SEARCH · Search NASA
Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.
Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.
Spacecraft electronics including those used at the Jet Propulsion Laboratory (JPL), demand production of highly reliable assemblies. More than 400 test vehicles were assembled using ceramic and plastic ball grid arrays (BGAs), LCCs, J-leads, and gull wing components.
Adequate performance was achieved relatively early in the development of ion engines and most subsequent development programs have focussed on demonstrating adequate engine life. The primary threats to engine reliability over the required service life are damage accumulation failure modes such as accelerator grid failure due to sputter erosion from charge exchange ions, erosion of discharge chamber components by lower energy ion sputtering and grid shorting by flakes of sputter-deposited material. These types of failure may typically be observed only after thousands of hours of operation. The purpose of this paper is to provide a critical review of the approaches used in past ion engine development programs to characterize and control these wearout failure mechanisms.
The objective of this task is to evaluate thermal cycle behavior of advanced 2.5/3D electronics — commercial-off the-shelf (COTS) —packages of different configurations assembled onto printed circuit boards (PCBs). Three key approaches were considered for evaluation. The first approach focused on the through-mold via (TMV™) technology at assembly level. The second approach focused on evaluation of 2.5D (also known as, System in Package (SiP)) in fine pitch ball grid array (FPGA). The third approach focused on evaluation of through-silicone-via (TSV) technologies. This report presents the test results for TMV™ and SiP packaging technologies and reliability, and it also provides lessons learned on quality assurance methods. Specifically, the report presents the test matrix for various 3D TMV™ packaging assembly configurations and reliability characterizations performed under two accelerated thermal cycling (ATC) and accelerated thermal shock cycling (ATSC) conditions. The ATC and ATSC were performed in the range of –55°C to 125°C and –100°C to 100°C, respectively. The report also includes assembly of a SiP— a 60-mm fine-pitch ball-grid array (FPGA) interposer with an IC at the center and six chip-scale package (CSP) daisy chains at the periphery—with package assembly characterizations. After assembly, the daisy chains were subjected to ATCs in the range of –40°C to 125°C for reliability evaluation. Finally, for both TMV™ and SiP packaging configurations, characterizations results by X-ray, optical imaging, and daisy-chain resistance evaluations were also presented.
The purpose of this text is to provide the reader with the background, understanding, and computational tools needed to master the practical aspects of photovoltaic (PV) technology, application, and cost. The focus is on stand-alone, silicon solar cell, flat-plate systems in the range of 1 to 25 kWh/day output. Technology topics covered include operation and performance of each of the major system components (e.g., modules, array, battery, regulators, controls, and instrumentation), safety, installation, operation and maintenance, and electrical loads. Application experience and trends are presented. Indices of electrical service performance - reliability, availability, and voltage control - are discussed, and the known service performance of central station electric grid, diesel-generator, and PV stand-alone systems are compared. PV system sizing methods are reviewed and compared, and a procedure for rapid sizing is described and illustrated by the use of several sample cases. The rapid sizing procedure yields an array and battery size that corresponds to a minimum cost system for a given load requirement, insulation condition, and desired level of service performance. PV system capital cost and levelized energy cost are derived as functions of service performance and insulation. Estimates of future trends in PV system costs are made.
The use of computational simulations in the prediction of complex aerodynamic flows is becoming increasingly prevalent in the design process within the aerospace industry. Continuing advancements in both computing technology and algorithmic development are ultimately leading to attempts at simulating ever-larger, more complex problems. However, by increasing the reliance on computational simulations in the design cycle, we must also increase the accuracy of these simulations in order to maintain or improve the reliability arid safety of the resulting aircraft. At the same time, large-scale computational simulations must be made more affordable so that their potential benefits can be fully realized within the design cycle. Thus, a continuing need exists for increasing the accuracy and efficiency of computational algorithms such that computational fluid dynamics can become a viable tool in the design of more reliable, safer aircraft. The objective of this research was the development of an error estimation and grid adaptive strategy for reducing simulation errors in integral outputs (functionals) such as lift or drag from from multi-dimensional Euler and Navier-Stokes simulations. In this final report, we summarize our work during this grant.
