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At least 811 records · Page 45

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NASA NTRS2017

Evaluation of Strain Measurement Devices for Inflatable Structures

Inflatable structures provide a significant volume savings for future NASA deep space missions. The complexity of these structures, however, provides difficulty for engineers in designing, analyzing, and testing. Common strain measurement systems for metallic parts cannot be used directly on fabrics. New technologies must be developed and tested to accuractly measure the strain of inflatable structures. This paper documents the testing of six candidate strain measurement devices for use on fabrics. The resistance devices tested showed significant hysteresis during creep and cyclic testing. The capacitive device, however, showed excellent results and little-to-no hysteresis. Because of this issue, only two out of the six proposed devices will continue in development. The resulting data and lessons learned from this effort provides direction for continued work to produce a structural health monitoring system for inflatable habitats.

Litteken, Douglas A.↗

NASA NTRS2017

Evaluation of Strain Measurement Devices for Inflatable Structures

Inflatable structures provide a significant volume savings for future NASA deep space missions. The complexity of these structures, however, provides difficulty for engineers in designing, analyzing, and testing. Common strain measurement systems for metallic parts cannot be used directly on fabrics. New technologies must be developed and tested to accurately measure the strain of inflatable structures. This paper documents the testing of six candidate strain measurement devices for use on fabrics. The resistance devices tested showed significant hysteresis during creep and cyclic testing. The capacitive device, however, showed excellent results and little-to-no hysteresis. Because of this issue, only two out of the six proposed devices will continue in development. The resulting data and lessons learned from this effort provides direction for continued work to produce a structural health monitoring system for inflatable habitats.

Litteken, Doug↗

DOE OSTI2020

Changes in SSL Device Efficiency and Optical Performance Under Accelerated Aging Conditions

