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At least 91 records · Page 5

Designing for Reliability and Robustness

Long duration spaceflight has a negative effect on the human body, and exercise countermeasures are used on-board the International Space Station (ISS) to minimize bone and muscle loss, combatting these effects. Given the importance of these hardware systems to the health of the crew, this equipment must continue to be readily available. Designing spaceflight exercise hardware to meet high reliability and availability standards has proven to be challenging throughout the time the crewmembers have been living on ISS beginning in 2000. Furthermore, restoring operational capability after a failure is clearly time-critical, but can be problematic given the challenges of troubleshooting the problem from 220 miles away. Several best-practices have been leveraged in seeking to maximize availability of these exercise systems, including designing for robustness, implementing diagnostic instrumentation, relying on user feedback, and providing ample maintenance and sparing. These factors have enhanced the reliability of hardware systems, and therefore have contributed to keeping the crewmembers healthy upon return to Earth. This paper will review the failure history for three spaceflight exercise countermeasure systems identifying lessons learned that can help improve future systems. Specifically, the Treadmill with Vibration Isolation and Stabilization System (TVIS), Cycle Ergometer with Vibration Isolation and Stabilization System (CEVIS), and the Advanced Resistive Exercise Device (ARED) will be reviewed, analyzed, and conclusions identified so as to provide guidance for improving future exercise hardware designs. These lessons learned, paired with thorough testing, offer a path towards reduced system down-time.

Svetlik, Randall G.↗

Experimental Setup for Mechanically Testing Subscale Triangular, Rollable, and Collapsible Deployable Composite Booms

High-strain composite deployable space structures are used for space infrastructure and science applications such as solar array supports, antennae, camera masts, and lightweight structures supporting solar sailing propulsion elements. Triangular, Rollable, and Collapsible (TRAC) deployable composite booms are one example of a high-strain composite deployable structure and were studied using novel experimental test and characterization methods developed under the Gravity Offloading and Analysis of Long Imperfection-sensitive Elements (GOALIE) project. In the present work, a subscale 7-m-long TRAC boom was suspended vertically to orient gravity along the length of the boom. By orienting vertically, highly nonlinear and unstable behavior often encountered during horizontally oriented gravity offload testing of similar structures was reduced. Pretest analytical predictions of TRAC booms indicated three unique failure modes, loads, and locations for three unique loading cases of in-plane bending, out-of-plane bending, and axial compression. To investigate the predicted behavior, an experimental test was set up to impart mechanical loads to a subscale TRAC boom. The experimental setup, loading cases, and instrumentation used to characterize the mechanical response of a subscale TRAC boom are described in this paper.

Experimental testing↗

Model-Based Data Integration and Process Standardization Techniques for Fault Management: A Feasibility Study

This paper describes the theory and considerations in the application of model-based techniques to assimilate information from disjoint knowledge sources for performing NASA's Fault Management (FM)-related activities using the TEAMS® toolset. FM consists of the operational mitigation of existing and impending spacecraft failures. NASA's FM directives have both design-phase and operational-phase goals. This paper highlights recent studies by QSI and DST of the capabilities required in the TEAMS® toolset for conducting FM activities with the aim of reducing operating costs, increasing autonomy, and conforming to time schedules. These studies use and extend the analytic capabilities of QSI's TEAMS® toolset to conduct a range of FM activities within a centralized platform.