The 472 Dimpled Ball Grid Array (D-BGA) package has not been used in past space flight environments, therefore it is necessary to determine the robustness and reliability of the solder joints. The 472 D-BGA packages passed the above environmental tests within the specifications and are now qualified for use on space flight electronics.
Surface mount electronic package test boards have been assembled using tin/lead (Sn/Pb) and lead-free (Pb-free or SnAgCu or SAC305) solders. The soldered surface mount packages include ball grid arrays (BGA), flat packs, various sizes of passive chip components, etc. They have been optically inspected after assembly and subsequently subjected to extreme temperature thermal cycling to assess their reliability or future deep space, long-term, extreme temperature environmental missions. In this study, the employed temperature range (-185oC to +125oC) covers military specifications (-55oC to +100oC), extreme old Martian (-120oC to +115oC), asteroid Nereus (-180oC to +25oC) and JUNO (-150oC to +120oC) environments. The boards were inspected at room temperature and at various intervals as a function of extreme temperature thermal cycling and bake duration. Electrical resistance measurements made at room temperature are reported and the tests to date have shown some change in resistance as a function of extreme temperature thermal cycling and some showed increase in resistance. However, the change in interconnect resistance becomes more noticeable with increasing number of thermal cycles. Further research work will be carried out to understand the reliability of packages under extreme temperature applications (-185oC to +125oC) via continuously monitoring the daisy chain resistance for BGA, Flat-packs, lead less chip packages, etc. This paper will describe the experimental reliability results of miniaturized passive components (01005, 0201, 0402, 0603, 0805, and 1206) assembled using surface mounting processes with tin-lead and lead-free solder alloys under extreme temperature environments.
In the beginning, a good measure of a GMCs performance was their ability to simulate the observed mean seasonal cycle. That is, a reasonable simulation of the means (i.e., small biases) and standard deviations of TODAY?S climate would suffice. Here, we argue that coupled GCM (CG CM for short) simulations of FUTURE climates should be evaluated in much more detail, both spatially and temporally. Arguably, it is not the bias, but rather the reliability of the model-generated anomaly time-series, even down to the [C]GCM grid-scale, which really matter. This statement is underlined by the social need to address potential REGIONAL climate variability, and climate drifts/changes in a manner suitable for policy decisions.
Forecast precipitation and radar characteristics are used by operational centers to guide the issuance of advisory products. As operational numerical weather prediction is performed at increasingly finer spatial resolution, convective precipitation traditionally represented by sub-grid scale parameterization schemes is now being determined explicitly through single- or multi-moment bulk water microphysics routines. Gains in forecasting skill are expected through improved simulation of clouds and their microphysical processes. High resolution model grids and advanced parameterizations are now available through steady increases in computer resources. As with any parameterization, their reliability must be measured through performance metrics, with errors noted and targeted for improvement. Furthermore, the use of these schemes within an operational framework requires an understanding of limitations and an estimate of biases so that forecasters and model development teams can be aware of potential errors. The National Severe Storms Laboratory (NSSL) Spring Experiments have produced daily, high resolution forecasts used to evaluate forecast skill among an ensemble with varied physical parameterizations and data assimilation techniques. In this research, high resolution forecasts of the 5-6 February 2008 Super Tuesday Outbreak are replicated using the NSSL configuration in order to evaluate two components of simulated convection on a large domain: sensitivities of quantitative precipitation forecasts to assumptions within a single-moment bulk water microphysics scheme, and to determine if these schemes accurately depict the reflectivity characteristics of well-simulated, organized, cold frontal convection. As radar returns are sensitive to the amount of hydrometeor mass and the distribution of mass among variably sized targets, radar comparisons may guide potential improvements to a single-moment scheme. In addition, object-based verification metrics are evaluated for their utility in gauging model performance and QPF variability.