Lighting application efficiency (LAE) describes the efficient delivery of light from the light source to the lighted task and is viewed as a new frontier—increasing energy savings with solid-state lighting (SSL) technologies. The framework for LAE that is proposed by the U.S. Department of Energy (DOE) consists of four major elements: light source efficiency, optical delivery efficiency, spectral efficiency, and intensity effectiveness. This report focuses on a sampling of the available SSL products that can be broadly defined as having modified spectral output because the method of spectra modification has a significant impact on light source efficiency and long-term optical delivery and spectral efficiencies. This report focused on the changes in light source, optical delivery, and spectral efficiencies that occur during aging of SSL devices. An accelerated stress test (AST) regiment was developed for the devices under test (DUTs) examined in this report to provide insights into how the performance of SSL devices change with aging. The AST protocols demonstrate that the SSL products discussed in this report often reduce light source efficiency to achieve different spectral characteristics. In addition, aging of the optical components (e.g., lenses, solder masks) in SSL devices can produce increased light absorption, which negatively impacts optical delivery efficiency and light source efficiency. The modified spectral outputs of the selected SSL products discussed in this report come in a variety of form factors and achieve enhanced optical performance by using a variety of methods. All of the products examined in this study use mid-power light-emitting diodes (MP-LEDs), although the number, configuration, phosphor content, and light-emitting diode (LED) pump of the MP-LEDs differ. Product MS-1 is a 60-watt (W) replacement A19 lamp with a hermetically sealed glass globe, which contains an embedded optical filter to absorb green and yellow emissions, thereby creating a “sunlike” modified spectrum. Product MS-2 is a 60-W replacement A19 lamp with 30 MP-LEDs, and it uses a violet LED pump, along with green and red phosphor emissions, to produce a “healthy” spectrum. This spectrum omits blue emissions in an effort to reduce melanopic lux. Product MS-3 is an LED module consisting of 21 MP-LEDs that use a violet LED pump, along with blue, green, and red phosphors, to produce a “sunlike” spectrum. Products MS-4 and MS-5 are both 6-inch (in) downlights that use a manual switching mechanism so that users can select application-specific correlated color temperatures before installation. Products MS-4 and MS-5 both contain two LED primaries (2,700 Kelvin [K] and 5,000 K) for spectral tuning. Product MS-4 contains 12 MP-LEDs for each LED primary, and Product MS-5 contains 10 MP-LEDs for each LED primary. This report summarizes the overall findings from up to 8,000 hours (hrs) of AST on the lamp DUTs (Products MS-1 and MS-2); up to 5,000 hrs of AST on the LED light engine DUTs (Product MS-3); and up to 7,000 hrs of AST on the downlight DUTs (Products MS-4 and MS-5). The AST procedures used in this study included a room temperature operational life (RTOL) test, an operational life test conducted at 45 degrees Celsius (°C; 45OL) test, an operational life test conducted at 75°C (75OL), a wet high-temperature operational life test performed at 65°C and 90% relative humidity (6590), and a wet high-temperature operational life test performed at 75°C and 75% relative humidity (7575). The AST procedures used for Products MS-1 and MS-2 were RTOL, 45OL, and 6590. The AST procedures used for Products MS-3, MS-4, and MS-5 were RTOL, 75OL, and 7575. During the ASTs described herein, separate populations of each product (three DUTs in each population for Products MS-1, MS-2, MS-4, and MS-5; four DUTs in each population for Product MS-3) were subjected to power cycling of 1 hr on and 1 hr off. The key findings from this study include the following. Enhanced optical performance came at the cost of reduced light source efficiency for the lamps and light engines examined in this study. The optical filter used to produce a “sunlike” spectrum for Product MS-1 reduced light source efficiency by 26%, from 113 lumens per watt (lm/W) to 85 lm/W. Products MS-2 and MS-3 that used a violet-pumped LED to achieve “healthy” and “sunlike” enhanced optical performance, respectively, suffered the largest reduction in initial light source efficiency (49 lm/W for Product MS-2 and 68 lm/W for Products MS-3) perhaps because of the use of violet LED as the optical pump. Product MS-2 also had the poorest color fidelity because of undersaturation of blues and oversaturation of greens and yellows. Chromaticity maintenance of the products in this study was generally good, with parametric failure only occurring for one product at one AST condition (i.e., Product MS-3 at 7575). The chromaticity shift for Product MS-3 in 7575 test conditions resulted from reduced emissions of the broad green and red phosphors used to mimic sunlight in the 500–750 nanometer (nm) range. As a result of these phosphor emission losses, chromaticity shifted toward the more stable violet-pumped LED and blue phosphor. Although chromaticity maintenance was acceptable for most products tested, different chromaticity shift mechanisms were observed for temperature and humidity tests compared with temperature alone for Products MS-1, MS-2, and MS-3. For Product MS-1, a relative increase in green emissions was observed with humidity, which may indicate humidity-accelerated degradation of the optical filter at green wavelengths (optical delivery efficiency reduction) or degradation of the emitters in the red region (spectral efficiency reduction). The violet-pumped products (i.e., MS-2 and MS-3) exhibited different chromaticity shift behavior in the temperature-humidity environments, with Product MS-2 shifting generally yellow because of photo-induced oxidation of the plastic globe (i.e., a reduction of optical delivery efficiency) and Product MS-3 shifting toward violet and blue emitters because of faster loss of emission from green and red phosphors (i.e., a reduction in spectral efficiency). Because of an initial drop in power consumption, the light source efficiency of downlights (Products MS-4 and MS-5) increased at RTOL throughout the test duration. The light source efficiency initially increased during 75OL until a decay in luminous flux maintenance (LFM) dominated light source efficiency, whereas the light source efficiency decreased for the entire 7575 test duration. It was found that increasing the ambient environment of an SSL device from 25°C to 75°C decreases the LFM by 2.7 to 5.5, depending on design of the SSL device. Adding humidity to the system (75OL to 7575) was found to decrease LFM by another factor of approximately 3.0. A common location of failure was identified for the downlights (Products MS-4 and MS-5) operated in the 7575 environment. This failure abruptly occurred between 3,000 to 5,000 hrs of testing on the film capacitor of the electromagnetic interference (EMI) filter near the diode bridge for 11 of the 12 downlights. It is likely that this failure was caused by a combination of the high electrical voltage across the capacitor, the location of the capacitor near the heat sources (e.g., transformers, diode bridges, power resistors), and the high stress environment of 7575. Longer test times are needed to fully understand the LFM, luminous efficacy changes, and chromaticity shifts for some of the products. Because of the high reliability, light source efficiency, and spectral tuning capabilities of LEDs, the expectations of LAE for SSL products are greatly increased over traditional lighting products. The data gathered in this report begin to provide an understanding of the tradeoffs that current SSL products undergo when optimizing the different efficiency elements of LAE. As discussed in this report, the findings from the tests conducted show that the optimization of spectral efficiency can come at the cost of initial light source efficiency. Furthermore, the introduction of violet LEDs can promote long-term optical delivery efficiency degradation, and the introduction of optical filters or new phosphors can lead to unwanted spectral efficiency changes because the ratio of phosphor emitters changes with aging. The data presented in this report also identified a common failure location in 6-in downlights. The results regarding long-term behavior of the modified spectra devices studied provide valuable information about changes to the light source, spectral, and optical delivery efficiencies as the devices age. This information can be used to improve future SSL designs.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2019

