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NASA NTRS2009

Bayes Analysis and Reliability Implications of Stress-Rupture Testing a Kevlar/Epoxy COPV Using Temperature and Pressure Acceleration

Composite Overwrapped Pressure Vessels (COPVs) that have survived a long service time under pressure generally must be recertified before service is extended. Flight certification is dependent on the reliability analysis to quantify the risk of stress rupture failure in existing flight vessels. Full certification of this reliability model would require a statistically significant number of lifetime tests to be performed and is impractical given the cost and limited flight hardware for certification testing purposes. One approach to confirm the reliability model is to perform a stress rupture test on a flight COPV. Currently, testing of such a Kevlar49 (Dupont)/epoxy COPV is nearing completion. The present paper focuses on a Bayesian statistical approach to analyze the possible failure time results of this test and to assess the implications in choosing between possible model parameter values that in the past have had significant uncertainty. The key uncertain parameters in this case are the actual fiber stress ratio at operating pressure, and the Weibull shape parameter for lifetime; the former has been uncertain due to ambiguities in interpreting the original and a duplicate burst test. The latter has been uncertain due to major differences between COPVs in the database and the actual COPVs in service. Any information obtained that clarifies and eliminates uncertainty in these parameters will have a major effect on the predicted reliability of the service COPVs going forward. The key result is that the longer the vessel survives, the more likely the more optimistic stress ratio model is correct. At the time of writing, the resulting effect on predicted future reliability is dramatic, increasing it by about one "nine," that is, reducing the predicted probability of failure by an order of magnitude. However, testing one vessel does not change the uncertainty on the Weibull shape parameter for lifetime since testing several vessels would be necessary.

Phoenix, S. Leigh↗

NASA NTRS1990

Billion shot flashlamp for spaceborne lasers

A billion-shot flashlamp developed under a NASA contract for spaceborne laser missions is presented. Lifetime-limiting mechanisms are identified and addressed. Two energy loadings of 15 and 44 Joules were selected for the initial accelerated life testing. A fluorescence-efficiency test station was used for measuring the useful-light output degradation of the lamps. The design characteristics meeting NASA specifications are outlined. Attention is focused on the physical properties of tungsten-matrix cathodes, the chemistry of dispenser cathodes, and anode degradation. It is reported that out of the total 83 lamps tested in the program, 4 lamps reached a billion shots and one lamp is beyond 1.7 billion shots, while at 44 Joules, 4 lamps went beyond 100 million shots and one lamp reached 500 million shots.

Richter, Linda↗

NASA NTRS1995

Reliability assessment of multiple quantum well avalanche photodiodes

The reliability of doped-barrier AlGaAs/GsAs multi-quantum well avalanche photodiodes fabricated by molecular beam epitaxy is investigated via accelerated life tests. Dark current and breakdown voltage were the parameters monitored. The activation energy of the degradation mechanism and median device lifetime were determined. Device failure probability as a function of time was computed using the lognormal model. Analysis using the electron beam induced current method revealed the degradation to be caused by ionic impurities or contamination in the passivation layer.

Yun, Ilgu↗

NASA NTRS2008

Status of the NEXT Ion Thruster Long-Duration Test After 10,100 hr and 207 kg Demonstrated

The NASA s Evolutionary Xenon Thruster (NEXT) program is developing the next-generation ion propulsion system with significant enhancements beyond the state-of-the-art in ion propulsion to provide future NASA science missions with enhanced mission capabilities at a low total development cost. As part of a comprehensive thruster service life assessment utilizing both testing and analyses, a Long-Duration Test (LDT) was initiated to validate and qualify the NEXT propellant throughput capability to a qualification-level of 450 kg, 1.5 times the mission-derived throughput requirement of 300 kg. This wear test is being conducted with a modified, flight-representative NEXT engineering model ion thruster, designated EM3. As of June 21, 2007, the thruster has accumulated 10,100 hr of operation at the thruster full-input-power of 6.9 kW with 3.52 A beam current and 1800 V beam power supply voltage. The thruster has processed 207 kg of xenon and demonstrated a total impulse of 8.5 106 N-s; the highest total impulse ever demonstrated by an ion thruster in the history of space propulsion. Thruster performance tests are conducted periodically over the entire NEXT throttle table with input power ranging 0.5 to 6.9 kW. Overall ion thruster performance parameters including thrust, input power, specific impulse, and thruster efficiency have been nominal with little variation to date. Lifetime-limiting component erosion rates have been consistent with the NEXT service life assessment, which predicts the earliest failure sometime after 750 kg of xenon propellant throughput; well beyond the mission-derived lifetime requirement. The NEXT wear test data confirm that the erosion of the discharge keeper orifice, enlarging of nominal-current-density accelerator grid aperture cusps, and the decrease in cold grid-gap observed during the NSTAR Extended Life Test have been mitigated. This paper presents the status of the NEXT LDT to date.

