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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.

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All sourcesNASA NTRSDOE OSTI
NASA NTRS2014

High Speed, Low Cost Telemetry Access from Space Development Update on Programmable Ultra Lightweight System Adaptable Radio (PULSAR)

Software Defined Radio (SDR) technology has been proven in the commercial sector since the early 1990's. Today's rapid advancement in mobile telephone reliability and power management capabilities exemplifies the effectiveness of the SDR technology for the modern communications market. In contrast, the foundations of transponder technology presently qualified for satellite applications were developed during the early space program of the 1960's. Conventional transponders are built to a specific platform and must be redesigned for every new bus while the SDR is adaptive in nature and can fit numerous applications with no hardware modifications. A SDR uses a minimum amount of analog / Radio Frequency (RF) components to up/down-convert the RF signal to/from a digital format. Once the signal is digitized, all processing is performed using hardware or software logic. Typical SDR digital processes include; filtering, modulation, up/down converting and demodulation. NASA Marshall Space Flight Center (MSFC) Programmable Ultra Lightweight System Adaptable Radio (PULSAR) leverages existing MSFC SDR designs and commercial sector enhanced capabilities to provide a path to a radiation tolerant SDR transponder. These innovations (1) reduce the cost of NASA Low Earth Orbit (LEO) and Deep Space standard transponders, (2) decrease power requirements, and (3) commensurately reduce volume. A second pay-off is the increased SDR flexibility by allowing the same hardware to implement multiple transponder types simply by altering hardware logic - no change of hardware is required - all of which will ultimately be accomplished in orbit. Development of SDR technology for space applications will provide a highly capable, low cost transponder to programs of all sizes. The MSFC PULSAR Project results in a Technology Readiness Level (TRL) 7 low-cost telemetry system available to Smallsat and CubeSat missions, as well as other platforms. This paper documents the continued development and verification/validation of the MSFC SDR, called PULSAR, which contributes to advancing the state-of-the-art in transponder design - directly applicable to the SmallSat and CubeSat communities. This paper focuses on lessons learned on the first sub-orbital flight (high altitude balloon) and the follow-on steps taken to validate PULSAR. A sounding rocket launch, currently planned for 03/2015, will further expose PULSAR to the high dynamics of sub-orbital flights. Future opportunities for orbiting satellite incorporation reside in the small satellite missions (FASTSat, CubeSat. etc.).

Simms, William Herbert, III↗
DOE OSTI2015

Dynamic Recrystallization Model for Whisker and Hillock Growth

Tin (Sn) whiskers are not a recent development. Studies in the late 1930’s investigated thin filaments that grew spontaneously from Sn coatings used for the corrosion protection of electronic hardware. It was soon recognized that these Sn filaments, or whiskers, could create short circuits in the same electronic equipment. Figure 1a illustrates whisker growth in the hole of a printed circuit board having an immersion Sn surface finish. The engineering solution was to contaminate the Sn with > 3 wt.% of lead (Pb). The result was that whisker growth was replaced with hillock formation (Fig. 1b) that posed a minimal reliability concern to electrical circuits. Today, Pb-containing finishes are being replaced with pure Sn coatings to meet environmental restrictions on Pb use. The same short-circuit concerns have been raised, once again, with respect to Sn whiskers.

Vianco, Paul T.↗
DOE OSTI2021

IEEE P2988: Recommended Practice of Use and Functions of Virtual Synchronous Machines

Power systems are going through a paradigm shift from centralized generation to distributed generation. This brings unprecedented challenges to power systems stability, reliability, and security. Operating power electronic converters as Virtual Synchronous Machines (VSMs) can bring backward compatibility to power systems, unify and harmonize the integration and interaction of future power systems players, and improve power system stability, reliability, and security. This is vital for the large-scale adoption of distributed energy resources, the advancement of sustainability, and the development of a low-carbon economy. This IEEE 2988 Recommended Practice will define the fundamental principles, mandatory functions, and optional functions of a VSM, i.e., a power electronic converter that is operated to behave like conventional synchronous machines. It will not describe or specify power semiconductor devices, hardware topologies, or micro-controllers that are used to build a VSM. This talk will discuss the activities and development plan for IEEE 2988 with the aim to engaging broad stakeholders and widening participation.