Multi-layer Printing of Complex Antennas Using Aerosol Jet Technology (CRADA NFE-18-07315 Final Report)

This project demonstrated the feasibility of producing multilayer radio-frequency (RF) and microwave-frequency components using aerosol jet additive manufacturing technology. Funded by the U.S. Department of energy, Advanced Manufacturing Office, this effort focused on novel stacked component designs for devices such as antennas, electronic filters, resistive/inductive/capacitive (RLC) components, and transmission lines. Our approach to RF/microwave component fabrication by aerosol jet printing has the potential to reduce component size, improve performance characteristics, and allow devices to be fabricated on non-planar surfaces. Specifically, folded micro-patch antenna designs were fabricated by stacking layers of conductors and dielectrics printed in sequence using Optomec’s aerosol jet technology. ORNL supported the effort by providing design input on printing parameters and characterizing the performance of printed structures. ORNL identified suitable stacked antenna designs, produced finite element models (FEM) in high-frequency simulation software (HFSS), and provided the designs to Optomec for printing. After printing, the devices were tested and characterized at ORNL to determine the frequency response and material characteristics of the printed components. These proof-of-principle devices will provide feedback on printing parameters, optimizations for the FEM models, and a path for more complex multilayer device designs.

42 ENGINEERING↗

NASA NTRS1998

Assembly and Integration of Superconductive Measurement Circuits for a Spaceflight Experiment

Hybrid microelectronics containing both conventional electronic components and high-temperature superconductive films have been designed, fabricated, and tested. The devices operate from room temperature to 75K and perform d.c. four-probe resistance measurements on six superconductive specimens resident on each circuit. Four of these hybrid circuits were incorporated into the Materials In Devices As Superconductors (MIDAS) spaceflight experiment and evaluated over a 90-day period on the Mir space station. Prior to launch, comprehensive testing of the flight circuits was performed to determine the effects of thermal cycling, vibration loads, and long-term operation on circuit performance. This report describes the fabrication and assembly procedures used to produce the hybrid circuits, the techniques used to integrate the circuits into the MIDAS hardware system, and the results of pre-flight evaluations which verified circuit functionality.