Herman, Daniel A.↗

NASA NTRS2009

NEXT Long-Duration Test After 11,570 h and 237 kg of Xenon Processed

The NASA s Evolutionary Xenon Thruster (NEXT) program is developing the next-generation ion propulsion system with significant enhancements beyond the state-of-the-art in ion propulsion to provide future NASA science missions with enhanced mission capabilities at a low total development cost. As part of a comprehensive thruster service life assessment utilizing both testing and analyses, a Long-Duration Test (LDT) was initiated to validate and qualify the NEXT propellant throughput capability to a qualification-level of 450 kg, 1.5 times the mission-derived throughput requirement of 300 kg. This wear test is being conducted with a modified, flight-representative NEXT engineering model ion thruster, designated EM3. As of September 1, 2007, the thruster has accumulated 11,570 h of operation primarily at the thruster full-input-power of 6.9 kW with 3.52 A beam current and 1800 V beam power supply voltage. The thruster has processed 237 kg of xenon surpassing the NSTAR propellant throughput demonstrated during the extended life testing of the Deep Space 1 (DS1) flight spare. The NEXT LDT has demonstrated a total impulse of 9.78 10(exp 6) N(dot)s; the highest total impulse ever demonstrated by an ion thruster. Thruster performance tests are conducted periodically over the entire NEXT throttle table with input power ranging 0.5 to 6.9 kW. Thruster performance parameters including thrust, input power, specific impulse, and thruster efficiency have been nominal with little variation to date. Lifetime-limiting component erosion rates have been consistent with the NEXT service life assessment, which predicts the earliest failure sometime after 750 kg of xenon propellant throughput; well beyond the mission-derived lifetime requirement. The NEXT wear test data confirm that the erosion of the discharge keeper orifice, enlarging of nominal-current-density accelerator grid aperture cusps at full-power, and the decrease in cold grid-gap observed during NSTAR wear testing have been mitigated in the NEXT design. NEXT grid-gap data indicate a hot grid-gap at full-power that is 60 percent of the nominal cold grid-gap. This paper presents the status of the NEXT LDT to date with emphasis on comparison to the NSTAR extended life test results.

Soulas, George C.↗

NASA NTRS2011

Composite Overwrapped Pressure Vessels (COPV): Flight Rationale for the Space Shuttle Program

Each Orbiter Vehicle (Space Shuttle Program) contains up to 24 Kevlar49/Epoxy Composite Overwrapped Pressure Vessels (COPV) for storage of pressurized gases. In the wake of the Columbia accident and the ensuing Return To Flight (RTF) activities, Orbiter engineers reexamined COPV flight certification. The original COPV design calculations were updated to include recently declassified Kevlar COPV test data from Lawrence Livermore National Laboratory (LLNL) and to incorporate changes in how the Space Shuttle was operated as opposed to orinigially envisioned. 2005 estimates for the probability of a catastrophic failure over the life of the program (from STS-1 through STS-107) were one-in-five. To address this unacceptable risk, the Orbiter Project Office (OPO) initiated a comprehensive investigation to understand and mitigate this risk. First, the team considered and eventually deemed unfeasible procuring and replacing all existing flight COPVs. OPO replaced the two vessels with the highest risk with existing flight spare units. Second, OPO instituted operational improvements in ground procedures to signficiantly reduce risk, without adversely affecting Shuttle capability. Third, OPO developed a comprehensive model to quantify the likelihood of occurrance. A fully-instrumented burst test (recording a lower burst pressure than expected) on a flight-certified vessel provided critical understanding of the behavior of Orbiter COPVs. A more accurate model was based on a newly-compiled comprehensive database of Kevlar data from LLNL and elsewhere. Considering hardware changes, operational improvements and reliability model refinements, the mean reliability was determined to be 0.998 for the remainder of the Shuttle Program (from 2007, for STS- 118 thru STS-135). Since limited hardware resources precluded full model validation through multiple tests, additional model confidence was sought through the first-ever Accelerated Stress Rupture Test (ASRT) of a flown flight article. A Bayesian statistical approach was developed to interpret possible test results. Since the lifetime observed in the ASRT exceeded initial estimates by one to two orders of magnitude, the Space Shuttle Program deemed there was significant conservatism in the model and accepted continued operation with existing flight hardware. Given the variability in tank-to-tank original prooftest response, a non-destructive evaluation (NDE) technique utilizing Raman Spectroscopy was developed to directly measure COPV residual stress state. Preliminary results showed that patterns of low fiber elastic strains over the outside vessel surface, together with measured permanent volume growth during proof, could be directly correlated to increased fiber stress ratios on the inside fibers adjacent to the liner, and thus reduced reliability.