Haste, Deepak↗

Practical Applications of Cables and Ropes in the ISS Countermeasures System

National Aeronautics and Space Administration (NASA) uses exercise countermeasures on the International Space Station (ISS) to maintain crew health and combat the negative effects of long-duration spaceflight on the human body. Most ISS exercise countermeasures system (CMS) equipment rely heavily on the use of textile and wire ropes to transmit resistive loads and provide stability in a microgravity environment. For a variety of reasons, including challenges in simulating microgravity environments for testing and limits on time available for life cycle testing, the textiles and wire ropes have contributed significantly to on-orbit planned and unplanned maintenance time. As a result, continued ground testing and on-orbit experience since the first expedition on the ISS in 2000 provide valuable data and lessons learned in materials selection, applications, and design techniques to increase service life of these ropes. This paper will present a review of the development and failure history of textile and wire ropes for four exercise countermeasure systems-the Treadmill with Vibration Isolation and Stabilization (TVIS) System, Cycle Ergometer with Vibration Isolation and Stabilization (CEVIS) System, Interim Resistive Exercise Device (IRED), and the Advanced Resistive Exercise Device (ARED)-to identify lessons learned in order to improve future systems. These lessons learned, paired with thorough testing on the ground, offer a forward path towards reduced maintenance time and up-mass for future space missions.

Svetlik, Randall G.↗

Experimental Setup for Mechanically Testing Subscale Triangular, Rollable, and Collapsible Deployable Composite Booms

High-strain composite deployable space structures are used for space infrastructure and science applications such as solar array supports, antennae, camera masts, and lightweight structures supporting solar sailing propulsion ele-ments. Triangular, Rollable, and Collapsible (TRAC) deployable composite booms are one example of a high-strain composite deployable structure and were studied using novel experimental test and characterization methods developed under the Gravity Offloading and Analysis of Long Imperfection-sensitive Ele-ments (GOALIE) project. In the present work, a subscale 7-m-long TRAC boom was suspended vertically to orient gravity along the length of the boom. By ori-enting vertically, highly nonlinear and unstable behavior often encountered dur-ing horizontally oriented gravity offload testing of similar structures was reduced. Pretest analytical predictions of TRAC booms indicated three unique failure modes, loads, and locations for three unique loading cases of in-plane bending, out-of-plane bending, and axial compression. To investigate the predicted behav-ior, an experimental test was set up to impart mechanical loads to a subscale TRAC boom. The experimental setup, loading cases, and instrumentation used to characterize the mechanical response of a subscale TRAC boom are described in this paper.

High-strain composites↗

Space Station Freedom NiH2 cell testing program

Testing for the Space Station Freedom Nickel Hydrogen Cell Test Program began in 1990 at Crave Division, Naval Surface Warfare Center. The program has included receipt inspection, random vibration, acceptance, characterization, and life cycle testing of Ni-H2 cells in accordance with the NASA LeRC Interagency Order C-31001-J. A total of 400 Ni-H2 cells have been received at NAVSURFWARCENDIV Crane from three separate manufacturers; Yardney Technical Products (Yardney), Eagle Picher Industries (Eagle Picher), and Gates Energy Products (Gates). Of those, 308 cells distributed among 39 packs have undergone life cycle testing under a test regime simulating low earth orbit conditions. As of 30 September 1993, there are 252 cells assembled into 32 packs still on life cycle test. Since the beginning of the program, failed cells have been detected in all phases of testing. The failures include the following; seven 65 AmpHr and 81 AmpHr Yardney cells were found to be leaking KOH on receipt, one 65 AmpHr Eagle Picher cell failed the acceptance test, one 65 AmpHr Gates cell failed during the characterization test, and six 65 AmpHr Gates cells failed the random vibration test. Of the 39 life cycle packs, testing on seven packs, 56 cells, has been suspended because of low end of discharge voltages. All of the failed life cycle packs were cycled at 60% depth of discharge.

Moore, Bruce↗

Microstructural Changes to Thermally Sprayed Materials Subjected to Dynamic Compression

Dynamic compression of materials can induce a variety of microstructural changes. As thermally-sprayed materials have highly complex microstructures, the expected pressure at which changes occur cannot be predicted a priori. In addition, typical in-situ measurements such as velocimetry are unable to adequately diagnose microstructural changes such as failure or pore collapse. Quasi-isentropic compression experiments with sample recovery were conducted to examine microstructural changes in thermally sprayed tantalum and tantalum-niobium blends up to 8 GPa pressure. Spall fracture was observed in all tests, and post-shot pore volume decreased relative to the initial state. The blended material exhibited larger spall planes with fracture occurring at interphase boundaries. An estimate of the pressure at which pore collapse is complete was determined to be ~26 GPa for pure tantalum and ~19 GPa for the tantalumniobium blend under these loading conditions.