Under the current Artemis Program, the National Aeronautics and Space Administration (NASA) will send its next set of astronauts (first woman and next man) to the Moon by 2024 and establish a sustainable presence on the lunar surface by 2028. The challenge of creating a sustained lunar surface presence is significantly different than previous efforts. Lunar surface operations will require access to continuous and highly reliable power to support mission needs, such as to support ISRU operations. Adding to this challenge, the lunar surface operations are not going to be established over a single effort, rather the system and operations will evolve and grow over time (years). The first initial loads that arrive on the lunar surface will be integrated to their own dedicated power sources. As the lunar surface operations grow, so will the demand for power and at some point these individual loads will require more power than can be generated with any single power device. This power demand drives the need for inter-connecting the loads and power devices to share power between them, resulting in a micro-grid. One of the advantages of developing a lunar surface micro-grid is that allows lunar surface operations to resemble electrical utility operations on Earth; it allows power to be generated where it is convenient and allows power to be consumed where it is convenient, rather than negotiating between generation and consumption. The micro-grid concept also provides another benefit of affording the ability to increase overall system reliability by integrating dissimilar power generation and energy storage devices together, for example modifying the power generation strategy to include both solar arrays and nuclear. Creating a lunar surface micro-grid has its advantages, however there are significant challenges associated with an evolvable micro-grid concept. The challenges include how to efficiently transmit large amounts of power (10kW+) long distances (1kW+), how to effectively integrate dissimilar power generation and energy storage devices to maximize power consumption and minimize downtime, and how to physically connect these devices together with a connector that can survive the lunar environment (dust, extreme cold temperatures) and is capable of both astronaut and robotic operation. The basic components of the micro-grid have to be designed to ensure the system is sustainable, modular, and reconfigurable. An interface to the micro-grid has to be designed that allows for additional technologies, some of which may not yet be fully designed, to easily integrate into the micro-grid concept. This presentation discusses these lunar challenges in some more depth and offers a path forward in designing an evolvable micro-grid to meet the needs of the lunar surface operations and proposes a Universal Micro-grid Interface Converter to connect these dissimilar power sources and mission loads to the micro-grid.
Area array packages (AAPs) with 1.27 mm pitch have been the packages of choice for commercial applications; they are now starting to be implemented for use in military and aerospace applications. Thermal cycling characteristics of plastic ball grid array (PBGA) and chip scale package assemblies, because of their wide usage for commercial applications, have been extensively reported on in literature. Thermal cycling represents the on-off environmental condition for most electronic products and therefore is a key factor that defines reliability.However, very limited data is available for thermal cycling behavior of ceramic packages commonly used for the aerospace applications. For high reliability applications, numerous AAPs are available with an identical design pattern both in ceramic and plastic packages. This paper compares assembly reliability of ceramic and plastic packages with the identical inputs/outputs(I/Os) and pattern. The ceramic package was in the form of ceramic column grid array (CCGA) with 560 I/Os peripheral array with the identical pad design as its plastic counterpart.
Prediction of Worldwide Energy Resources (POWER) project provides irradiance dataset to support renewable energy, building energy efficiency and agricultural needs. These datasets are derived from Global Energy and Water Cycle Experiment Surface Radiation Budget (GEWEX SRB) and Clouds and the Earth’s Radiant Energy System (CERES SYN1Deg). A systematic bias has been reported between these two datasets for the years with overlapping observations. For obtaining a consistent climate data record spanning the entire time record of observations, it is crucial to understand and remove the bias in the irradiance dataset. Inconsistency in solar radiation data can lead to inaccurate conclusions about solar energy potential and obscure real trends in solar radiation patterns that would impact energy availability assessments. In this study, we adapt quantile mapping approach to remove the systematic bias and to improve reliability of shortwave and longwave irradiance data. We present a validation of the bias corrected data against ground truth. For each 1° latitude and 1° longitude grid box across the globe, we match the CDFs of the reference dataset (CERES SYN1Deg) to that of the SRB dataset, thereby, adjusting the irradiance values to match the empirical distribution of two different measurements. The performance of quantile mapping is evaluated by using the metrics such as Mean Absolute Deviation (MAD). The results indicate that the quantile mapping significantly improves the accuracy and reliability of solar irradiance dataset especially for the weather conditions associated with high cloud cover and extreme irradiance values. The initial range of MAD for the studied sites for daily data was 4 to 19 Wm-2. After correction these reduced to 3 to 7 Wm-2. The findings from this study have important implications for solar energy system design, agricultural planning, and climate modeling community. Reducing the inconsistency and biases in solar irradiance dataset can enable better planning and operation of solar energy systems, leading to increased efficiency and cost-effectiveness. Additionally, this work also contributes to the statistical post-processing techniques in the renewable energy domain and highlights the potential of historical and near-real-time NASA POWER dataset as a valuable resource for solar energy research and applications.