Zhong, Qing-Chang↗
DOE OSTI2018

Environmental Cracking and Irradiation Resistant Stainless Steels by Additive Manufacturing

Metal additive manufacturing (AM), or metal 3D printing is an emergent advanced manufacturing method that can create near net shape geometries directly from computer models. This technology can provide the capability to rapidly fabricate complex parts that may be required to enhance the integrity of reactor internals components. Such opportunities may be observed during a plant refueling outage and AM parts can be rapidly custom designed, manufactured and deployed within the outage interval. Additive manufacturing of stainless steel (SS) components can add business benefits on fast delivery on repair hardware, installation tooling, new design prototypes tests, etc. For the nuclear industry, the supply chain is always an issue for reactor service. AM can provide through-life supply chain (40-60 years) for high-value low-volume components. In the meantime, the capability of generating complex geometries and functional gradient materials will improve the performance, reduce the overall component cost, plant asset management cost and increase the plant reliability by the improvement in materials performance in nuclear environments. While extensive work has been conducted regarding additively manufacturing of austenitic SS parts, most efforts focused only on basic attributes such as porosity, residual stress, basic tensile properties, along with components yield and process monitoring. Little work has been done to define and evaluate the material requirements for nuclear applications. Technical gaps exist, which limit this technology adoption in the nuclear industry, which includes high manufacturing cost, unknown risks, limited nuclear related data, lack of specification and qualification methods, and no prior business experience. The main objective of this program was to generate research data to address all these technical gaps and establish a commercial practice to use AM technology in the nuclear power industry. The detailed objectives are listed as follows: (1) Evaluate nuclear related properties of AM 316L SS, including microstructure, tensile properties, impact toughness, stress corrosion cracking (SCC), corrosion fatigue (CF), irradiation effects, and irradiation assisted stress corrosion cracking (IASCC). (2) Understand the correlations among laser processing, heat treatment, microstructure and SCC/irradiation properties; (3) Optimize and improve the manufacturing process to achieve enhanced nuclear application properties; (4) Fabricate, evaluate, qualify and test a prototype reactor component to demonstrate the commercial viability and cost benefit; (5) Create regulatory approval path and commercialization plans for the production of a commercial reactor component.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
NASA NTRS1971

Shuttle cryogenic supply system optimization study

Technical information on different cryogenic supply systems is presented for selecting representative designs. Parametric data and sensitivity studies, and an evaluation of related technology status are included. An integrated mathematical model for hardware program support was developed. The life support system, power generation, and propellant supply are considered. The major study conclusions are the following: Optimum integrated systems tend towards maximizing liquid storage. Vacuum jacketing of tanks is a major effect on integrated systems. Subcritical storage advantages over supercritical storage decrease as the quantity of propellant or reactant decreases. Shuttle duty cycles are not severe. The operational mode has a significant effect on reliability. Components are available for most subsystem applications. Subsystems and components require a minimum amount of technology development.

Source record↗
NASA NTRS1972

Silicon-germanium technology program of the Jet Propulsion Laboratory.

The outer planetary exploration missions studied by the Jet Propulsion Laboratory require silicon-germanium radioisotope thermoelectric generators (RTGs) in which the factors of safety are as low as is compatible with the reliable satisfaction of the power needs. Work on silicon germanium sublimation performed at the Jet Propulsion Laboratory is presented. Analytical modeling work on the solid-diffusion process involved in the steady-state (free) sublimation of silicon germanium is described. Analytical predictions are made of the sublimation suppression which can be achieved by using a cover gas. A series of accelerated (high-temperature) tests which were performed on simulated hardware (using four SiGe couples) to study long-term sublimation and reaction mechanisms are also discussed.

