Hermetic seal evaluation for electronic components Final report
Leakage rate limits of hermetically sealed spacecraft electronic components, and correlation of radioactive gas and helium mass spectrometer detection methods
Guyton, R. D.↗
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Zero leakage separable and semipermanent ducting joints
A study program has been conducted to explore new methods of achieving zero leakage, separable and semipermanent, ducting joints for space flight vehicles. The study consisted of a search of literature of existing zero leakage methods, the generation of concepts of new methods of achieving the desired zero leakage criteria and the development of detailed analysis and design of a selected concept. Other techniques of leak detection were explored with a view toward improving this area.
Mischel, H. T.↗
Hydrogen passivation of n+p and p+n heteroepitaxial InP solar cell structures
High-efficiency, heteroepitaxial (HE) InP solar cells, grown on GaAs, Si or Ge substrates, are desirable for their mechanically strong, light-weight and radiation-hard properties. However, dislocations, caused by lattice mismatch, currently limit the performance of the HE cells. This occurs through shunting paths across the active photovoltaic junction and by the formation of deep levels. In previous work we have demonstrated that plasma hydrogenation is an effective and stable means to passivate the electrical activity of dislocations in specially designed HE InP test structures. In this work, we present the first report of successful hydrogen passivation in actual InP cell structures grown on GaAs substrates by metalorganic chemical vapor deposition (MOCVD). We have found that a 2 hour exposure to a 13.56 MHz hydrogen plasma at 275 C reduces the deep level concentration in HE n+n InP cell structures from as-grown values of approximately 10(exp 15)/cm(exp -3), down to 1-2 x 10(exp 13)/cm(exp -3). The deep levels in the p-type base region of the cell structure match those of our earlier p-type test structures, which were attributed to dislocations or related point defect complexes. All dopants were successfully reactivated by a 400 C, 5 minute anneal with no detectable activation of deep levels. I-V analysis indicated a subsequent approximately 10 fold decrease in reverse leakage current at -1 volt reverse bias, and no change in the forward biased series resistance of the cell structure which indicates complete reactivation of the n+ emitter. Furthermore, electrochemical C-V profiling indicates greatly enhanced passivation depth, and hence hydrogen diffusion, for heteroepitaxial structures when compared with identically processed homoepitaxial n+p InP structures. An analysis of hydrogen diffusion in dislocated InP will be discussed, along with comparisons of passivation effectiveness for n+p versus p+n heteroepitaxial cell configurations. Preliminary hydrogen-passivated HE InP cell results will also be presented.
Chatterjee, B.↗
Hydrogen passivation of N(+)-P and P(+)-N heteroepitaxial InP solar cell structures
Dislocations and related point defect complexes caused by lattice mismatch currently limit the performance of heteroepitaxial InP cells by introducing shunting paths across the active junction and by the formation of deep traps within the base region. We have previously demonstrated that plasma hydrogenation is an effective and stable means to passivate the electrical activity of such defects in specially designed heteroepitaxial InP test structures to probe hydrogen passivation at typical base depths within a cell structure. In this work, we present our results on the hydrogen passivation of actual heteroepitaxial n-p and p-n InP cell structures grown on GaAs substrates by metalorganic chemical vapor deposition (MOCVD). We have found that a 2 hour exposure to a 13.56 MHz hydrogen plasma at 275 C reduces the deep level concentration in the base regions of both n(+)-p and p(+)-n heteroepitaxial InP cell structures from as-grown values of 5-7 x 10(exp 14) cm(exp -3), down to 3-5 x 10(exp 12) cm(exp -3). All dopants were successfully reactivated by a 400 C, 5 minute anneal with no detectable activation of deep levels. One to five analysis indicated a subsequent approximately 100 fold decrease in reverse leakage current at -1 volt reverse bias, and an improved built in voltage for the p(+)-n structures. In addition to being passivated, dislocations are also shown to participate in secondary interactions during hydrogenation. We find that the presence of dislocations enhances hydrogen diffusion into the cell structure, and lowers the apparent dissociation energy of Zn-H complexes from 1.19 eV for homoepitaxial Zn-doped InP to 1.12 eV for heteroepitaxial Zn-doped InP. This is explained by additional hydrogen trapping at dislocations subsequent to the reactivation of Zn dopants after hydrogenation.
