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A Physics of Failure Approach to Evaluate Printed Circuit Board Reliability

Risk based technology infusion is a deliberate and systematic process which defines the analysis and communication methodology by which new technology is applied and integrated into existing and new designs, identifies technology development needs based on trends analysis and facilitates the identification of shortfalls against performance objectives. This presentation at IPC Works Asia Aerospace 2019 Events provides the audience a snapshot of quality variations in printed wiring board quality, as assessed, using experiences in processing and risk analysis of PWB structural integrity coupons. The presentation will focus on printed wiring board quality metrics used, the relative type and number of non-conformances observed and trend analysis using statistical methods. Trend analysis shows the top five non-conformances observed across PWB suppliers, the root cause(s) behind these non-conformance and suggestions of mitigation plans. The trends will then be matched with the current state of the PWB supplier base and its challenges and opportunities. The presentation further discusses the risk based SMA approaches and methods being applied at GSFC for evaluating candidate printed wiring board technologies which promote the adoption of higher throughput and faster processing technology for GSFC missions.

Printed Circuit Boards

Lubrication of space systems: Challenges and potential solutions

Future space missions will all require advanced mechanical moving components which will require wear protection and lubrication. The tribology practices used today are primarily based upon a technology base that is more than 20 years old. This paper will discuss NASA's future space missions and some of the mechanism tribology challenges that will be encountered. Potential solutions to these challenges using coatings technology will be assessed.

Fusaro, Robert L.

Aeronautics Research and Technology Program and specific objectives, fiscal year 1982

The Aeronautics Research and Technology program is broken down into two program areas (research and technology base, and systems technology programs) which are further broken down into succeedingly more detailed activities to form a work breakdown structure for the aeronautics program: program area, program/discipline objective, specific objective, and research and technology objective and plan (RTOP). A detailed view of this work breakdown structure down to the specific objective level is provided, and goals or objectives at each of these levels are set forth. What is to be accomplished and why are addressed, but not how. The letter falls within the domain of the RTOP.

Olstad, W. B.

Develop and test fuel cell powered on-site integrated total energy systems: Phase 3, full-scale power plant development

Two 25 cell stacks of the 13 inch x 23 inch cell size (about 4kW) remain on test after 4000 hours and 2900 hours, respectively, using simulated reformate fuel. These tests are focusing on the durability of fuel cell stack components developed through the end of 1983. Also, these stacks are serving as forerunners of a 25kW stack that will contain 175 cells of the same size and will employ the same technology base. The stack technology development program has focused on a new, low cost bipolar plate edge seal technique and evaluation of advanced cathode catalysts, an electrolyte replenishment system, and nonmetallic cooling plates in small stacks.

Kaufman, A.

Center for development technology and program in technology and human affairs

The role of technology in nontraditional higher education with particular emphasis on technology-based networks is analyzed nontraditional programs, institutions, and consortia are briefly reviewed. Nontraditional programs which utilize technology are studied. Technology-based networks are surveyed and analyzed with regard to kinds of students, learning locations, technology utilization, interinstitutional relationships, cost aspects, problems, and future outlook.

Wong, M. D.

Lunar base mission technology issues and orbital demonstration requirements on space station

The International Space Station has been the object of considerable design, redesign, and alteration since it was originally proposed in early 1984. In the intervening years the station has slowly evolved to a specific design that was thoroughly reviewed by a large agency-wide Critical Evaluation Task Force (CETF). As space station designs continue to evolve, studies must be conducted to determine the suitability of the current design for some of the primary purposes for which the station will be used. This paper concentrates on the technology requirements and issues, the on-orbit demonstration and verification program, and the space station focused support required prior to the establishment of a permanently manned lunar base as identified in the National Commission on Space report. Technology issues associated with the on-orbit assembly and processing of the lunar vehicle flight elements are also discussed.

Llewellyn, Charles P.