36 MATERIALS SCIENCE↗

Lessons Learned Study Final Report for the Exploration Systems Mission Directorate

This report is the final product of a 90-day study performed for the Exploration Systems Mission Directorate. The study was to assemble lessons NASA has learned from previous programs that could help the Exploration Systems Mission Directorate pursue the Exploration vision. It focuses on those lessons that should have the greatest significance to the Directorate during the formulation of program and mission plans. The study team reviewed a large number of lessons learned reports and data bases, including the Columbia Accident Investigation Board and Rogers Commission reports on the Shuttle accidents, accident reports from robotic space flight systems, and a number of management reviews by the Defense Sciences Board, Government Accountability Office, and others. The consistency of the lessons, findings, and recommendations validate the adequacy of the data set. In addition to reviewing existing databases, a series of workshops was held at each of the NASA centers and headquarters that included senior managers from the current workforce as well as retirees. The full text of the workshop reports is included in Appendix A. A lessons learned website was opened up to permit current and retired NASA personnel and on-site contractors to input additional lessons as they arise. These new lessons, when of appropriate quality and relevance, will be brought to the attention of managers. The report consists of four parts: Part 1 provides a small set of lessons, called the Executive Lessons Learned, that represent critical lessons that the Exploration Systems Mission Directorate should act on immediately. This set of Executive Lessons and their supporting rationale have been reviewed at length and fully endorsed by a team of distinguished NASA alumni; Part 2 contains a larger set of lessons, called the Selected Lessons Learned, which have been chosen from the lessons database and center workshop reports on the basis of their specific significance and relevance to the near-term work of the Exploration Directorate. These lessons frequently support the Executive lessons but are more general in nature; Part 3 consists of the reports of the center workshops that were conducted as part of this activity. These reports are included in their entirety (approximately 200 pages) in Appendix G and have significance for specific managers; Part 4 consists of the remainder of the lessons that have been selected by this effort and assembled into a database for the use of the Explorations Directorate. The database is archived and hosted in the Lessons Learned Knowledge Network, which provides a flexible search capability using a wide variety of search terms. Finally, a spreadsheet lists databases searched and a bibliography identifies reports that have been reviewed as sources of lessons for this task. NASA has been presented with many learning opportunities. We have conducted numerous programs, some extremely successful and others total failures. Most have been documented with a formal lessons learned activity, but we have not always incorporated these learning opportunities into our normal modes of business. For example, the Robbins Report of 2001 clearly indicates that many project failures of the past two decades were the result of violating well documented best practices, often in direct violation of management instructions and directives. An overarching lesson emerges: that disciplined execution in accordance with proven best practices is the greatest single contributor to a successful program. The Lessons Learned task team offers a sincere hope that the lessons presented herein will be helpful to the Exploration Systems Directorate in charting and executing their course. The success of the Directorate and of NASA in general depends on our collective ability to move forward without having to relearn the lessons of those who have gone before.

Van Laak, Jim↗

Evaluating Supply Prioritization Strategies for Risk-Informed Decision Making in an Arbitrary Gas Network

Supply disruptions and infrastructure failures in natural gas networks present critical challenges to energy reliability and risk-informed planning. This study evaluates two supply prioritization strategies, Maximum Delivery Prioritization (MDP) and Demand-Based Prioritization (DBP), within an arbitrary natural gas network under conditions of supply shortage. Model performance under both strategies is assessed in response to node and edge failure using demand satisfaction metrics, system-wide and localized dependency scores, and geographic information system (GIS)-based spatial analysis. Results show that DBP better preserves supply for high-demand nodes, while MDP offers broader coverage. The underlying network topology plays a critical role in shaping prioritization outcomes. Integrated GIS visualization enhances the interpretability of vulnerability assessments, revealing structurally critical components and localized vulnerabilities. The proposed framework supports scalable, data-driven decision-making for infrastructure planners and engineers, enabling improved disruption recovery and efficiency in constrained natural gas networks. These insights contribute to the development of more robust energy systems capable of withstanding stress and disruptions.