Chatterjee, Basab↗
Hydrogen Passivation of N(+)P and P(+)N Heteroepitaxial InP Solar Cell Structures
Dislocations and related point defect complexes caused by lattice mismatch currently limit the performance of heteroepitaxial InP cells by introducing shunting paths across the active junction and by the formation of deep traps within the base region. We have previously demonstrated that plasma hydrogenation is an effective and stable means to passivate the electrical activity of such defects in specially designed heteroepitaxial InP test structures to probe hydrogen passivation at typical base depths within a cell structure. In this work, we present our results on the hydrogen passivation of actual heteroepitaxial n(+)p and p(+)n InP cell structures grown on GaAs substrates by metalorganic chemical vapor deposition (MOCVD). We have found that a 2 hour exposure to a 13.56 MHz hydrogen plasma at 275 C reduces the deep level concentration in the base regions of both n(+)p and p(+)n heteroepitaxial InP cell structures from as-grown values of 5 - 7 x 10(exp 14)/cc, down to 3 - 5 x 10(exp 12)/cc. All dopants were successfully reactivated by a 400 C, 5 minute anneal With no detectable activation of deep levels. I-V analysis indicated a subsequent approx. 100 fold decrease In reverse leakage current at -1 volt reverse bias, and an improved built in voltage for the p(+)n structures. ln addition to being passivated,dislocations are also shown to participate in secondary interactions during hydrogenation. We find that the presence of dislocations enhances hydrogen diffusion into the cell structure, and lowers the apparent dissociation energy of Zn-H complexes from 1.19 eV for homoepitaxial Zn-doped InP to 1.12 eV for heteroepitaxial Zn-doped InP. This is explained by additional hydrogen trapping at dislocations subsequent to the reactivation of Zn dopants after hydrogenation.
Chatterjee, B.↗
Method and apparatus for testing surface characteristics of a material
A method, apparatus and system for testing characteristics of a material sample is provided. The system includes an apparatus configured to house the material test sample while defining a sealed volume against a surface of the material test sample. A source of pressurized fluid is in communication with, and configured to pressurize, the sealed volume. A load applying apparatus is configured to apply a defined load to the material sample while the sealed volume is monitored for leakage of the pressurized fluid. Thus, the inducement of surface defects such as microcracking and crazing may be detected and their effects analyzed for a given material. The material test samples may include laminar structures formed of, for example, carbon cloth phenolic, glass cloth phenolic, silica cloth phenolic materials or carbon-carbon materials. In one embodiment the system may be configured to analyze the material test sample while an across-ply loading is applied thereto.
Johnson, David L.↗
Insulation Resistance and Leakage Currents in Low-Voltage Ceramic Capacitors with Cracks
Measurement of insulation resistance (IR) in multilayer ceramic capacitors (MLCCs) is considered a screening technique that ensures the dielectric is defect-free. This work analyzes the effectiveness of this technique for revealing cracks in ceramic capacitors. It is shown that absorption currents prevail over the intrinsic leakage currents during standard IR measurements at room temperature. Absorption currents, and consequently IR, have a weak temperature dependence, increase linearly with voltage (before saturation), and are not sensitive to the presence of mechanical defects. In contrary, intrinsic leakage currents increase super-linearly with voltage and exponentially with temperature (activation energy is in the range from 0.6 eV to 1.1 eV). Leakage currents associated with the presence of cracks have a weaker dependence on temperature and voltage compared to the intrinsic leakage currents. For this reason, intrinsic leakage currents prevail at high temperatures and voltages, thus masking the presence of defects.