De Winter, F.↗
NASA NTRS2003

Equivalent Mass versus Life Cycle Cost for Life Support Technology Selection

The decision to develop a particular life support technology or to select it for flight usually depends on the cost to develop and fly it. Other criteria such as performance, safety, reliability, crew time, and technical and schedule risk are considered, but cost is always an important factor. Because launch cost would account for much of the cost of a future planetary mission, and because launch cost is directly proportional to the mass launched, equivalent mass has been used instead of cost to select advanced life support technology. The equivalent mass of a life support system includes the estimated mass of the hardware and of the spacecraft pressurized volume, power supply, and cooling system that the hardware requires. The equivalent mass of a system is defined as the total payload launch mass needed to provide and support the system. An extension of equivalent mass, Equivalent System Mass (ESM), has been established for use in the Advanced Life Support project. ESM adds a mass-equivalent of crew time and possibly other cost factors to equivalent mass. Traditional equivalent mass is strictly based on flown mass and reflects only the launch cost. ESM includes other important cost factors, but it complicates the simple flown mass definition of equivalent mass by adding a non-physical mass penalty for crew time that may exceed the actual flown mass. Equivalent mass is used only in life support analysis. Life Cycle Cost (LCC) is much more commonly used. LCC includes DDT&E, launch, and operations costs. For Earth orbit rather than planetary missions, the launch cost is less than the cost of Design, Development, Test, and Evaluation (DDTBE). LCC is a more inclusive cost estimator than equivalent mass. The relative costs of development, launch, and operations vary depending on the mission destination and duration. Since DDTBE or operations may cost more than launch, LCC gives a more accurate relative cost ranking than equivalent mass. To select the lowest cost technology for a particular application we should use LCC rather than equivalent mass.

Jones, Harry↗
NASA NTRS2008

Launch and Landing Effects Ground Operations (LLEGO) Model

LLEGO is a model for understanding recurring launch and landing operations costs at Kennedy Space Center for human space flight. Launch and landing operations are often referred to as ground processing, or ground operations. Currently, this function is specific to the ground operations for the Space Shuttle Space Transportation System within the Space Shuttle Program. The Constellation system to follow the Space Shuttle consists of the crewed Orion spacecraft atop an Ares I launch vehicle and the uncrewed Ares V cargo launch vehicle. The Constellation flight and ground systems build upon many elements of the existing Shuttle flight and ground hardware, as well as upon existing organizations and processes. In turn, the LLEGO model builds upon past ground operations research, modeling, data, and experience in estimating for future programs. Rather than to simply provide estimates, the LLEGO model s main purpose is to improve expenses by relating complex relationships among functions (ground operations contractor, subcontractors, civil service technical, center management, operations, etc.) to tangible drivers. Drivers include flight system complexity and reliability, as well as operations and supply chain management processes and technology. Together these factors define the operability and potential improvements for any future system, from the most direct to the least direct expenses.

Source record↗
DOE OSTI2022

Fault Injection for TensorFlow Applications

As machine learning (ML) has seen increasing adoption in safety-critical domains (e.g., autonomous vehicles), the reliability of ML systems has also grown in importance. While prior studies have proposed techniques to enable efficient error-resilience (e.g., selective instruction duplication), a fundamental requirement for realizing these techniques is a detailed understanding of the application’s resilience. In this work, we present TensorFI 1 and TensorFI 2, high-level fault injection (FI) frameworks for TensorFlow-based applications. TensorFI 1 and 2 are able to inject both hardware and software faults in any general TensorFlow 1 and 2 program respectively. Both are configurable FI tools that are flexible, easy to use, and portable. They can be integrated into existing TensorFlow programs to assess their resilience for different fault types (e.g., bit-flips in particular operations or layers). We use the TensorFI 1 and TensorFI 2 to evaluate the resilience of 12 and 10 ML programs written in TensorFlow, including DNNs used in the autonomous vehicle domain. The results give us insights into why some of the models are more resilient. We also measure the performance overheads of the two injectors, and present 4 case studies, two for each tool, to demonstrate their utility.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2025

