, a methodology was needed for the quantitative evaluation of their relative cost effectiveness. Such a methodology was developed and is described, together with three examples for its application. The criterion for the evaluation is the cost of the energy produced by the system. The method permits the evaluation of competing design options for subsystems, based on the differences in cost and efficiency of the subsystems, assuming comparable reliability and service life, or of competing manufacturing process options for such subsystems, which include solar cells or modules. This process option analysis is based on differences in cost, yield, and conversion efficiency contribution of the process steps considered.

Wolf, M.↗
DOE OSTI2025

Pervaporative Dehydration of 2,3-Butanediol by Dense Poly(vinylidene fluoride) Hollow Fiber Membranes: Parameter Estimation, Process Design, and Technoeconomic Evaluation under Uncertainty

Pervaporation, combined with other separation processes, can effectively remove water from fermentation product streams, making it highly suitable for purifying alcohols like 2,3-butanediol (BDO). In this study, a dense poly(vinylidene fluoride) (PVDF) hollow fiber membrane module prototype was fabricated for BDO dehydration, achieving >0.2 LMH total flux and >95% BDO rejection. With a Markov chain Monte Carlo (MCMC) approach, Bayesian inference was used to quantify the uncertainty of the permeance parameters. A membrane cascade model was developed to scale up a process that purifies a preconcentrated BDO feed (70 wt %) to high purity (90 wt %). Through propagation of the uncertainty of the parameters and sensitivity analyses of the process variables, a cascade design was recommended. Despite data and model limitations, the framework enabled a reliable system analysis and economic evaluation, validated through tight confidence intervals in key process metrics, establishing the foundation for future applications of Bayesian methods in membrane-based processes.

Animal feed↗
NASA NTRS1992

Development of a material processing plant for lunar soil

Currently there is considerable interest in developing in-situ materials processing plants for both the Moon and Mars. Two of the most important aspects of developing such a materials processing plant is the overall system design and the integration of the different technologies into a reliable, lightweight, and cost-effective unit. The concept of an autonomous materials processing plant that is capable of producing useful substances from lunar regolith was developed. In order for such a materials processing plant to be considered as a viable option, it must be totally self-contained, able to operate autonomously, cost effective, light weight, and fault tolerant. In order to assess the impact of different technologies on the overall systems design and integration, a one-half scale model was constructed that is capable of scooping up (or digging) lunar soil, transferring the soil to a solar furnace, heating the soil in the furnace to liberate the gasses, and transferring the spent soil to a 'tile' processing center. All aspects of the control system are handled by a 386 class PC via D/A, A/D, and DSP (Digital Signal Processor) control cards.

Goettsch, Ulix↗
NASA NTRS1997

Hydrogen Transport to Mars Enables the Sabatier/Electrolysis Process

The Sabatier/Electrolysis (S/E) process is an attractive approach to in situ propellant production (ISPP), and a breadboard demonstration of this process at Lockheed Martin Astronautics funded by JPL performed very well, with high conversion efficiency, and reliable diurnal operation. There is a net usage of hydrogen in the S/E process, and this has been the principal problem for this approach to ISPP.

Mueller, P. J.↗
DOE OSTI2026

Flash electropolishing for TEM: Reducing FIB‐induced defects in tungsten with protocols for new materials