testing↗
Breakdown in Tantalum Capacitors
Failures in tantalum capacitors can be considered as a time-dependent-breakdown and reliability of all types of capacitors, including wet, MnO2 and polymer cathode parts, depends on the efficiency of self-healing that can mend parts after breakdown. A mechanism of self-healing in MnO2 capacitors is associated with oxygen reduction in the cathode layer and isolation of the breakdown site with high-resistive Mn2O3/Mn3O4 compositions. Although this mechanism is commonly accepted, details of self-healing have not been analyzed sufficiently yet, and the effects of scintillations on behavior of the parts has not been fully understood. There is a lack of data on the self-healing efficiency in different lots of capacitors. Even less is known about self-healing in polymer tantalum capacitors. In this work, different types of polymer and MnO2 capacitors have been tested for scintillation breakdown using a constant current stress (CCS) technique modified to allow detection of the amplitudes and durations of current spikes during breakdown. Characteristics of the parts and in particular leakage currents were measured to assess the efficiency of self-healing and improve screening processes for tantalum capacitors. Damaged sites were localized using infrared camera and their appearance analyzed after deprocessing and crosssectioning. Thermal effects during scintillations have been modeled, self-healing processes in polymer and MnO2 cathode capacitors discussed, and mechanisms of breakdown based on the growth of conductive filaments in the dielectric suggested.
tantalum polymer capacitors↗
The UCSD/MIT hard X-ray and low energy gamma ray experiment for HEAO-A
An HEAO-A spacecraft is described which is scheduled for launch in April 1977 to survey the sky in the 0.15 keV to 10 MeV range of X-rays with improved sensitivity and angular resolution. The spectral and time variations of discrete sources, and the spectrum and isotropy of the diffuse component will be measured. A hard X-ray and low energy gamma ray experiment is described which will use as an array of seven (NaI)(Tl)/CsI(Na) phoswich detectors and eight large CsI(Na) shields. Detector events are pulse-height analyzed with a selectable time resolution of 0.1, 0.005, or 0.00002 sec. The instrument background is expected to be comprised of approximately equal parts of diffuse gamma rays entering the aperture, radioactive decay of spallation products, and gamma ray leakage through the shields. Detailed background predictions are presented, and sensitivity estimates indicate that the Crab nebula should be detected up to approximately 5 MeV. Approximate 1% isotropy limits for the diffuse component of cosmic gamma rays should be achieved, and its spectrum measured with improved precision.
Matteson, J. L.↗
Review of the NASA Voyager spacecraft polycarbonate capacitor failure incident
The premission failure of a Voyager spacecraft capacitor has prompted an investigation into the use of polycarbonate capacitors in high impedance circuits, during which capacitor failures were induced by thermal cycling together with extended periods at high temperature. Measurement of leakage path temperature coefficients indicates that there are two distinct leakage types whose mechanisms are complicated by movement within the capacitor during temperature changes. A novel system for pulse detection during capacitor burn-in and ramp testing has proven to be beneficial.
Ott, F. M.↗
Seal testing of large diameter rocket motors
This investigative program examines leakage testing of elastomeric O-ring seals for a solid rocket casing and provides direction towards an improved nondestructive postassembly test. It also details test equipment for the Space Shuttle systems solid rocket boosters (SRB). The results are useful to designers of hardware for pressure containment vessels which use O-ring seals. Using several subscale seal and groove configuration test fixtures equipped with either two or three O-ring seals in series, seal integrity is investigated with both a pressure decay and flowmeter methods. Both types of test equipment adequately detect the practical range of expected seal leak rates of 1 to 0.0001 sccs. The flowmeter leak test equipment appears to reduce testing time substantially. Limited seal leakage testing is performed on full-sized rocket motor segment seals, a pre-Challenger short stack, providing comparison of bore seals to test specimen bore and face seals. The conclusions are that seal reliability, verified via a performance pressure test, can be affected by temperature, quantity of grease, test pressure, and seal pressure load direction. Potential seal failure scenarios including contamination, seal damage, and sealing surface damage are discussed. Recommendations are made for an improved test procedure.