Peterson, Steven [ORNL] (ORCID:0000000287672998)↗

Lossless Phonon Transition Through GaN‐Diamond and Si‐Diamond Interfaces

Abstract Advancing Silicon (Si) technology beyond Moore's law through 3D architectures requires highly efficient heat management methods compatible with foundry processes. While continued increases in transistor density can be achieved through 3D architectures, self‐heating in the upper tiers degrades the performance. Self‐heating is a critical problem for high‐power, high‐frequency, wide bandgap, and ultra‐wide bandgap devices as well. Diamond, known for its exceptional thermal conductivity, offers a viable solution in both these cases. Since thermal boundary resistance (between the channel/junction and diamond plays a crucial role in overall thermal resistance, this study investigates various dielectrics for interface engineering, such as Silicon dioxide (SiO 2 ), amorphous‐ Silicon Carbide (a‐SiC), and Silicon Nitride (SiN x ), to make a phonon bridge at gallium nitride (GaN)‐diamond and Si‐diamond interfaces. The a‐SiC interlayer reduces diamond/GaN (<5 m 2 K per GW) and diamond/Si (<2 m 2 K per GW) thermal boundary resistances by linking low‐ and high‐frequency phonons, boosting phonon transport through the interface. Engineered interfaces enhance heat spreading from the channel/junction and rule out premature failure.

Malakoutian, Mohamadali↗

Structural Anomaly Detection Using Fiber Optic Sensors and Inverse Finite Element Method

NASA Langley Research Center is investigating a variety of techniques for mitigating aircraft accidents due to structural component failure. One technique under consideration combines distributed fiber optic strain sensing with an inverse finite element method for detecting and characterizing structural anomalies anomalies that may provide early indication of airframe structure degradation. The technique identifies structural anomalies that result in observable changes in localized strain but do not impact the overall surface shape. Surface shape information is provided by an Inverse Finite Element Method that computes full-field displacements and internal loads using strain data from in-situ fiberoptic sensors. This paper describes a prototype of such a system and reports results from a series of laboratory tests conducted on a test coupon subjected to increasing levels of damage.

Quach, Cuong C.↗

Application of redundancy in the Saturn 5 guidance and control system

The Saturn launch vehicle's guidance and control system is so complex that the reliability of a simplex system is not adequate to fulfill mission requirements. Thus, to achieve the desired reliability, redundancy encompassing a wide range of types and levels was employed. At one extreme, the lowest level, basic components (resistors, capacitors, relays, etc.) are employed in series, parallel, or quadruplex arrangements to insure continued system operation in the presence of possible failure conditions. At the other extreme, the highest level, complete subsystem duplication is provided so that a backup subsystem can be employed in case the primary system malfunctions. In between these two extremes, many other redundancy schemes and techniques are employed at various levels. Basic redundancy concepts are covered to gain insight into the advantages obtained with various techniques. Points and methods of application of these techniques are included. The theoretical gain in reliability resulting from redundancy is assessed and compared to a simplex system. Problems and limitations encountered in the practical application of redundancy are discussed as well as techniques verifying proper operation of the redundant channels. As background for the redundancy application discussion, a basic description of the guidance and control system is included.

Moore, F. B.↗

The Geopause

Coupled to the Earth and protected by the geomagnetic field, terrestrial matter in the plasma state dominates a larger region of space than was suspected when the 'space age' began, a region we refer to as the geosphere. Accelerated and heated by solar wind energy, this matter expands in size and increases in mass density in response to the Sun's ultraviolet spectrum, heliospheric conditions, and the occurrence of severe space storms. Such storms regularly damage spacecraft, interfere with communications, and trigger power grid interruptions or failures. They occur within the geopause region, that is, the volume defined by the limits of the instantaneous boundary between plasmas that are primarily heliospheric and geospheric. The geopause is analogous in some ways to the heliopause but also resembles the terrestrial air-sea interface. It is the boundary layer across which the supersonically expanding solar plasma delivers momentum and energy to the terrestrial plasma and gas, exciting them into motion, 'evaporating' them into space, and dissipating considerable amounts of power in thermal forms, while generating energetic particles through repeated storage and explosive release of electromagnetic energy. The intensity of the solar wind and the orientation of its magnetic field jointly control the strength of the coupling between solar and terrestrial plasmas and hence the occurrence of severe storms in the geopause region.