Kezirian, Michael T.↗

DOE OSTI2026

Experimental Demonstration of a Two-Dimensional Nonlinear Integrable System in a Particle Accelerator

A two-dimensional nonlinear integrable system was experimentally demonstrated at the Fermilab Integrable Optics Test Accelerator. The system was implemented by inserting a special nonlinear magnet in a conventional accelerator lattice. We characterized the system by measuring lifetimes, transverse profiles and transverse oscillation frequencies of the 150-MeV electron beam as a function of the strength of the nonlinear insert. The measured shift of the working point and the amplitude-dependent detuning were consistent with theoretical predictions. We also observed the predicted bifurcation of the stable closed orbit. A striking consequence of the system's implementation was the possibility to operate the storage ring with integer tunes without lifetime degradation. This research opens up novel ways to design particle accelerators and to stabilize particle beams.

Wieland, John [Fermilab] (ORCID:0000000289718523)↗

NASA NTRS2004

Numerical Modeling and Testing of an Inductively-Driven and High-Energy Pulsed Plasma Thrusters

Pulsed Plasma Thrusters (PPTs) are advanced electric space propulsion devices that are characterized by simplicity and robustness. They suffer, however, from low thrust efficiencies. This summer, two approaches to improve the thrust efficiency of PPTs will be investigated through both numerical modeling and experimental testing. The first approach, an inductively-driven PPT, uses a double-ignition circuit to fire two PPTs in succession. This effectively changes the PPTs configuration from an LRC circuit to an LR circuit. The LR circuit is expected to provide better impedance matching and improving the efficiency of the energy transfer to the plasma. An added benefit of the LR circuit is an exponential decay of the current, whereas a traditional PPT s under damped LRC circuit experiences the characteristic "ringing" of its current. The exponential decay may provide improved lifetime and sustained electromagnetic acceleration. The second approach, a high-energy PPT, is a traditional PPT with a variable size capacitor bank. This PPT will be simulated and tested at energy levels between 100 and 450 joules in order to investigate the relationship between efficiency and energy level. Arbitrary Coordinate Hydromagnetic (MACH2) code is used. The MACH2 code, designed by the Center for Plasma Theory and Computation at the Air Force Research Laboratory, has been used to gain insight into a variety of plasma problems, including electric plasma thrusters. The goals for this summer include numerical predictions of performance for both the inductively-driven PPT and high-energy PFT, experimental validation of the numerical models, and numerical optimization of the designs. These goals will be met through numerical and experimental investigation of the PPTs current waveforms, mass loss (or ablation), and impulse bit characteristics.

Parma, Brian↗

NASA NTRS1977

Real-time and accelerated outdoor endurance testing of solar cells

Real-time and accelerated outdoor endurance testing was performed on a variety of samples of interest to the National Photovoltaic Conversion Program. The real-time tests were performed at seven different sites and the accelerated tests were performed at one of those sites in the southwestern United States. The purpose of the tests were to help evaluate the lifetime of photovoltaic systems. Three types of samples were tested; transmission samples of possible cover materials, sub-modules constructed using these materials attached to solar cells, and solar cell modules produced by the manufacturers for the ERDA program. Results indicate that suitable cover materials are glass, FEP-A and PFA. Dirt accumulation and cleanability are important factors in the selection of solar cell module covers and encapsulants.