Focused ion beam (FIB) milling has become the dominant approach for site-specific transmission electron microscopy (TEM) specimen preparation; however, FIB damage remains a critical limitation for reliable microstructural characterisation, particularly in radiation effects studies. Tungsten is especially susceptible to FIB damage due to its high nuclear stopping power, which promotes the formation and strong diffraction contrast of FIB-induced ‘black spot’ defects that are indistinguishable from very fine irradiation-induced loops/defects resulting from low to intermediate temperature neutron irradiation. In this work, flash electropolishing is systematically evaluated as a post-FIB treatment for minimising preparation-induced artefacts for TEM analysis of tungsten-based alloys. Using a range of non-, ion-, and neutron-irradiated tungsten materials, the effectiveness of flash electropolishing has been assessed through direct comparison with conventional FIB and plasma-FIB preparation including low-energy Ga, Ar, Xe ion cleaning. The results demonstrate that flash electropolishing effectively removes FIB-damaged layers and ‘black spot’ defects, thereby enabling reliable observation of irradiation-induced dislocation structures. Key processing parameters governing flash electropolishing quality – including lamella thickness, applied voltage, polishing duration, electrolyte chemistry, and cathode geometry – have been systematically evaluated, and clear criteria were established for determining when flash electropolishing is required to ensure reliable microstructural analysis. This work also provides practical guidance for implementing flash electropolishing as an artefact-controlled specimen-preparation approach for TEM characterisation of FIB-produced specimens. The systematic protocol can be extended to other, non-tungsten materials.

TEM sample preparation↗
NASA NTRS1998

Reusable Rocket Engine Operability Modeling and Analysis

This paper describes the methodology, model, input data, and analysis results of a reusable launch vehicle engine operability study conducted with the goal of supporting design from an operations perspective. Paralleling performance analyses in schedule and method, this requires the use of metrics in a validated operations model useful for design, sensitivity, and trade studies. Operations analysis in this view is one of several design functions. An operations concept was developed given an engine concept and the predicted operations and maintenance processes incorporated into simulation models. Historical operations data at a level of detail suitable to model objectives were collected, analyzed, and formatted for use with the models, the simulations were run, and results collected and presented. The input data used included scheduled and unscheduled timeline and resource information collected into a Space Transportation System (STS) Space Shuttle Main Engine (SSME) historical launch operations database. Results reflect upon the importance not only of reliable hardware but upon operations and corrective maintenance process improvements.

Christenson, R. L.↗
NASA NTRSDate not supplied

Optical Navigation Attitude Estimation and Calibration Performance Improvement using Outlier Rejection

Spacecraft optical navigation (OpNav) systems process a sequence of images of celestial bodies against a starfield background to estimate the position and velocity of the vehicle. While attitude is sometimes available from an onboard star tracker, it is often desirable to recognize the background stars in the OpNav images to better align the image. While many image processing algorithms exist for finding stars, efficiency and reliability remain key issues in the presence of extended bodies(e.g. the Moon, Earth), especially when attempting to solve the full lost-in-space problem. Some star outliers(stars identified with high residuals)could appear in the camera field of view, however using them in the attitude estimation or camera calibration would lead to less accurate results. Therefore, we require new and robust approaches to remove these outliers before any further processing. The emphasis of the work is on developing a simple and robust iterative technique to detect and reject the outliers which could be found in any frame during the lost in space attitude determination or during the camera calibration. These outliers are determined based on the residuals of the centroids of the detected stars and the corresponding location using the star catalog. If the residuals exceed a predetermined threshold value, the object will be detected as an outlier and will be removed before another attitude determination and calibration iteration is performed. The performance for both attitude determination and on-orbit camera calibration are improved by an almost two-fold increase in accuracy when applying this outlier rejection technique.

OpNav↗
NASA NTRS2015

Evaluation of Case Size 0603 BME Ceramic Capacitors

High volumetric efficiency of commercial base metal electrode (BME) ceramic capacitors allows for a substantial reduction of weight and sizes of the parts compared to currently used military grade precious metal electrode (PME) capacitors. Insertion of BME capacitors in space applications requires a thorough analysis of their performance and reliability. In this work, six types of cases size 0603 BME capacitors from three vendors have been evaluated. Three types of multilayer ceramic capacitors (MLCCs) were designed for automotive industry and three types for general purposes. Leakage currents in the capacitors have been measured in a wide range of voltages and temperatures, and measurements of breakdown voltages (VBR) have been used to assess the proportion and severity of defects in the parts. The effect of soldering-related thermal shock stresses was evaluated by analysis of distributions of VBR for parts in 'as is' condition and after terminal solder dip testing at 350 C. Highly Accelerated Life Testing (HALT) at different temperatures was used to assess the activation energy of degradation of leakage currents and predict behavior of the parts at life test and normal operating conditions. To address issues related to rework and manual soldering, capacitors were soldered onto different substrates at different soldering conditions. The results show that contrary to a common assumption that large-size capacitors are mostly vulnerable to soldering stresses, cracking in small size capacitors does happen unless special measures are taken during assembly processes.