Moore, T. E.↗

Reusable Solid Rocket Motor - Accomplishments, Lessons, and a Culture of Success

The Reusable Solid Rocket Motor represents the largest solid rocket motor ever flown and the only human rated solid motor. Each Reusable Solid Rocket Motor (RSRM) provides approximately 3-million lb of thrust to lift the integrated Space Shuttle vehicle from the launch pad. The motors burn out approximately 2 minutes later, separate from the vehicle and are recovered and refurbished. The size of the motor and the need for high reliability were challenges. Thrust shaping, via shaping of the propellant grain, was needed to limit structural loads during ascent. The motor design evolved through several block upgrades to increase performance and to increase safety and reliability. A major redesign occurred after STS-51L with the Redesigned Solid Rocket Motor. Significant improvements in the joint sealing systems were added. Design improvements continued throughout the Program via block changes with a number of innovations including development of low temperature o-ring materials and incorporation of a unique carbon fiber rope thermal barrier material. Recovery of the motors and post flight inspection improved understanding of hardware performance, and led to key design improvements. Because of the multidecade program duration material obsolescence was addressed, and requalification of materials and vendors was sometimes needed. Thermal protection systems and ablatives were used to protect the motor cases and nozzle structures. Significant understanding of design and manufacturing features of the ablatives was developed during the program resulting in optimization of design features and processing parameters. The project advanced technology in eliminating ozone-depleting materials in manufacturing processes and the development of an asbestos-free case insulation. Manufacturing processes for the large motor components were unique and safety in the manufacturing environment was a special concern. Transportation and handling approaches were also needed for the large hardware segments. The reusable solid rocket motor achieved significant reliability via process control, ground test programs, and postflight assessment. Process control is mandatory for a solid rocket motor as an acceptance test of the delivered product is not feasible. Process control included process failure modes and effects analysis, statistical process control, witness panels, and process product integrity audits. Material controls and inspections were maintained throughout the sub tier vendors. Material fingerprinting was employed to assess any drift in delivered material properties. The RSRM maintained both full scale and sub-scale test articles. These enabled continuous improvement of design and evaluation of process control and material behavior. Additionally RSRM reliability was achieved through attention to detail in post flight assessment to observe any shift in performance. The postflight analysis and inspections provided invaluable reliability data as it enables observation of actual flight performance, most of which would not be available if the motors were not recovered. These unique challenges, features of the reusable solid rocket motor, materials and manufacturing issues, and design improvements will be discussed in the paper.

Moore, Dennis R.↗

Vacuum Insulator Flashover Physics LDRD Report

Large, pulsed power and high voltage systems often employ a stack of insulators to separate a vacuum section away from water or oil sections. The size of this insulator stack often drives overall costs and feasibility of these systems. An electric breakdown along the insulator surface is a primary failure mechanism and is especially impactful if it occurs while power is still being delivered downstream. This report describes a set of experimental and modeling investigations into the cause of these breakdowns, especially focusing on the much less well-understood anode-initiated breakdowns that occur during early parts of power delivery. Additionally, new diagnostics for assessing relevant material properties and behavior of insulators are described. These results describe breakdown behavior and evolution at new temporal and spatial fidelities and provide hypotheses and some answers as to how these breakdowns can occur. This new understanding of the roles of different physics phenomena guide modifications and trade-offs in generating newer insulator stack designs that are smaller and/or have higher electrical stress thresholds.