Automating Testing of DUNE Electronics via a Finite State Machine

The Deep Underground Neutrino Experiment (DUNE) is a flagship international collaboration designed to study neutrinos tiny, nearly massless particles that may hold answers to fundamental questions about the Universe. Fermilab s Robotic Test Stand (RTS) plays a critical role in ensuring the quality of approximately 50,000 Application-Specific Integrated Circuit (ASIC) chips that will be used in DUNE s massive liquid argon detectors. These electronics will be inside the cryostat; therefore, they will need to have a high yield of working chips and low noise. To improve the automation and reliability of the RTS, this project focused on designing and implementing a Python-based finite state machine (FSM) to manage chip handling workflows. The FSM was developed as a modular software framework to coordinate robotic arm movements, manage chip tray positions, and monitor system states during testing. Key features include robust error handling routines, a pause/resume system for safe mid-cycle interruptions, and a simulation mode for iterative testing without hardware dependencies. The system was designed to prepare for seamless integration with RTS hardware components such as the robotic arm and vision system. This integration will streamline collaboration and enable efficient deployment of updates across the six total institutions performing testing. The outcomes of this internship contribute to Fermilab s mission to advance high-energy physics and support the DOE s national goals by directly improving the testing of equipment to be used in DUNE. The project also provided valuable experience in software design and contributing to the success of DUNE.

Kang, Caleb [William Rainey Harper Coll.]↗
NASA NTRS1993

SPOT4 Operational Control Center (CMP)

CNES(F) is responsible for the development of a new generation of Operational Control Center (CMP) which will operate the new heliosynchronous remote sensing satellite (SPOT4). This Operational Control Center takes large benefit from the experience of the first generation of control center and from the recent advances in computer technology and standards. The CMP is designed for operating two satellites all the same time with a reduced pool of controllers. The architecture of this CMP is simple, robust, and flexible, since it is based on powerful distributed workstations interconnected through an Ethernet LAN. The application software uses modern and formal software engineering methods, in order to improve quality and reliability, and facilitate maintenance. This software is table driven so it can be easily adapted to other operational needs. Operation tasks are automated to the maximum extent, so that it could be possible to operate the CMP automatically with very limited human interference for supervision and decision making. This paper provides an overview of the SPOTS mission and associated ground segment. It also details the CMP, its functions, and its software and hardware architecture.

Zaouche, G.↗
NASA NTRS1999

Die Attachment for -120 C to +20 C Thermal Cycling of Microelectronics for Future Mars Rovers: An Overview

Active thermal control for electronics on Mars Rovers imposes a serious penalty in weight, volume, power consumption, and reliability. Thus, we propose that thermal control be eliminated for future Rovers. From a functional standpoint there is no reason that the electronics could not operate over the entire temperature range of the Martian environment, which can vary from a low of approximately equal -90 C to a high of approximately equal +20 C during the Martian night and day. The upper end of this range is well within that for conventional electronics. Although the lower end is considerably below that for which conventional--even high-reliability electronics is designed or tested, it is well established that electronic devices can operate to such low temperatures. The primary concern is reliability of the overall electronic system, especially in regard to the numerous daily temperature cycles that it would experience over the duration of a mission on Mars. Accordingly, key reliability issues have been identified for elimination of thermal control on future Mars Rovers. One of these is attachment of semiconductor die onto substrates and into packages. Die attachment is critical since it forms a mechanical, thermal and electrical interface between the electronic device and the substrate or package. This paper summarizes our initial investigation of existing information related to this issue, in order to form an opinion whether die attachment techniques exist, or could be developed with reasonable effort, to withstand the Mars thermal environment for a mission duration of approximately I year. Our conclusion, from a review of literature and personal contacts. is that die attachment can be made sufficiently reliable to satisfy the requirements of future Mars Rovers. Moreover, it appears that there are several possible techniques from which to choose and that the requirements could be met by judicious selection from existing methods using hard solders, soft solders, or organic adhesives. Thus from the standpoint of die attachment. it appears feasible to eliminate thermal control for Rover electronics. We recommend that this be further investigated and verified for the specific hardware and thermal conditions appropriate to Mars Rovers.