testing↗
DOE OSTI2026

Eutectic Processing of Semiconductor Colloidal Nanocrystals for Energy Applications

Colloidal semiconductor nanocrystals (NCs) offer a costeffective platform for light-energy conversion in X-ray scintillators, photovoltaics, lasers, and display technologies. Yet, device-relevant NCs often require complex heterostructured compositions, where lattice imperfections compromise the efficiency and stability of photoconversion processes. Here, we show that a simple synthetic detour through a eutectic state of II−VI semiconductor NCs (e.g., CdSe, ZnSe) with halide salts (e.g., CdCl 2 , ZnCl 2 ) overcomes this limitation by melting and reconstructing NC lattices into defect-free alloyed and core/shell architectures. Applied to ternary CdSeTe NCs, this process produces downconverters with record brightness and minimal line widths, delivering a 3-fold increase in film-side external quantum efficiency of commercial CdTe photovoltaic modules (First Solar Inc.). Meanwhile, eutectic processing of CdSe-based core/shell emitters yields an 8-fold enhancement in their photoluminescence stability under backlight operation, addressing the reliability bottleneck for display technologies. Together, these findings establish eutectic NC processing as a scalable route to efficient, durable photoconversion materials for energy applications.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2025

MC Formula Protocol for H35HF Fueling (CRADA Final Report)

The National Renewable Energy Lab (NREL), Frontier Energy, and the industry partners worked together to help SAE J2601-5 develop an H35 high-flow (HF) medium-duty (MD) and heavy-duty (HD) fueling protocol. The team upgraded NREL's hydrogen filling simulations (H2FillS) model to accommodate an MC Formula fueling (t-final) table generation capability by leveraging NREL's high-performance computing system. Based on protocol boundary conditions (e.g., allowable maximum flow rate, range of storage system size) set by SAE J2601-5, the team generated the fueling tables and then validated the reliability of those tables by installing them on NREL's HD dispenser and ZBT's H35HF dispenser and then performing H35HF fueling experiments. Through the validation process, this team certified that the fueling tables generated were reliable to install in commercial H35HF dispensers and then performed H35HF fueling of commercial MD/HD vehicles.

08 HYDROGEN↗
NASA NTRS1990

Generation and analysis of large reliability models

An effort has been underway for several years at NASA's Langley Research Center to extend the capability of Markov modeling techniques for reliability analysis to the designers of highly reliable avionic systems. This effort has been focused in the areas of increased model abstraction and increased computational capability. The reliability model generator (RMG), a software tool which uses as input a graphical, object-oriented block diagram of the system, is discussed. RMG uses an automated failure modes-effects analysis algorithm to produce the reliability model from the graphical description. Also considered is the ASSURE software tool, a parallel processing program which uses the ASSIST modeling language and SURE semi-Markov solution technique. An executable failure modes-effects analysis is used by ASSURE. The successful combination of the power of graphical representation, automated model generation, and parallel computation leads to the conclusion that large system architectures can now be analyzed.

Aerospace electronics↗
NASA NTRS1995

Reliability Analysis of Uniaxially Ground Brittle Materials

The fast fracture strength distribution of uniaxially ground, alpha silicon carbide was investigated as a function of grinding angle relative to the principal stress direction in flexure. Both as-ground and ground/annealed surfaces were investigated. The resulting flexural strength distributions were used to verify reliability models and predict the strength distribution of larger plate specimens tested in biaxial flexure. Complete fractography was done on the specimens. Failures occurred from agglomerates, machining cracks, or hybrid flaws that consisted of a machining crack located at a processing agglomerate. Annealing eliminated failures due to machining damage. Reliability analyses were performed using two and three parameter Weibull and Batdorf methodologies. The Weibull size effect was demonstrated for machining flaws. Mixed mode reliability models reasonably predicted the strength distributions of uniaxial flexure and biaxial plate specimens.