Ceramic applications in turbine engines

The application of ceramic components to demonstrate improved cycle efficiency by raising the operating temperature of the existing Allison IGI 404 vehicular gas turbine engine is discussed. This effort was called the Ceramic Applications in Turbine Engines (CATE) program and has successfully demonstrated ceramic components. Among these components are two design configurations featuring stationary and rotating caramic components in the IGT 404 engine. A complete discussion of all phases of the program, design, materials development, fabrication of ceramic components, and testing-including rig, engine, and vehicle demonstation test are presented. During the CATE program, a ceramic technology base was established that is now being applied to automotive and other gas turbine engine programs. This technology base is outlined and also provides a description of the CATE program accomplishments.

Helms, H. E.

Printed Wiring Board Technology Infusion and Supplier Capability Overview

Risk based technology infusion is a deliberate and systematic process which defines the analysis and communication methodology by which new technology is applied and integrated into existing and new designs, identifies technology development needs based on trends analysis and facilitates the identification of shortfalls against performance objectives. This presentation at QLF 2018 provides the audience a snapshot of quality variations in printed wiring board quality, as assessed, using experiences in processing and risk analysis of PWB structural integrity coupons. The presentation will focus on printed wiring board quality metrics used, the relative type and number of non-conformances observed and trend analysis using statistical methods. Trend analysis shows the top five non-conformances observed across PWB suppliers, the root cause(s) behind these non-conformance and suggestions of mitigation plans. The trends will then be matched with the current state of the PWB supplier base and its challenges and opportunities. The presentation further discusses the methods being applied at GSFC for evaluating candidate printed wiring board technologies which promote the adoption of higher throughput and faster processing technology for GSFC missions.

PCB fabrication

Learning New Techniques for Remediation of Contaminated Sites

The project emphasizes NASA's Missions of understanding and protecting our home planet as well as of inspiring the next generation of explorers. The project fellow worked as part of a team on the development of new emulsion-based technologies for the removal of Contaminants from soil, sediment, and groundwater media with the scientists in charge of the emulsion-based technologies. Hands-on chemistry formulation and analyses using a GCM, as well as field sampling was done. The fellow was tidy immersed in lab and fieldwork, as well as, training sessions to qualify her to do the required work. The principal outcome of the project is the motivation to create collaboration links between major research university (UCF) and an emerging research university (UT).

Lipsett-Ruiz, Teresa

Coal to Carbon Fibers

This report documents activities carried out by Oak Ridge National Laboratory and by Ramaco Carbon LLC under CRADA project NFE-20-08273 entitled “Coal to Carbon Fibers.” This project’s main objective was the demonstration of commercially relevant utilization of coal as a precursor for high-value-added products, such as carbon fibers. The specific objectives included the following: • Deploy a production platform for the conversion of coal into carbon fibers in a way that utilizes preexisting base technologies and accelerates the commercialization of coal to carbon fibers. • Rapid deployment and utilization of versatile conversion test beds for accommodating preexisting base technologies for both the conversion of coal-to-pitch (proven donor solvent liquefaction techniques) and conversion of pitch-to-fiber (proven melt spun and melt blown techniques). Results from the generation of an isotropic pitch from a subbituminous coal through the low severity direct coal liquefaction process are presented. Carbon fibers were produced from this isotropic pitch through melt spinning and melt blowing.

01 COAL, LIGNITE, AND PEAT

Technology, Data Bases and System Analysis for Space-to-Ground Optical Communications

Optical communications is becoming an ever-increasingly important option for designers of space-to- ground communications links, whether it be for government or commercial applications. In this paper the technology being developed by NASA for use in space-to-ground optical communications is presented. Next, a program which is collecting a long term data base of atmospheric visibility statistics for optical propagation through the atmosphere will be described. Finally, a methodology for utilizing the statistics of the atmospheric data base in the analysis of space-to-ground links will be presented. This methodology takes into account the effects of station availability, is useful when comparing optical communications with microwave systems, and provides a rationale establishing the recommended link margin.

Space-to-Ground Optical Communications

Composite structural materials

The promise of filamentary composite materials, whose development may be considered as entering its second generation, continues to generate intense interest and applications activity. Fiber reinforced composite materials offer substantially improved performance and potentially lower costs for aerospace hardware. Much progress has been achieved since the initial developments in the mid 1960's. Rather limited applications to primary aircraft structure have been made, however, mainly in a material-substitution mode on military aircraft, except for a few experiments currently underway on large passenger airplanes in commercial operation. To fulfill the promise of composite materials completely requires a strong technology base. NASA and AFOSR recognize the present state of the art to be such that to fully exploit composites in sophisticated aerospace structures, the technology base must be improved. This, in turn, calls for expanding fundamental knowledge and the means by which it can be successfully applied in design and manufacture.