Moore, N. B.↗
Deep Flaw Detection with Giant Magnetoresistive (GMR) Based Self-Nulling Probe
In this paper a design modification to the Very-Low Frequency GMR Based Self-Nulling Probe has been presented to enable improved signal to noise ratio for deeply buried flaws. The design change consists of incorporating a feedback coil in the center of the flux focusing lens. The use of the feedback coil enables cancellation of the leakage fields in the center of the probe and biasing of the GMR sensor to a location of high magnetic field sensitivity. The effect of the feedback on the probe output was examined, and experimental results for deep flaw detection were presented. The experimental results show that the modified probe is capable of clearly identifying flaws up to 1 cm deep in aluminum alloy structures.
Wincheski, Buzz↗
The Resource Prospector Neutron Spectrometer System: RP's Bloodhound
The primary goal of the Resource Prospector Neutron Spectrometer System (NSS) is to locate and characterize hydrogen-bearing volatile deposits, especially subsurface ice, that may exist at the lunar poles. A key objective is to detect water-equivalent hydrogen concentrations of 0.5 wt% or greater while on a moving rover. A second objective is to determine approximate burial depth of enhanced hydrogen-bearing materials up to 1 meter below otherwise dry regolith. The instrument will be carried aboard a landed mobility system at the lunar poles. The instrument operates by measuring the changes in the leakage flux of low energy neutrons out of the regolith. These neutrons are produced by galactic cosmic rays, which are so energetic that they shatter the nuclei in surface materials. The neutrons interact with other nuclei and lose energy, becoming thermalized in the process. Hydrogen is most efficient at thermalizing neutrons owing to protons' similar mass - statistically, neutrons lose half their energy per collision with protons. With hydrogen in the soil, leakage fluxes of neutrons in the 0.5 eV to 500 keV energy range are reduced. A concentration of only1-2 wt% water-equivalent hydrogen results in a decrease in epithermal leakage flux of a factor of two. The leakage flux of thermal neutrons, from 0 to 0.5 eV in energy, can either increase or decrease depending on the hydrogen abundance and stratigraphy. As with the highly successful Lunar Prospector Neutron Spectrometer, the RP NSS detects both thermal and epithermal neutrons by using two helium-3 gas proportional counters, one covered by cadmium and the other uncovered. The former detects only epithermal neutrons with energies above approximately 0.5 eV, the latter detects both thermal (less than 0.5 eV) and epithermal energies (greater than 0.5 eV). When a neutron enters the detector tube and interacts with a helium-3 nucleus, the resulting reaction produces an energetic proton and triton that ionize the gas. The resulting electrons are accelerated toward a high-voltage anode and cascade, amplifying the net charge, which is collected at the anode. The number of electrons produced is proportional to the energy that the triton and proton deposit in the gas. A charge sensitive pre-amplifier converts the total charge to a step voltage output. A shaper amplifier then shapes this step into a uni-polar waveform with peaking time appropriate for the detection depending on the event rate. The integrated shaped waveform, representing the deposited triton/proton energy, is then measured. A histogram, or pulse height analysis, is performed to record the main capture peak and wall effect pulses. A threshold for detection is also required to limit the low amplitude counting rate such as noise floor. The system electronics consists of 2 modules - the Sensor Module (SM) front-end and the Data Processing Module (DPM) back-end circuits. SM is designed as a light-weight and low power front-end housing the two helium-3 proportional counter detectors, preamp and HVPS. It is mounted external to the rover body to detect the thermalized neutron flux with a minimum of host background. The DPM is located inside the rover; it digitizes the SM signals, performs pulse height analysis and accumulates the count rate for each spectral channel. The DPM controls high voltage and thresholding, and sends the science data to the host craft via an RS422 serial asynchronous protocol. The payload host provides all thermal management and control for the SM and DPM.