Salem, Jonathan A.↗
NASA NTRS1988

Functional description of signal processing in the Rogue GPS receiver

Over the past year, two Rogue GPS prototype receivers have been assembled and successfully subjected to a variety of laboratory and field tests. A functional description is presented of signal processing in the Rogue receiver, tracing the signal from RF input to the output values of group delay, phase, and data bits. The receiver can track up to eight satellites, without time multiplexing among satellites or channels, simultaneously measuring both group delay and phase for each of three channels (L1-C/A, L1-P, L2-P). The Rogue signal processing described requires generation of the code for all three channels. Receiver functional design, which emphasized accuracy, reliability, flexibility, and dynamic capability, is summarized. A detailed functional description of signal processing is presented, including C/A-channel and P-channel processing, carrier-aided averaging of group delays, checks for cycle slips, acquistion, and distinctive features.

Thomas, J. B.↗
NASA NTRS1997

Develop Advanced Nonlinear Signal Analysis Topographical Mapping System

During the development of the SSME, a hierarchy of advanced signal analysis techniques for mechanical signature analysis has been developed by NASA and AI Signal Research Inc. (ASRI) to improve the safety and reliability for Space Shuttle operations. These techniques can process and identify intelligent information hidden in a measured signal which is often unidentifiable using conventional signal analysis methods. Currently, due to the highly interactive processing requirements and the volume of dynamic data involved, detailed diagnostic analysis is being performed manually which requires immense man-hours with extensive human interface. To overcome this manual process, NASA implemented this program to develop an Advanced nonlinear signal Analysis Topographical Mapping System (ATMS) to provide automatic/unsupervised engine diagnostic capabilities. The ATMS will utilize a rule-based Clips expert system to supervise a hierarchy of diagnostic signature analysis techniques in the Advanced Signal Analysis Library (ASAL). ASAL will perform automatic signal processing, archiving, and anomaly detection/identification tasks in order to provide an intelligent and fully automated engine diagnostic capability. The ATMS has been successfully developed under this contract. In summary, the program objectives to design, develop, test and conduct performance evaluation for an automated engine diagnostic system have been successfully achieved. Software implementation of the entire ATMS system on MSFC's OISPS computer has been completed. The significance of the ATMS developed under this program is attributed to the fully automated coherence analysis capability for anomaly detection and identification which can greatly enhance the power and reliability of engine diagnostic evaluation. The results have demonstrated that ATMS can significantly save time and man-hours in performing engine test/flight data analysis and performance evaluation of large volumes of dynamic test data.

Jong, Jen-Yi↗
NASA NTRS1991

Architecture for Survivable System Processing (ASSP)

The Architecture for Survivable System Processing (ASSP) Program is a multi-phase effort to implement Department of Defense (DOD) and commercially developed high-tech hardware, software, and architectures for reliable space avionics and ground based systems. System configuration options provide processing capabilities to address Time Dependent Processing (TDP), Object Dependent Processing (ODP), and Mission Dependent Processing (MDP) requirements through Open System Architecture (OSA) alternatives that allow for the enhancement, incorporation, and capitalization of a broad range of development assets. High technology developments in hardware, software, and networking models, address technology challenges of long processor life times, fault tolerance, reliability, throughput, memories, radiation hardening, size, weight, power (SWAP) and security. Hardware and software design, development, and implementation focus on the interconnectivity/interoperability of an open system architecture and is being developed to apply new technology into practical OSA components. To insure for widely acceptable architecture capable of interfacing with various commercial and military components, this program provides for regular interactions with standardization working groups (e.g.) the International Standards Organization (ISO), American National Standards Institute (ANSI), Society of Automotive Engineers (SAE), and Institute of Electrical and Electronic Engineers (IEEE). Selection of a viable open architecture is based on the widely accepted standards that implement the ISO/OSI Reference Model.

Wood, Richard J.↗