Forestieri, A. F.↗

NASA NTRS1981

Natural sunlight accelerated weathering of photovoltaic modules

Photovoltaic modules are exposed to the equivalent of ten years of sunlight aging in an accelerated exposure testing and evaluation program, the objective being to determine the long-term durability characteristics of flat plate modules in comparatively short periods of time. The modules are illuminated with concentrated sunlight in a large, sun-tracking, Fresnel-reflecting solar concentrator. The effects of the accelerated exposure are assessed by performing periodic visual inspections and electrical measurements. It is found that field-experienced failure modes are duplicated, that acceleration factors of 6x to 8x are readily attainable, and that the test method is feasible as a predictive tool for photovoltaic module lifetime durability.

Zerlaut, G. A.↗

NASA NTRS2010

Application of the NEXT Ion Thruster Lifetime Assessment to Thruster Throttling

Ion thrusters are low thrust, high specific impulse devices with typical operational lifetimes of 10,000 to 30,000 hr over a range of throttling conditions. The NEXT ion thruster is the latest generation of ion thrusters under development. The NEXT ion thruster currently has a qualification level propellant throughput requirement of 450 kg of xenon, which corresponds to roughly 22,000 hr of operation at the highest input power throttling point. This paper will provide a brief review the previous life assessment predictions for various throttling conditions. A further assessment will be presented examining the anticipated accelerator grid hole wall erosion and related electron backstreaming limit. The continued assessment of the NEXT ion thruster indicates that the first failure mode across the throttling range is expected to be in excess of 36,000 hr of operation from charge exchange induced groove erosion. It is at this duration that the groove is predicted to penetrate the accelerator grid possibly resulting in structural failure. Based on these lifetime and mission assessments, a throttling approach is presented for the Long Duration Test to demonstrate NEXT thruster lifetime and validate modeling.

VanNoord, Jonathan L.↗

NASA NTRS1983

Investigation of test methods, material properties and processes for solar cell encapsulants

Low cost encapsulation materials for the Flat Plate Solar Array Program (FSA) are investigated. The goal of the program is to identify, test, evaluate and recommend encapsulation materials and processes for the fabrication of cost effective and long life solar modules. Accelerated aging techniques for module component lifetime studies, investigation of candidate outer cover films and continued evaluation of soil repellant coatings are also included.

Willis, P. B.↗

NASA NTRSDate not supplied

Ground Testing of the MISSE-16 Materials

External spacecraft materials play an important role in satellite protection from the harsh space environment. Research has shown that the physical, chemical, and optical properties of matter change continuously as a result of exposure to solar radiation and aggressive chemical species produced in Earth’s upper atmosphere. Thorough knowledge of the material properties evolution throughout a planned mission lifetime helps to improve the reliability of spacecraft. Moreover, the establishment of correlation factors between true space exposure and accelerated space weather experiments at ground facilities enables accurate prediction of on-orbit material performance based on laboratory-based testing. The presented work aims to evaluate the radiation effects of low Earth orbit (LEO) environment, namely, exposure to the high-energy electrons and atomic oxygen (AO), of heritage and novel spacecraft materials selection. The studied materials represent the “flight duplicates” of samples that are launched as a part of the 16th Materials International Space Station Experiment Flight Facility (MISSE-FF) mission in 2022.

Elena A. Plis↗

NASA NTRS1979

Integral Glass Encapsulation for Solar Arrays

Progress in the development of permanent, integral glass encapsulation of terrestrial solar photovoltaic arrays by electrostatic bonding is reported. Two basic types of electrostatically bonded modules were demonstrated and their reliability proven in accelerated environmental testing. Economic analyses indicate that electrostatic bonding can be a cost effective, practical, and automatable process for large-scale production of arrays with lifetimes of more than 20 years.

Source record↗

NASA NTRS1988

Internal erosion rates of a 10-kW xenon ion thruster

A 30 cm diameter divergent magnetic field ion thruster, developed for mercury operation at 2.7 kW, was modified and operated with xenon propellant at a power level of 10 kW for 567 h to evaluate thruster performance and lifetime. The major differences between this thruster and its baseline configuration were elimination of the three mercury vaporizers, use of a main discharge cathode with a larger orifice, reduction in discharge baffle diameter, and use of an ion accelerating system with larger acceleration grid holes. Grid thickness measurement uncertainties, combined with estimates of the effects of reactive residual facility background gases gave a minimum screen grid lifetime of 7000 h. Discharge cathode orifice erosion rates were measured with three different cathodes with different initial orifice diameters. Three potential problems were identified during the wear test: the upstream side of the discharge baffle eroded at an unacceptable rate; two of the main cathode tubes experienced oxidation, deformation, and failure; and the accelerator grid impingement current was more than an order of magnitude higher than that of the baseline mercury thruster. The charge exchange ion erosion was not quantified in this test. There were no measurable changes in the accelerator grid thickness or the accelerator grid hole diameters.