Wise, Stephanie A.↗

NASA NTRS1993

Heart Imaging System

Johnson Space Flight Center's device to test astronauts' heart function in microgravity has led to the MultiWire Gamma Camera, which images heart conditions six times faster than conventional devices. Dr. Jeffrey Lacy, who developed the technology as a NASA researcher, later formed Proportional Technologies, Inc. to develop a commercially viable process that would enable use of Tantalum-178 (Ta-178), a radio-pharmaceutical. His company supplies the generator for the radioactive Ta-178 to Xenos Medical Systems, which markets the camera. Ta-178 can only be optimally imaged with the camera. Because the body is subjected to it for only nine minutes, the radiation dose is significantly reduced and the technique can be used more frequently. Ta-178 also enables the camera to be used on pediatric patients who are rarely studied with conventional isotopes because of the high radiation dosage.

Source record↗

DOE OSTI2016

SU-F-T-470: Implementation of a Daily Quality Assurance Phantom for Six Degrees-Of-Freedom Couch Testing

Purpose: To develop a daily quality assurance (QA) device that can test the 6DoF (degrees of freedom) couch repositioning accuracy, prior to SBRT treatment deliveries, with an accuracy of ±0.3 degrees and ±0.3 mm. Methods: A daily QA phantom is designed with a focus on the derived center of projections of its markers, rather than tracking its individual markers one at a time. This approach can be the most favorable to address the intended machining accuracy of the QA phantom and the CBCT spatial resolution limitations, primarily 1 mm min slice thickness, simultaneously. With the current design, ±0.1 mm congruence of the resultant center of gravity of the markers with reference CT (0.6 mm minimum slice thickness) vs CBCT (1.0 mm minimum slice thickness) can be achieved. If successful, the QA device should be qualified to test 6DoF couch performance with a gauged accuracy of ±0.3 degrees/±0.3 mm. Testing is performed for the Varian True Beam 2.0 6DoF system. Results: Once the QA phantom is constructed and tested, agreement of the center of gravity of the reference CT scan and the CBCT scan of ±0.1 mm is achieved. This has translated into a consistent 3D-3D match on the treatment machine, CT vs CBCT, with a repetitive ±0.1 mm variation, thus exceeding our expectations. We have deployed the phantom for daily QA on one of our accelerators, and found that the QA time has increased by only 10 minutes. Conclusion: A 6DoF phantom has been designed (patent pending) and built with a realistic work flow in mind where the daily couch accuracy QA checks taking less than 10 minutes. Current developments include integration with the Varian’s Machine Performance Check consistency module.

60 APPLIED LIFE SCIENCES↗

NASA NTRS1988

The NASA Integrated Test Facility and its impact on flight research

NASA-Ames' Integrated Test Facility (ITF), when completed, will provide ground test facilities for the safe and efficient testing of advanced research aircraft with fully integrated flight control, propulsion systems, structures, and aerodynamic configurations. Flight test risk will be minimized through the reduction of differences between flight and ground test environments; the latter will involve the interfacing of real-time flight simulation with the actual aircraft through a simulation-interface device. The test process and the collection and management of test data will be automated. Attention is given to preliminary ITF results for the X-29 aircraft.

Mackall, D. A.↗

NASA NTRS1992

Forebody flow control on a full-scale F/A-18 aircraft

A full-scale F/A-18 was tested in the 80- by 120-Foot Wind Tunnel at NASA Ames Research Center to measure the effectiveness of pneumatic forebody vortex control devices. By altering the forebody vortex flow, yaw control can be maintained to angles of attack greater than 50 deg. Two forebody vortex control devices were tested: a discrete circular jet and a tangential slot. The tests were conducted for angles of attack between 25 and 50 deg, and angles of sideslip from 0 to +/- 15 deg. The Reynolds number based on wing mean aerodynamic chord ranged from 4.5 x 10 exp 6 to 12.0 x 10 exp 6. The time-averaged side forces and yawing moments, along with both time-averaged and time-dependent pressures on the forebody of the aircraft are presented here for various configurations. Of particular interest was the results that the tangential slot blowing had a greater effect on the yawing moment than the discrete circular jet. Additionally, it was found that blowing very close to the radome apex was not as effective as blowing slightly farther aft on the radome, and that a 16-inch slot was more effective than either an 8- or 48-inch long slot.