The development of breakthrough open-rotor propulsion systems that meet performance, fuel efficiency, and noise requirements for commercial viability relies heavily on the availability of reliable and computationally efficient aerodynamic performance and noise prediction tools.This investigation showcases the proficiency of the structured curvilinear overset grid Computational Fluid Dynamics solver implemented in the Launch, Ascent, and Vehicle Aerodynamics framework for predicting the aerodynamic and aeroacoustic characteristics of a Contra-RotatingOpen Rotor propulsion system. Additionally, the study includes comprehensive sensitivity analyses employing a Hybrid Reynolds-Averaged Navier-Stokes/Large Eddy Simulation - based scale-resolving turbulence closure treatment. The computed results are validated through comparison with existing experimental measurements.
This paper summarizes a joint study by Gates Aerospace Batteries (GAB) and the Reliability Analysis Center (RAC). This study characterizes the reliability and robustness of the temperature compensated strain gages currently specified for sensing of internal pressure of NiH2 cells. These strain gages are characterized as fully encapsulated, metallic foil grids with known resistance that varies with deformation. The measurable deformation, when typically installed on the hemispherical portion of a NiH2 cell, is proportional to the material stresses as generated by internal cell pressures. The internal pressure sensed in this manner is calibrated to indicate the state-of-charge for the cell. This study analyzes and assesses both robustness and reliability for the basic design of the strain gage, the installation of the strain gage, and the circuitry involved.
In large area, low cost solar cells of any type, the contact and grid structure metallization is an important factor which has an effect on the efficiency of the solar cell and its reliability. The present investigation is concerned with aspects of solar cell efficiency. An optimized metallization design leads to minimum total power loss, which is related to a simultaneous minimization of ohmic voltage drops and of shading of the front surface of the cell by the overlaid metal. The requirements regarding the design for a low-loss metallization pattern for the front surface of large area solar cells are represented by a set of design rules listed in a table. The total shading and voltage drop on such cells can be held to about 5%. However, not every metallization process is suited for meeting the requirements of the low-cost design. The low losses can be achieved only by use of several bus lines containing a bulk conductor, such as a wire.
The ROBUST nature (biases are not as important as previous GCM-evaluations suggest) of the AIRS-observations-generated ARC-maps and ATs as well as their interrelations suggest that they could be a useful tool to select CGCMs which may be considered the reliable, i.e., to be trusted even for longer-term climate drift/change predictions (even on the regional scale). Get monthly gridded CGCM time-series of atmospheric variables coinciding with the timeframe of the AIRS analyses for at least 5-6 years and do the actual evaluations of ARC-maps and ATs for the coinciding time periods.
A two-part algorithm is presented for reliably computing weather forecast model and observational error covariances during data assimilation. Data errors arise from instrumental inaccuracies and sub-grid scale variability, whereas forecast errors occur because of modeling errors and the propagation of previous analysis errors. A Kalman filter is defined as the primary algorithm for estimating the forecast and analysis error convariance matrices. A second algorithm is described for quantifying the noise covariance matrices of any degree to obtain accurate values for the observational error covariances. Numerical results are provided from a linearized one-dimensional shallow-water model. The results cover observational noise covariances, initial instrumental errors and erroneous model values.
Flow non-uniformity at the discharge of high power density impellers can result in significant unsteady interactions between impeller blades and downstream diffuser vanes. These interactions result in degradation of both performance and pump reliability. The MSFC Pump Technology Team has recognized the importance of resolving this problem and has thus initiated the development and testing of a high head coefficient impeller. One of the primary goals of this program is to improve impeller performance and discharge flow uniformity. The objective of the present work is complimentary. Flow uniformity and performance gains were sought through the application of a tandem blade arrangement. The approach adopted was to numerically establish flow characteristics at the impeller discharge for the baseline MSFC impeller and then parametrically evaluate tandem blade configurations. A tandem design was sought that improves both impeller performance and discharge uniformity. The Navier-Stokes solver AEROVISC was used to conduct the study. Grid embedding is used to resolve local gradients while attempting to minimize model size. Initial results indicate that significant gains in flow uniformity can be achieved through the tandem blade concept and that blade clocking rather than slot location is the primary driver for flow uniformity.