hydrogen-bearing volatile deposits↗
The International Space Station (ISS) Port 1 (P1) External Active Thermal Control System (EATCS) Ammonia Leak
From 2011 to 2017, the crew onboard the International Space Station (ISS) was at risk of dire consequences due to an external ammonia leak. Ammonia is used in the External Active Thermal Control System (EATCS) to cool the pressurized modules and external electrical systems. Engineers at NASA's Johnson Space Center (JSC) initially detected the leak in one of two cooling loops by monitoring the system ammonia inventory decay over time. White flakes seen on High Definition (HD) cameras were also thought to be associated with the leakage but not confirmed. Initially, the leak was small enough that the ammonia inventory and system operations were not in jeopardy. However, the leak began to accelerate to the point where troubleshooting and corrective action were vital to the sustainability of the ISS. Therefore, it became imperative that the leak be located and repaired for ISS operations to continue. No tools were readily available on the ISS to locate such a leak when it was initially detected, however NASA engineers were already in the process of developing a new device for this purpose called the Robotic External Leak Locator (RELL). The RELL is a robotic instrument package with a mass spectrometer and an ion pressure gauge. Initial checkout operations with RELL happened to coincide with the increasing leak, and ammonia vapors were measured around the P1 EATCS Radiator #3 flexible jumper hoses. The leak stopped after the radiator and its flexible hoses were remotely isolated from the loop and the ammonia from the isolated segment was vented to space. Astronauts conducted a spacewalk that successfully removed the hoses, which were returned to ground for further investigation. The purpose of this paper is to review the leak detection and isolation efforts, investigation results, lessons learned and the recovery plan.
Cowan, Darnell T.↗
The International Space Station (ISS) Port 1 (P1) External Active Thermal Control System (EATCS) Ammonia Leak
From 2011 to 2017, the crew onboard the International Space Station (ISS) was at risk of dire consequences due to an external ammonia leak. Ammonia is used in the External Active Thermal Control System (EATCS) to cool the pressurized modules and external electrical systems. Engineers at NASA's Johnson Space Center (JSC) initially detected the leak in one of two cooling loops by monitoring the system ammonia inventory decay over time. White flakes seen on High Definition (HD) cameras were also thought to be associated with the leakage but not confirmed. Initially, the leak was small enough that the ammonia inventory and system operations were not in jeopardy. However, the leak began to accelerate to the point where troubleshooting and corrective action were vital to the sustainability of the ISS. Therefore, it became imperative that the leak be located and repaired for ISS operations to continue. No tools were readily available on the ISS to locate such a leak when it was initially detected, however NASA engineers were already in the process of developing a new device for this purpose called the Robotic External Leak Locator (RELL). The RELL is a robotic instrument package with a mass spectrometer and an ion pressure gauge. Initial checkout operations with RELL happened to coincide with the increasing leak, and ammonia vapors were measured around the P1 EATCS Radiator #3 flexible jumper hoses. The leak stopped after the radiator and its flexible hoses were remotely isolated from the loop and the ammonia from the isolated segment was vented to space. Astronauts conducted a spacewalk that successfully removed the hoses, which were returned to ground for further investigation. The purpose of this paper is to review the leak detection and isolation efforts, investigation results, lessons learned and the recovery plan.
Cowan, Darnell T.↗
A solenoid failure detection system for cold gas attitude control jet valves
The development of a solenoid valve failure detection system is described. The technique requires the addition of a radioactive gas to the propellant of a cold gas jet attitude control system. Solenoid failure is detected with an avalanche radiation detector located in the jet nozzle which senses the radiation emitted by the leaking radioactive gas. Measurements of carbon monoxide leakage rates through a Mariner type solenoid valve are presented as a function of gas activity and detector configuration. A cylindrical avalanche detector with a factor of 40 improvement in leak sensitivity is proposed for flight systems because it allows the quantity of radioactive gas that must be added to the propellant to be reduced to a practical level.