Lanser, Wendy R.↗

DOE OSTI2025

Closing the Accuracy Gap in Tandem Photovoltaic Testing: An Accessible and Efficient Spectral Tuning Method Using LED-Based Simulators for Research Laboratories and Industry

Accurate performance calibration of multijunction (MJ) solar cells is critical for advancing this technology toward large-scale terrestrial application, yet existing testing methods developed by photovoltaics calibration laboratories remain prohibitively complex and resource intensive for most research laboratories. Current approaches rely on expensive multisource simulators and/or intricate spectral tuning algorithms, limiting accessibility and hindering standardized comparisons of emerging MJ technologies such as perovskite-based tandems. This paper introduces a streamlined spectral irradiance adjustment method for light-emitting diode (LED)-based solar simulators, which are increasingly adopted in the photovoltaics community due to their versatility and cost-effectiveness. The method we present bins LED channels into groups based on the number of junctions of the MJ photovoltaic device under test (DUT) and their corresponding band gaps and incorporates an automated tuning algorithm that eliminates the need to adjust each channel’s irradiance individually. This tuning algorithm requires the relative spectral responsivities of both the DUT and a broadband reference cell, as well as a calibrated spectroradiometer. Measurement validation across various MJ devices, including III-V and perovskite/silicon tandems, demonstrates excellent agreement within 1% with well-established xenon-tungsten multisource simulators and associated tuning algorithms. By enabling precise spectral tuning with readily available equipment and a simple tuning algorithm, our approach bridges the measurement accuracy gap between research laboratories and accredited testing facilities, fostering more reliable device comparisons and accelerating the translation of MJ technologies into real-world energy systems.

14 SOLAR ENERGY↗

DOE OSTI2018

Laboratory Testing of a Utility-Scale PV Inverter's Operational Response to Grid Disturbances

This paper provides experimental results of a utility-scale (500 kW) solar PV inverter during simulated grid disturbances. This device was tested using simulations of system voltage during three different disturbances; simulated distribution and transmission faults, and voltage records that were collected during the Blue Cut Fire Event. The methods used for testing the three different scenarios of grid disturbances are detailed and the test setup is described. Additionally, the test results for each of the grid events are provided and an analysis of the test results is given. The test results show that the tested PV inverter's response to grid disturbances depends in part on the fault-induced phase shift and harmonic content of the system voltage. These factors can impact the inverters ability to accurately calculate system frequency and can cause erroneous tripping on miscalculated frequency. The information provided in this paper can inform utilities, manufacturers, developers, and system planners of the potential performance of solar PV inverters during grid events.

14 SOLAR ENERGY↗

NASA NTRS1982

Aeroacoustic performance of an externally blown flap configuration with several flap noise suppression devices

Small scale model acoustic experiments were conducted to measure the noise produced in the flyover and sideline planes by an engine under the wing externally blown flap configuration in its approach attitude. Broadband low frequency noise reductions as large as 9 dB were produced by reducing the separation distance between the nozzle exhaust plane and the flaps. Experiments were also conducted to determine the noise suppression effectiveness in comparison with a reference configuration of three passive types of devices that were located on the jet impingement surfaces of the reference configuration. These devices produced noise reductions that varied up to 10 dB at reduced separation distances. In addition, a qualitative estimate of the noise suppression characteristics of the separate devices was made. Finally static aerodynamic performance data were obtained to evaluate the penalties incurred by these suppression devices. The test results suggest that further parametric studies are required in order to understand more fully the noise mechanisms that are affected by the suppression devices used.