42 ENGINEERING↗

The Physical and Engineering Limits of Coupled In situ TEM Experiments

Almost all future energy systems (advanced nuclear reactors, fusion energy system, concentrating solar-thermal power (CSP), and wind technologies) are limited by degradation of key material systems exposed to multiple environmental stressors. The degradation during exposure to high temperatures, radiation, mechanical loading, and chemical attack is often dictated by mechanisms active at the microstructural level. The nature of these mechanisms and the associated variations between sequential and concurrent interplay can be explored if the transmission electron microscope (TEM) is utilized as a toolbox for exploration [1]. One such tool developed at Sandia National Laboratories to couple several of these environments is the In situ Ion Irradiation TEM (I3TEM) [2]. Several studies over the last decade utilizing this tool have shown that the scientific intuition developed over decades of sequential experiments is not always a good indicator of concurrent mechanisms or failure routes. This presentation will highlight the recent and planned additions into the I3TEM facility of a Waviks gas injection system and Raman system, respectively, as can be seen in Fig. 1, permitting environmental degradation from gas species leaked into the pole piece region during quantitative mechanical loading (indentation, monotonic loading, high temperature creep, irradiation induced creep, and high-cycle fatigue); multi-beam ion irradiation (energies ranging from 1 keV to 48 MeV and species from H to Au); laser exposure (20 W and 1064 nm), or various combinations thereof that are already possible [3]. This addition permits the facility to explore both sequential or concurrently the four axes of stressors: thermal, mechanical, radiation, and chemical. This information can be directly coupled to modeling, expediting the refinement and validation of both atomistic and mesoscale models.

degradation↗

Understanding Phase and Interfacial Effects of Spall Fracture in Additively Manufactured Ti-5Al-5V-5Mo-3Cr

Additive manufactured Ti-5Al-5V-5Mo-3Cr (Ti-5553) is being considered as an AM repair material for engineering applications because of its superior strength properties compared to other titanium alloys. Here, we describe the failure mechanisms observed through computed tomography, electron backscatter diffraction (EBSD), and scanning electron microscopy (SEM) of spall damage as a result of tensile failure in as-built and annealed Ti-5553. We also investigate the phase stability in native powder, as-built and annealed Ti-5553 through diamond anvil cell (DAC) and ramp compression experiments. We then explore the effect of tensile loading on a sample containing an interface between a Ti-6Al-V4 (Ti-64) baseplate and additively manufactured Ti-5553 layer. Post-mortem materials characterization showed spallation occurred in regions of initial porosity and the interface provides a nucleation site for spall damage below the spall strength of Ti-5553. Preliminary peridynamics modeling of the dynamic experiments is described. Finally, we discuss further development of Stochastic Parallel PARticle Kinteic Simulator (SPPARKS) Monte Carlo (MC) capabilities to include the integration of alpha (α)-phase and microstructural simulations for this multiphase titanium alloy.

36 MATERIALS SCIENCE↗

Landform Degradation and Slope Processes on Io: The Galileo View

The Galileo mission has revealed remarkable evidence of mass movement and landform degradation on Io. We recognize four major slope types observed on a number of intermediate resolution (250 m/pixel) images and several additional textures on very high resolution (10 m/pixel) images. Slopes and scarps on Io often show evidence of erosion, seen in the simplest form as alcove-carving slumps and slides at all scales. Many of the mass movement deposits on Io are probably mostly the consequence of block release and brittle slope failure. Sputtering plays no significant role. Sapping as envisioned by McCauley et al. remains viable. We speculate that alcove-lined canyons seen in one observation and lobed deposits seen along the bases of scarps in several locations may reflect the plastic deformation and 'glacial' flow of interstitial volatiles (e.g., SO2) heated by locally high geothermal energy to mobilize the volatile. The appearance of some slopes and near-slope surface textures seen in very high resolution images is consistent with erosion from sublimation-degradation. However, a suitable volatile (e.g., H2S) that can sublimate fast enough to alter Io's youthful surface has not been identified. Disaggregation from chemical decomposition of solid S2O and other polysulfur oxides may conceivably operate on Io. This mechanism could degrade landforms in a manner that resembles degradation from sublimation, and at a rate that can compete with resurfacing.

Moore, Jeffrey M.↗