Johnston, P. A.↗
ISS External Microorganisms: Collecting Planetary Protection Samples During Extravehicular Activity
Introduction: We have designed1, built, and tested a sampling kit (Fig. 1) to aseptically collect microbiological samples from exterior surfaces on the ISS (International Space Station). The kit was flown to ISS as part of the NG-19 commercial cargo mission in August of 2023. Astronauts will use the kit to collect samples from six exterior surfaces on ISS. These samples will be frozen at -80°C after collection and returned to the ground for next generation DNA sequencing. The results of this experiment will help inform planetary protection requirements for crewed missions. We hypothesize that there are detectable microbial communities outside ISS and that these communities originate from inside ISS. Current life support systems do not include any components for reducing microbial leakage. Gases are vented from inside ISS without filtration and there are currently no protocols in place to minimize bioburden on space suit exteriors prior to use. It is important to quantify the bioburden on current vehicles so that achievable limits can be set for crewed missions to astrobiologically relevant locations like Mars. Figure 1: The sampling kit contains eight swab canisters in total (six on the top and two on the bottom). A resuable end effector (1) is used to remove and reinstall the swabs. The kit also contains a handrail (2), tether loop (3), and, bayonet probes(4) to allow easy manipulation during EVA. Methods: We have designed a kit to carry 8 commercially available foam swabs into and out of vacuum without compromising the swabs’ sterility. The specially designed swab canisters contain a 0.2 µm Teflon filter that allows the canister to accommodate pressure changes without introducing unwanted contaminants. The kit meets existing EVA (Extravehicular Activity) safety requirements and has been used by human test subjects in the neutral buoyance lab and at vacuum in test chambers at the Johnson Space Center. In the early part of 2024, astronauts will use this sampling kit to swab six surfaces on the exterior of ISS. We will collect samples from: the airlock vestibule, the interior surface of the airlock thermal cover, an exterior handrail, a vent connected to the CO2 removal system, and a vent connected to the payload vacuum system inside ISS. Approximately 300 cm2 will be swabbed at each location. A seventh swab will be exposed to the vacuum of space without touching any surfaces as a blank. The eighth swab will remain sealed as a process control. After the EVA the swab kit will be frozen at -80°C and returned to earth at the earliest possible opportunity. The samples will remain frozen until they are thawed for next generation DNA sequencing on earth. We will use amplicon sequencing to identify any bacteria, archaea or fungi present in the samples. If there is enough DNA present, we will use shotgun metagenomic sequencing to further characterize the microbial ecology outside ISS. Preliminary Results: Results from ground-based testing demonstrate that the swab kit is capable of cycling in and out of vacuum without contaminating the swabs. Test subjects, wearing flight-like EVA gloves could remove swabs from the canister and sample discrete locations without inadvertently touching any other surfaces. Several types of bacteria and fungi were collected during these ground tests and survived up to 6 hours at vacuum. This includes non-spore forming bacterial like Staphyloccus capitis that are not traditionally considered extremophiles. Shotgun metagenomic sequencing of the ground-test samples revealed bacteria associated with human skin and airways on the exterior of space suits used during these tests 2 In addition to these results we will present preliminary results from our space-flight samples. We will also present lessons learned from attempting to collect microbiological samples during an EVA and describe how our results will affect planetary protection requirements for future crewed missions.
Aaron B. Regberg↗
ISS External Microorganisms: Tools and Techniques for Collecting Planetary Protection Samples During Extravehicular Activity
We have designed, built, and tested a sampling kit (Fig. 1) to aseptically collect microbiological samples from exterior surfaces on the ISS (International Space Station). The kit was flown to ISS as part of the NG-19 commercial cargo mission in August of 2023. Astronauts will use the kit to collect samples from six exterior surfaces on ISS. These samples will be frozen at -80°C after collection and returned to the ground for next generation DNA sequencing. The results of this experiment will help inform planetary protection requirements for crewed missions. We hypothesize that there are detectable microbial communities outside ISS and that these communities originate from inside ISS. Current life support systems do not include any components for reducing microbial leakage. Gases are vented from inside ISS without filtration and there are currently no protocols in place to minimize bioburden on space suit exteriors prior to use. It is important to quantify the bioburden on current vehicles so that achievable limits can be set for crewed missions to astrobiologically relevant locations like Mars.
Planetary Protection↗