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NASA NTRS2012

Reliability of High I/O High Density CCGA Interconnect Electronic Packages under Extreme Thermal Environment

This paper provides the experimental test results of advanced CCGA packages tested in extreme temperature thermal environments. Standard optical inspection and x-ray non-destructive inspection tools were used to assess the reliability of high density CCGA packages for deep space extreme temperature missions. Ceramic column grid array (CCGA) packages have been increasing in use based on their advantages such as high interconnect density, very good thermal and electrical performances, compatibility with standard surface-mount packaging assembly processes, and so on. CCGA packages are used in space applications such as in logic and microprocessor functions, telecommunications, payload electronics, and flight avionics. As these packages tend to have less solder joint strain relief than leaded packages or more strain relief over lead-less chip carrier packages, the reliability of CCGA packages is very important for short-term and long-term deep space missions. We have employed high density CCGA 1152 and 1272 daisy chained electronic packages in this preliminary reliability study. Each package is divided into several daisy-chained sections. The physical dimensions of CCGA1152 package is 35 mm x 35 mm with a 34 x 34 array of columns with a 1 mm pitch. The dimension of the CCGA1272 package is 37.5 mm x 37.5 mm with a 36 x 36 array with a 1 mm pitch. The columns are made up of 80% Pb/20%Sn material. CCGA interconnect electronic package printed wiring polyimide boards have been assembled and inspected using non-destructive x-ray imaging techniques. The assembled CCGA boards were subjected to extreme temperature thermal atmospheric cycling to assess their reliability for future deep space missions. The resistance of daisy-chained interconnect sections were monitored continuously during thermal cycling. This paper provides the experimental test results of advanced CCGA packages tested in extreme temperature thermal environments. Standard optical inspection and x-ray non-destructive inspection tools were used to assess the reliability of high density CCGA packages for deep space extreme temperature missions. Keywords: Extreme temperatures, High density CCGA qualification, CCGA reliability, solder joint failures, optical inspection, and x-ray inspection.

high density CCGA qualifications↗

NASA NTRSDate not supplied

A Preliminary Modeling Study of Biofilm Accumulation in the Water Recovery System

Bacterial biofilms are ubiquitous in wastewater systems on earth and in spacecraft, such as in the International Space Station (ISS) wastewater processing assembly (WPA), where they cause problems in the tank, solenoid valves, and pipelines. Downstream filter applications, tank cycling, and regular biocide water flushing have been used to control biofilm accumulation on board the ISS. Biofilm control is expected to be a challenge for long-term missions with a dormancy period of up to a year, as stagnant water systems are highly susceptible to biofilm growth. Flushing of the system with biocidal water has been proposed to avoid biomass problems for long-term missions. To validate the proposed flush method, a mathematical model, based on the metabolism maintenance rate of bacteria, is being developed to understand the current biofilm accumulation rate in the ISS WPA system and to calculate the biomass production rate under dormancy-like conditions. This method of quantification of biofilm can be applied as a function of nutrient inputs to guide the selection and optimization of biofilm mitigation approaches. The method can also be helpful in understanding, defining, quantifying, visualizing, and simulating the state of the water processing system during operation and after dormancy.

Angie M Diaz↗

NASA NTRS1967

Microelectronic packaging

Hybrid assembly processes for packaging of thin film and semiconductor microelectronic devices

THIN FILM↗

NASA NTRS1971

Simple two-speed tape transport drive

High data rate storage system B tape transport fits to existing hysteresis motor thus reducing flutter, lowering assembly cost, simplifying assembly process and increasing reliability. Motor may be used on any tape recorder or similar device having two speed ratio of up to 32 to 1.

Clurman, S. P.↗

NASA NTRS1972

Information management advanced development. Volume 1: Summary

The information management systems designed for the modular space station are discussed. Subjects presented are: (1) communications terminal breadboard configuration, (2) digital data bus breadboard configuration, (3) data processing assembly definition, and (4) computer program (software) assembly definition.

Gerber, C. R.↗

NASA NTRS1978

Quantitative Ultrasonic Evaluation of Mechanical Properties of Engineering Materials

Progress in the application of ultrasonic techniques to nondestructive measurement of mechanical strength of engineering materials is reviewed. A dormant concept in nondestructive evaluation (NDE) is invoked. The availability of ultrasonic methods that can be applied to actual parts to assess their potential susceptibility to failure under design conditions is discussed. It was shown that ultrasonic methods yield measurements of elastic moduli, microstructure, hardness, fracture toughness, tensile strength, yield strength, and shear strength for a wide range of materials (including many types of metals, ceramics, and fiber composites). It was also indicated that although most of these methods were shown feasible in laboratory studies, more work is needed before they can be used on actual parts in processing, assembly, inspection, and maintenance lines.

Vary, A.↗

NASA NTRS1981

Design requirements for SRB production control system. Volume 2: System requirements and conceptual description

In the development of the business system for the SRB automated production control system, special attention had to be paid to the unique environment posed by the space shuttle. The issues posed by this environment, and the means by which they were addressed, are reviewed. The change in management philosphy which will be required as NASA switches from one-of-a-kind launches to multiple launches is discussed. The implications of the assembly process on the business system are described. These issues include multiple missions, multiple locations and facilities, maintenance and refurbishment, multiple sources, and multiple contractors. The implications of these aspects on the automated production control system are reviewed including an assessment of the six major subsystems, as well as four other subsystem. Some general system requirements which flow through the entire business system are described.