Kirschman, Randall K.↗
NASA NTRS2006

Optical Microscopy Techniques to Inspect for Metallic Whiskers

Metal surface finishes of tin, zinc and cadmium are often applied to electronic components, mechanical hardware and other structures. These finishes sometimes unpredictably may form metal whiskers over periods that can take from hours to months or even many years. The metal whiskers are crystalline structures commonly having uniform cross sectional area along their entire length. Typical whisker dimensions are nominally on the order of only a few microns (um) across while their lengths can extend from a few microns to several millimeters. Metal whiskers pose a reliability hazard to electronic systems primarily as an electrical shorting hazard. The extremely narrow dimensions of metal whiskers can make observation with optical techniques very challenging. The videos herein were compiled to demonstrate the complexities associated with optical microscope inspection of electronic and mechanical components and assemblies for the presence or absence of metal whiskers. The importance of magnification, light source and angle of illumination play critical roles in being able to detect metal whiskers when present. Furthermore, it is demonstrated how improper techniques can easily obscure detection. It is hoped that these videos will improve the probability of detecting metal whiskers with optical inspection techniques.

Brusse, Jay A.↗
NASA NTRS2004

Four-Channel PC/104 MIL-STD-1553 Circuit Board

The mini bus interface card (miniBIC) is the first four-channel electronic circuit board that conforms to MIL-STD-1553 and to the electrical-footprint portion of PC/104. [MIL-STD-1553 is a military standard that encompasses a method of communication and electrical- interface requirements for digital electronic subsystems connected to a data bus. PC/104 is an industry standard for compact, stackable modules that are fully compatible (in architecture, hardware, and software) with personal-computer data- and power-bus circuitry.] Prior to the development of the miniBIC, only one- and two-channel PC/104 MIL-STD-1553 boards were available. To obtain four channels, it was necessary to include at least two boards in a PC/104 stack. In comparison with such a two-board stack, the miniBIC takes up less space, consumes less power, and is more reliable. In addition, the miniBIC includes 32 digital input/output channels. The miniBIC (see figure) contains four MIL-STD-1553B hybrid integrated circuits (ICs), four transformers, a field-programmable gate array (FPGA), and an Industry Standard Architecture (ISA) interface. Each hybrid IC includes a MILSTD-1553 dual transceiver, memory-management circuitry, processor interface logic circuitry, and 64Kx16 bits of shared static random access memory. The memory is used to configure message and data blocks. In addition, 23 16-bit registers are available for (1) configuring the hybrid IC for, and starting it in, various modes of operation; (2) reading the status of the functionality of the hybrid IC; and (3) resetting the hybrid IC to a known state. The miniBIC can operate as a remote terminal, bus controller, or bus monitor. The FPGA provides the chip-select and data-strobe signals needed for operation of the hybrid ICs. The FPGA also receives interruption signals and forwards them to the ISA bus. The ISA interface connects the address, data, and control interfaces of the hybrid ICs to the ISA backplane. Each channel is, in effect, a MIL-STD-1553 interface that can operate either independently of the others or else as a redundant version of one of the others. The transformer in each channel provides electrical isolation between the rest of the miniBIC circuitry and the bus to which that channel is connected.

Cox, Gary L.↗
DOE OSTI2025

Automating Testing of DUNE Electronics via a Finite State Machine

The Deep Underground Neutrino Experiment (DUNE) is a flagship international collaboration designed to study neutrinos—tiny, nearly massless particles that may hold answers to fundamental questions about the Universe. Fermilab’s Robotic Test Stand (RTS) plays a critical role in ensuring the quality of approximately 50,000 Application-Specific Integrated Circuit (ASIC) chips that will be used in DUNE’s massive liquid argon detectors. These electronics will be inside the cryostat; therefore, they will need to have a high yield of working chips and low noise. To improve the automation and reliability of the RTS, this project focused on designing and implementing a Python-based finite state machine (FSM) to manage chip handling workflows. The FSM was developed as a modular software framework to coordinate robotic arm movements, manage chip tray positions, and monitor system states during testing. Key features include robust error handling routines, a pause/resume system for safe mid-cycle interruptions, and a simulation mode for iterative testing without hardware dependencies. The system was designed to prepare for seamless integration with RTS hardware components such as the robotic arm and vision system. This integration will streamline collaboration and enable efficient deployment of updates across the six institutions performing testing. The outcomes of this internship contribute to Fermilab’s mission to advance high-energy physics and support the DOE’s national goals by directly improving the testing of equipment to be used in DUNE. The project also provided valuable experience in software design and contributing to the success of DUNE.