Ansell, G. S.

Laser-powered MHD generators for space application

Magnetohydrodynamic (MHD) energy conversion systems of the pulsed laser-supported detonation (LSD) wave, plasma MHD, and liquid-metal MHD (LMMHD) types are assessed for their potential as space-based laser-to-electrical power converters. These systems offer several advantages as energy converters relative to the present chemical, nuclear, and solar devices, including high conversion efficiency, simple design, high-temperature operation, high power density, and high reliability. Of these systems, the Brayton cycle liquid-metal MHD system appears to be the most attractive. The LMMHD technology base is well established for terrestrial applications, particularly with regard to the generator, mixer, and other system components. However, further research is required to extend this technology base to space applications and to establish the technology required to couple the laser energy into the system most efficiently. Continued research on each of the three system types is recommended.

Jalufka, N. W.

Human factors: Space

The objectives are to provide a technology base for intelligent operator interfaces, especially with autonomous subsystems, and to develop a new generation of high performance space suits, gloves, and tools/end effectors to meet the requirements of advanced space missions. The technology base is intended to meet the requirements of productivity, efficiency, and safety in complex manned operations within automated onboard systems and extravehicular activities (EVA) environments. Crew station research is the first of two major areas. Development of methods for the astronaut to supervise, monitor, and evaluate the performance of robotic systems, other space subsystems, and orbital vehicles are key areas of research. The second major area is development of an EVA space suit and gloves. Emphasis in the space human factors research program is placed on technology baseline studies and development of methods, techniques, and data to support productive and safe operations by the astronaut and crew as they interface with complex systems, advance automation, and robotic assistants.

Jenkins, James P.

Green Applications for Space Power Project

Spacecraft propulsion and power for many decades has relied on Hydrazine monopropellant technology for auxiliary power units (APU), orbital circularization, orbit raising/lowering and attitude control. However, Hydrazine is toxic and therefore requires special ground handling procedures to ensure launch crew safety. The Swedish Company ECAPS has developed a technology based upon the propellant Ammonium Dinitramide (ADN) that offers higher performance, higher density and reduced ground handling support than Hydrazine. This blended propellant is called LMP-103S. Currently, the United States Air Force (USAF) is pursuing a technology based on Hydroxyl Ammonium Nitrate (HAN, otherwise known as AF-M315E) with industry partners Aerojet and Moog. Based on the advantages offered by these propellants, MSFC should explore powering APU's with these propellants. Due to the availability of space hardware, the principal investigator has found a collection of USAF hardware, that will act as a surrogate, which operates on a Hydrazine derivative. The F-16 fighter jet uses H-70 or 30% diluted Hydrazine for an Emergency Power Unit (EPU) which supplies power to the plane. The PI has acquired two EPU's from planes slated for destruction at the Davis Monthan AFB. This CIF will include a partnership with 2 other NASA Centers who are individually seeking seed funds from their respective organizations: Kennedy Space Center (KSC) and Dryden Flight Research Center (DFRC). KSC is preparing for future flights from their launch pads that will utilize green propellants and desire a low-cost testbed in which to test and calibrate new leak detection sensors. DFRC has access to F-16's which can be used by MSFC & KSC to perform a ground test that demonstrates emergency power supplied to the jet. Neither of the green propellant alternatives have been considered nor evaluated for an APU application. Work has already been accomplished to characterize and obtain the properties of these 2 propellants. However, the spacecraft are using existing leak detection sensors that are typically used for Hydrazine. Using these green propellants for the APU application requires decrementing their TRL down to 3. This task would aim to establish a TRL of 4 at conclusion by showing a proof of concept with a KSC-instrumented EPU asset at the MSFC Component Development Area (CDA). The task to accomplish this is called Green Application for Space Power or GRASP.