Source record↗

NASA NTRS1984

Fabrication of glass gas cells for the HALOE and MAPS satellite experiments

The Halogen Occultation Experiment (HALOE) and the Measurement of Air Pollution from Satellites (MAPS) experiment are satellite-borne experiments which measure trace constituents in the Earth's atmosphere. The instruments which obtain the data for these experiments are based on the gas filter correlation radiometer measurement technique. In this technique, small samples of the gases of interest are encapsulated in glass cylinders, called gas cells, which act as very selective optical filters. This report describes the techniques employed in the fabrication of the gas cells for the HALOE and MAPS instruments. Details of the method used to fuse the sapphire windows (required for IR transmission) to the glass cell bodies are presented along with detailed descriptions of the jigs and fixtures used during the assembly process. The techniques and equipment used for window inspection and for pairing the HALOE windows are discussed. Cell body materials and the steps involved in preparing the cell bodies for the glass-to-sapphire fusion process are given.

Sullivan, E. M.↗

NASA NTRS1985

A sequential decoding performance analysis for International Comet Explorer

The effect of a noisy reference carrier on the performance of International Comet Explorer (ICE) Sequential decoder is analyzed. Ideal reference models for frame deletion probability are given for the Telemetry Processing Assembly (TPA) and the Linkabit (LS4815) sequential decoders. Based on these ideal reference models the deletion probability in the presence of noisy reference carrier is computed for both the high and the low data rate cases. A medium data rate performance model is then derived using an interpolation method. The derived medium rate performance model depends on the phase locked loop bandwidth-integration time product. Results are obtained for frame length 1024 bits, data bit rates of 1024 bps and 512 bps, modulation index of 60 deg, and threshold loop bandwidths of 10 Hz and 3 Hz. The medium rate model agrees with experimental data to within measurement uncertainty. For the 10 Hz loop bandwidth and modulation index of 60 deg at frame deletion rate of 0.0001, the required total received power to noise ratio is 36 dB. The analysis given is general and applicable to any sequential decoder, provided that the ideal reference model of the decoder is available.

Divsalar, D.↗

NASA NTRS1985

Dendritic web-type solar cell mini-modules

Twenty-five minimodules composed of dendritic web solar cells with nominal glass size of 12 by 40 cm were provided for study. The modules were identical with respect to design, materials, and manufacturing and assembly processes to full scale modules. The modules were also electrically functional. These minimodules were fabricated to provide test vehicle for environmental testing and to assess reliability of process and design procedures. The module design and performance are outlined.

Campbell, R. B.↗

NASA NTRS1987

Hubble Space Telescope particulate optical test

The Particulate Optical Test was designed to record and measure particulate contaminants on the Hubble Space Telescope primary mirror. The objective of the test was to quantify the primary mirror particulate contamination prior to launch. The test consists of taking dark-field photographs of the primary mirror from in front of the telescope's aperture door. These photographs are subsequently digitized and analyzed to produce the areal coverage estimates. The estimated particulate areal obscuration is approximately 1.0 percent of the primary mirror surface in the usable region. This level of contamination is within the budget value of 2.5 percent and indicates that there was little increase in particulate contamination during the HST assembly process or the acoustic test period.

Metheny, Wayne↗

NASA NTRS1988

End-effector - joint conjugates for robotic assembly of large truss structures in space: A second generation

Current designs, a first generation intended for robotic assembly, have given priority to the ease and certainty of the assembly process under less than ideal conditions with a minimum of sensory feedback. As a consequence they are either heavy or expensive and all exhibit a relatively low packaging density. Low packaging density is caused by extensive scars applied to the node, increasing its envelope diameter by as much as 150 percent. Strut envelopes are violated to a lessor extent with diameters increased by 25 percent or more. This smaller percentage is still a significant problem owing to a much higher fraction of the packaged volume represented by struts. As structures in space become larger, packaging density becomes an important consideration. The objective is to develop end-effector-joint conjugates that do not violate the envelopes of a 2.5 inch diameter node or a 1.0 inch diameter strut.

Brewer, W. V.↗

NASA NTRS1988

Center for Advanced Space Propulsion (CASP)

With a mission to initiate and conduct advanced propulsion research in partnership with industry, and a goal to strengthen U.S. national capability in propulsion technology, the Center for Advanced Space Propulsion (CASP) is the only NASA Center for Commercial Development of Space (CCDS) which focuses on propulsion and associated technologies. Meetings with industrial partners and NASA Headquarters personnel provided an assessment of the constraints placed on, and opportunities afforded commercialization projects. Proprietary information, data rights, and patent rights were some of the areas where well defined information is crucial to project success and follow-on efforts. There were five initial CASP projects. At the end of the first year there are six active, two of which are approaching the ground test phase in their development. Progress in the current six projects has met all milestones and is detailed. Working closely with the industrial counterparts it was found that the endeavors in expert systems development, computational fluid dynamics, fluid management in microgravity, and electric propulsion were well received. One project with the Saturn Corporation which dealt with expert systems application in the assembly process, was placed on hold pending further direction from Saturn. The Contamination Measurment and Analysis project was not implemented since CASP was unable to identify an industrial participant. Additional propulsion and related projects were investigated during the year. A subcontract was let to a small business, MicroCraft, Inc., to study rocket engine certification standards. The study produced valuable results; however, based on a number of factors it was decided not to pursue this project further.