Kang, Caleb [Fermilab]↗
NASA NTRS1987

Flight problem evaluation for Space Shuttle Orbiter

The flight problems experienced with the reusable Space Shuttle Orbiter have decreased during subsequent flights of each vehicle. By comparison to first flights of previous vehicles, the problems encountered on the initial flight of each new vehicle entering the fleet decreased. This improvement in turn has reduced the turnaround time between flights significantly and thus greatly enhanced the increased Space Shuttle launch frequency. The reusable manned space vehicle concept necessitated the development of a flight problem recognition and resolution system which would enable a thorough and timely vehicle turnaround flow. Flight evaluation, testing, and repair of manned spacecraft to enhance reliability and to ensure mission success is a unique activity. Real-time recognition of the flight problem, prompt isolation of the cause, and timely implementation of the corrective action are the keys to maintaining an operational fleet. Examples of flight problems that have been encountered as well as the corrective actions implemented during the first 24 Space Shuttle missions are presented. The corrective actions taken to preclude problem recurrence include modifications of hardware designs, manufacturing processes, flight software, test methods, and operational procedures.

Mechelay, Joseph E.↗
NASA NTRS2002

Report on Project to Characterize Multi-Junction Solar Cells in the Stratosphere using Low-Cost Balloon and Communication Technologies

Balloon, control and communication technologies are under development in our laboratory for testing multi-junction solar cells in the stratosphere to achieve near AM0 conditions. One flight, Suntracker I, has been carried out reported earlier. We report on our efforts in preparation for a second flight, Suntracker II, that was aborted due to hardware problems. The package for Suntracker I system has been modified to include separate electronics and battery packs for the 70 centimeter and 2 meter systems. The collimator control system and motor gearboxes have been redesigned to address problems with the virtual stops and backlash. Surface mount technology on a printed circuit board was used in place of the through-hole prototype circuit in efforts to reduce weight and size, and improve reliability. A mobile base station has been constructed that includes a 35' tower with a two axis rotator and multi-element yagi antennas. Modifications in Suntracker I and the factors that lead to aborting Suntracker II are discussed.

Mirza, Ali↗
NASA NTRS2006

Efficient and Robust Data Collection Using Compact Micro Hardware, Distributed Bus Architectures and Optimizing Software

Future In-Space propulsion systems for exploration programs will invariably require data collection from a large number of sensors. Consider the sensors needed for monitoring several vehicle systems states of health, including the collection of structural health data, over a large area. This would include the fuel tanks, habitat structure, and science containment of systems required for Lunar, Mars, or deep space exploration. Such a system would consist of several hundred or even thousands of sensors. Conventional avionics system design will require these sensors to be connected to a few Remote Health Units (RHU), which are connected to robust, micro flight computers through a serial bus. This results in a large mass of cabling and unacceptable weight. This paper first gives a survey of several techniques that may reduce the cabling mass for sensors. These techniques can be categorized into four classes: power line communication, serial sensor buses, compound serial buses, and wireless network. The power line communication approach uses the power line to carry both power and data, so that the conventional data lines can be eliminated. The serial sensor bus approach reduces most of the cabling by connecting all the sensors with a single (or redundant) serial bus. Many standard buses for industrial control and sensor buses can support several hundreds of nodes, however, have not been space qualified. Conventional avionics serial buses such as the Mil-Std-1553B bus and IEEE 1394a are space qualified but can support only a limited number of nodes. The third approach is to combine avionics buses to increase their addressability. The reliability, EMI/EMC, and flight qualification issues of wireless networks have to be addressed. Several wireless networks such as the IEEE 802.11 and Ultra Wide Band are surveyed in this paper. The placement of sensors can also affect cable mass. Excessive sensors increase the number of cables unnecessarily. Insufficient number of sensors may not provide adequate coverage of the system. This paper also discusses an optimal technique to place and validate sensors.

micro hardware↗