Mckinzie, D. J., Jr.↗

NASA NTRS2003

NASA Tech Briefs, February 2003

opics covered include: Integrated Electrode Arrays for Neuro-Prosthetic Implants; Eroding Potentiometers; Common/Dependent-Pressure-Vessel Nickel-Hydrogen Batteries; 120-GHz HEMT Oscillator With Surface-Wave-Assisted Antenna; 80-GHz MMIC HEMT Voltage-Controlled Oscillator; High-Energy-Density Capacitors; Microscale Thermal-Transpiration Gas Pump; Instrument for Measuring Temperature of Water; Improved Measurement of Coherence in Presence of Instrument Noise; Compact Instruments Measure Helium-Leak Rates; Irreversible Entropy Production in Two-Phase Mixing Layers; Subsonic and Supersonic Effects in Bose-Einstein Condensate; Nanolaminate Mirrors With "Piston" Figure-Control Actuators; Mixed Conducting Electrodes for Better AMTEC Cells; Process for Encapsulating Protein Crystals; Lightweight, Self-Deployable Wheels; Grease-Resistant O Rings for Joints in Solid Rocket Motors; LabVIEW Serial Driver Software for an Electronic Load; Software Computes Tape-Casting Parameters; Software for Tracking Costs of Mars Projects; Software for Replicating Data Between X.500 and LDAP Directories; The Technical Work Plan Tracking Tool; Improved Multiple-DOF SAW Piezoelectric Motors; Propulsion Flight-Test Fixture; Mechanical Amplifier for a Piezoelectric Transducer; Swell Sleeves for Testing Explosive Devices; Linear Back-Drive Differentials; Miniature Inchworm Actuators Fabricated by Use of LIGA; Using ERF Devices to Control Deployments of Space Structures; High-Temperature Switched-Reluctance Electric Motor; System for Centering a Turbofan in a Nacelle During Tests; Fabricating Composite-Material Structures Containing SMA Ribbons; Optimal Feedback Control of Thermal Networks; Artifacts for Calibration of Submicron Width Measurements; Navigating a Mobile Robot Across Terrain Using Fuzzy Logic; Designing Facilities for Collaborative Operations; and Quantitating Iron in Serum Ferritin by Use of ICP-MS.

Source record↗

DOE OSTI2020

Surface Acoustic Wave H2 and O2 Sensors Based on Conducting Metal Oxides/Langasite for Elevated Temperature Applications - presentation

• SAW reflective delay line devices were designed and successfully fabricated on Langasite by patterning platinum electrodes.• Fabricated devices successfully tested up to 500°C for temperature sensing applications.• Indium oxide (IO) and indium tin oxide (ITO) sensing layers were developed on the SAW devices using sputtering and sol-gel method.• IO- and ITO-functionalized langasite SAW reflective delay line devices were used for sensing H2 and O2 at 350°C.

Mao, Elizabeth↗

DOE OSTI2018

Operational domain of Proto-MPEX

The Prototype-Material Plasma Exposure eXperiment (Proto-MPEX) is a linear plasma device to test the plasma source concepts for the future Material Plasma Exposure eXperiment (MPEX). MPEX is planned to address plasma material interactions under fusion reactor divertor conditions as will occur in devices like DEMO, including the plasma exposure of a-priori neutron irradiated materials. This requires a novel linear plasma device with a plasma source that can produce high electron densities along with heating systems to obtain high electron and ion temperatures. In Proto-MPEX a high-power helicon source was tested together with electron heating (28 GHz microwaves) and ion cyclotron heating (8.5-12 MHz). Electron densities in excess of 1 × 1020 m-3 were produced with the helicon antenna. Electron temperatures can reach 20 eV and are typically below 6 eV at high densities (>5 × 1019 m-3). Ion heating has been demonstrated at low electron densities (<2 × 1019 m-3) with ion temperatures of up to 13 eV. Maximum heat fluxes of 14 MW/m2 have been obtained in low density discharges (~5 × 1018 m-3), while heat fluxes are typically only 2–3 MW/m2 in high density discharges (>2 × 1019 m-3).