Rawlin, Vincent K.↗

NASA NTRS1988

Internal erosion rates of a 10-kW xenon ion thruster

A 30 cm diameter divergent magnetic field ion thruster, developed for mercury operation at 2.7 kW, was modified and operated with xenon propellant at a power level of 10 kW for 567 h to evaluate thruster performance and lifetime. The major differences between this thruster and its baseline configuration were elimination of the three mercury vaporizers, use of a main discharge cathode with a larger orifice, reduction in discharge baffle diameter, and use of an ion accelerating system with larger acceleration grid holes. Grid thickness measurement uncertainties, combined with estimates of the effects of reactive residual facility background gases gave a minimum screen grid lifetime of 7000 h. Discharge cathode orifice erosion rates were measured with three different cathodes with different initial orifice diameters. Three potential problems were identified during the wear test: the upstream side of the discharge baffle eroded at an unacceptable rate; two of the main cathode tubes experienced oxidation, deformation, and failure; and the accelerator grid impingement current was more than an order of magnitude higher than that of the baseline mercury thruster. The charge exchange ion eroison was not quantified in this test. There were no measurable changes in the accelerator grid thickness or the accelerator grid hole diameters.

Rawlin, Vincent K.↗

NASA NTRS1979

A model for predicting the wearout lifetime of the LeRC/Hughes 30-cm mercury ion thruster

An investigation of parameters that affect the erosion rates of 30-cm-diameter mercury-ion-thruster components is described. A sputter-erosion model is formulated in terms of the design, operational, and material characteristics of the thruster. The erosion model is applied to the screen electrode, which is assumed to be the life-limiting component of the 30-cm thruster, resulting in a model of wearout lifetime. Results of short-term erosion-rate tests are presented that illustrate the dependence of component wear rates on variables such as discharge voltage, accelerator-grid open-area fraction, ion energy, electrode material, and the partial pressure of facility residual gases such as nitrogen. Test results are compared with wearout rates predicted by the sputter-erosion model.

Beattie, J. R.↗

DOE OSTI2024

Promoting the regulatory acceptance of combined ion and neutron irradiation for material degradation in nuclear reactors

The Advanced Materials and Manufacturing Technologies (AMMT) program within the Department of Energy (DOE) Office of Nuclear Energy has developed its current recommendation for promoting the use of combined ion irradiation and neutron irradiation for the accelerated qualification of materials to be deployed in nuclear reactors. This plan is intended to provide a collaborative path forward that can be adopted by academia, national laboratories, and industry, and has been developed with input from the regulatory research arm of the U.S. Nuclear Regulatory Commission (NRC). To deploy new materials or materials manufactured with new technologies, such as additive manufacturing, materials must be evaluated for reactor-induced degradation from the combination of harsh temperatures, corrosive environments, and radiation fields. However, rapid deployment of materials necessitates accelerated testing methods rather than relying on years of neutron irradiation in a material test reactor. Ion irradiation has demonstrated success in reproducing material microstructure and select property evolution resulting from neutron irradiation with three to four orders of magnitude reduction in time and cost, making it an ideal candidate for accelerated irradiation testing. This presentation provides context governing both the scientific and regulatory aspects of the proposed goal. The discussion is aimed at a broad audience including researchers from industry, national laboratories, and academia. The recommended path forward is presented as a conceptual framework of specific steps. In brief, the strategy entails developing an integrated ion and neutron irradiation test plan for the material property of interest based on the fundamental tenet of the linkage of microstructure and properties in materials. Physics-based modeling interprets ion irradiation data and predicts neutron irradiation microstructure and properties with uncertainty bounds. The first round of testing is sufficient for an initial licensing application using a risk-informed approach, while a minimum required neutron irradiation test plan reduces cost and time requirements. A surveillance program with witness specimens in-reactor provides additional data over time to improve model predictions to higher damage levels and further reduce uncertainty bounds, which can be used for license extensions or longer lifetimes in new license applications.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