Robinson, Joel

HAN-Based Monopropellant Technology Development

NASA Glenn Research Center is sponsoring efforts to develop technology for high-performance, high-density, low-freezing point, low-hazards monopropellant systems. The program is focused on a family of monopropellant formulations composed of an aqueous solution of hydroxylammonium nitrate (HAN) and a fuel component. HAN-based monopropellants offer significant mass and volume savings to small (less than 100 kg) satellite for orbit raising and on-orbit propulsion applications. The low-hazards characteristics of HAN-based monopropellants make them attractive for applications where ground processing costs are a significant concern. A 1-lbf thruster has been demonstrated to a 20-kg satellite orbit insertion duty cycle, using a formulation compatible with currently available catalysts. To achieve specific impulse levels above those of hydrazine, catalyst materials that can withstand the high-temperature, corrosive combustion environment of HAN-based monopropellants have to be developed. There also needs to be work done to characterize propellant properties, burning behavior, and material compatibility. NASA is coordinating their monopropellant efforts with those of the United States Air Force.

Reed, Brian

TCF Base Technology-Specific Final Report: Negative Cracked Film Lithography for PERC CdTe

NLR worked with the world's leading thin-film photovoltaic manufacturer - First Solar, an American company - to develop electrical contacting methods that improve the power conversion efficiency of First Solar's cells by 0.5% absolute. We met this milestone but contrary to our hypothesis, these performance gains are not passivation (PERC)-based. Instead, we identified another mechanism by which our micropatterned Al 2 O 3 contacts improve efficiency. Using the results of this project, we will adapt NLR's cracked film lithography intellectual property (IP) toward the application we identified, which is a new route to commercialization.

14 SOLAR ENERGY

Mobile Router Developed and Tested

The NASA Glenn Research Center, under a NASA Space Act Agreement with Cisco Systems, has been performing joint networking research to apply Internet-based technologies and protocols to space-based communications. As a result of this research, NASA performed stringent performance testing of the mobile router, including the interaction of routing and the transport-level protocol. In addition, Cisco Systems developed the mobile router for both commercial and Government markets. The code has become part of the Cisco Systems Internetworking Operating System (IOS) as of release 12.2 (4) T--which will make this capability available to the community at large. The mobile router is software code that resides in a network router and enables entire networks to roam while maintaining connectivity to the Internet. This router code is pertinent to a myriad of applications for both Government and commercial sectors, including the "wireless battlefield." NASA and the Department of Defense will utilize this technology for near-planetary observation and sensing spacecraft. It is also a key enabling technology for aviation-based information applications. Mobile routing will make it possible for information such as weather, air traffic control, voice, and video to be transmitted to aircraft using Internet-based protocols. This technology shows great promise in reducing congested airways and mitigating aviation disasters due to bad weather. The mobile router can also be incorporated into emergency vehicles (such as ambulances and life-flight aircraft) to provide real-time connectivity back to the hospital and health-care experts, enabling the timely application of emergency care. Commercial applications include entertainment services, Internet protocol (IP) telephone, and Internet connectivity for cruise ships, commercial shipping, tour buses, aircraft, and eventually cars. A mobile router, which is based on mobile IP, allows hosts (mobile nodes) to seamlessly "roam" among various IP subnetworks. This is essential in many wireless networks. A mobile router, unlike a mobile IP node, allows entire networks to roam. Hence, a device connected to the mobile router does not need to be a mobile node because the mobile router provides the roaming capabilities. There are three basic elements in the mobile IP: the home agent, the foreign agent, and the mobile node. The home agent is a router on a mobile node's home network that tunnels datagrams for delivery to the mobile node when it is away from home. The foreign agent is a router on a remote network that provides routing services to a registered mobile node. The mobile node is a host or router that changes its point of attachment from one network or subnetwork to another. In mobile routing, virtual communications are maintained by the home agent, which forwards all packets for the mobile networks to the foreign agent. The foreign agent passes the packets to the mobile router, which then forwards the packets to the devices on its networks. As the mobile router moves, it will register with its home agent on its whereabouts via the foreign agent to assure continuous connectivity.

Ivancic, William D.