Source record↗

NASA NTRS1990

Flight set 360T004 (STS-30)

The performance of 360T004, Forth Flight, Redesigned Solid Rocket Motors (RSRM) is assessed in respect to joint sealing issues as seen from post-test inspection of the seals and sealing surfaces. The factory joint disassembly inspections for this flight set were omitted. The decision was based on the rational that there is sufficient information in the present data base, and this would give H-7 refurbishment operations faster turn around time for this set of hardware. The factory joint disassembly inspections will resume for 360H005, Fifth Flight, through 360L007, Seventh Flight, due to a new grease application being in effect during the assembly process. The left hand nozzle was forced into the snubbed position upon splash down. This required unique tooling to be manufactured to perform the disassembly of the internal nozzle joints. This was completed on February 5 and 6, 1990 at the H-5 Clearfield, Utah facility. The RSRM consisting of capture feature, field joints with the J-joint insulation configuration is illustrated. The nozzle-to-case joint design, which includes 100, 7/8-inch radial bolts in conjunction with a wiper O-ring and modified insulation design is also illustrated, as is the ignition system seals and a cross section of the igniter. The configuration of all internal nozzle joints is shown.

Nelsen, Lowell V.↗

NASA NTRS1990

A&R challenges for in-space operations

Automation and robotics (A&R) challenges for in-space operations are examined, with emphasis on the interaction between developing requirements, developing solutions, design concepts, and the nature of the applicability of automation in robotic technologies. Attention is first given to the use of A&R in establishing outposts on the moon and Mars. Then emphasis is placed on the requirements for the assembly of transportation systems in low earth orbit. Concepts of the Space Station which show how the assembly, processing, and checkout of systems in LEO might be accommodated are examined.

Underwood, James↗

NASA NTRS1990

Space Station Freedom - Optimized to support microgravity research and earth observations

The Space Station Freedom Program is reviewed, with particular attention given to the Space Station configuration, program elements description, and utilization accommodation. Since plans call for the assembly of the initial SSF configuration over a 3-year time span, it is NASA's intention to perform useful research on it during the assembly process. The research will include microgravity experiments and observational sciences. The specific attributes supporting these attempts are described, such as maintainance of a very low microgravity level and continuous orientation of the vehicle to maintain a stable, accurate local-vertical/local-horizontal attitude.

Bilardo, Vincent J., Jr.↗

NASA NTRS1991

Space Shuttle Solid Rocket Motor Program - Lessons learned

An evaluation is given of the most important lessons learned concerning the Space Shuttle's Solid Rocket Motors with respect to flight safety, reuse requirements, system reliability, structural integrity, and hardware damage due to reentry, water impact, and retrieval. Within the major categories of flight safety, performance, and reuse/cost, priorities are identified for implementation of envisioned improvements; schedule and cost considerations are noted to have been substantially downgraded in favor of flight safety. The consequences of the primacy of flight safety are discussed in the areas of primary systems design, redundant systems, manufacturing and assembly processing, and launch constraints.

Mccool, A. A.↗

NASA NTRS1990

Hubble Space Telescope: SRM/QA observations and lessons learned

The Hubble Space Telescope (HST) Optical Systems Board of Investigation was established on July 2, 1990 to review, analyze, and evaluate the facts and circumstances regarding the manufacture, development, and testing of the HST Optical Telescope Assembly (OTA). Specifically, the board was tasked to ascertain what caused the spherical aberration and how it escaped notice until on-orbit operation. The error that caused the on-orbit spherical aberration in the primary mirror was traced to the assembly process of the Reflective Null Corrector, one of the three Null Correctors developed as special test equipment (STE) to measure and test the primary mirror. Therefore, the safety, reliability, maintainability, and quality assurance (SRM&QA) investigation covers the events and the overall product assurance environment during the manufacturing phase of the primary mirror and Null Correctors (from 1978 through 1981). The SRM&QA issues that were identified during the HST investigation are summarized. The crucial product assurance requirements (including nonconformance processing) for the HST are examined. The history of Quality Assurance (QA) practices at Perkin-Elmer (P-E) for the period under investigation are reviewed. The importance of the information management function is discussed relative to data retention/control issues. Metrology and other critical technical issues also are discussed. The SRM&QA lessons learned from the investigation are presented along with specific recommendations. Appendix A provides the MSFC SRM&QA report. Appendix B provides supplemental reference materials. Appendix C presents the findings of the independent optical consultants, Optical Research Associates (ORA). Appendix D provides further details of the fault-tree analysis portion of the investigation process.

Rodney, George A.↗