Rapp, Juergen↗

NASA NTRS1990

A new method for using Cf-252 in SEU testing

A system using Cf-252 and associated nuclear instrumentation has determined the single-event upset (SEU) cross section versus linear energy transfer (LET) curve for several 2K x 8 static random access memories (SRAMs). The Cf-252 fission fragments pass through a thin-film organic scintillator detector (TFD) on the way to the device under test (DUT). The TFD provides energy information for each transiting fragment. Data analysis provides the energy of the individual ion responsible for each SEU; thus, separate upset cross sections can be developed for different energy and mass regions of the californium spectrum. This californium-based device is quite small and fits onto a bench top. It provides a convenient and inexpensive supplement or alternative to accelerator and high-altitude/space SEU testing.

Costantine, A.↗

NASA NTRS2014

Verification of Dosimetry Measurements with Timepix Pixel Detectors for Space Applications

The current capabilities of modern pixel-detector technology has provided the possibility to design a new generation of radiation monitors. Timepix detectors are semiconductor pixel detectors based on a hybrid configuration. As such, the read-out chip can be used with different types and thicknesses of sensors. For space radiation dosimetry applications, Timepix devices with 300 and 500 microns thick silicon sensors have been used by a collaboration between NASA and University of Houston to explore their performance. For that purpose, an extensive evaluation of the response of Timepix for such applications has been performed. Timepix-based devices were tested in many different environments both at ground-based accelerator facilities such as HIMAC (Heavy Ion Medical Accelerator in Chiba, Japan), and at NSRL (NASA Space Radiation Laboratory at Brookhaven National Laboratory in Upton, NY), as well as in space on board of the International Space Station (ISS). These tests have included a wide range of the particle types and energies, from protons through iron nuclei. The results have been compared both with other devices and theoretical values. This effort has demonstrated that Timepix-based detectors are exceptionally capable at providing accurate dosimetry measurements in this application as verified by the confirming correspondence with the other accepted techniques.

Kroupa, M.↗

NASA NTRS2016

James Webb Space Telescope Integrated Science Instrument Module Thermal Vacuum Thermal Balance Test Campaign at NASA's Goddard Space Flight Center

The James Webb Space Telescope is a large infrared telescope with a 6.5-meter primary mirror, designed as a successor to the Hubble Space Telescope when launched in 2018. Three of the four science instruments contained within the Integrated Science Instrument Module (ISIM) are passively cooled to their operational temperature range of 36K to 40K with radiators, and the fourth instrument is actively cooled to its operational temperature of approximately 6K. Thermal-vacuum testing of the flight science instruments at the ISIM element level has taken place in three separate highly challenging and extremely complex thermal tests within a gaseous helium-cooled shroud inside Goddard Space Flight Centers Space Environment Simulator. Special data acquisition software was developed for these tests to monitor over 1700 flight and test sensor measurements, track over 50 gradients, component rates, and temperature limits in real time against defined constraints and limitations, and guide the complex transition from ambient to final cryogenic temperatures and back. This extremely flexible system has proven highly successful in safeguarding the nearly $2B science payload during the 3.5-month-long thermal tests. Heat flow measurement instrumentation, or Q-meters, were also specially developed for these tests. These devices provide thermal boundaries o the flight hardware while measuring instrument heat loads up to 600 mW with an estimated uncertainty of 2 mW in test, enabling accurate thermal model correlation, hardware design validation, and workmanship verification. The high accuracy heat load measurements provided first evidence of a potentially serious hardware design issue that was subsequently corrected. This paper provides an overview of the ISIM-level thermal-vacuum tests and thermal objectives; explains the thermal test configuration and thermal balances; describes special measurement instrumentation and monitoring and control software; presents key test thermal results; lists problems encountered during testing and lessons learned.

JWST ISIM Thermal↗