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NASA NTRS2003

Implications of Pb-free microelectronics assembly in aerospace applications

The commercial microelectronics industry is rapidly moving to completely Pb-free assembly strategies within the next decade. This trend is being driven by existing and proposed legislation in Europe and in Japan. The microelectronics industry has become truly global, as indicated by major U .S. firms who already adopted Pb-free implementation programs. Among these forward-looking firms are AT&T, IBM, Motorola, HP and Intel to name a few.Following Moore's law, advances in microelectronics are happening very rapidly. In many cases, commercial industry is ahead of the aerospace sector in technology. Progress by commercial industry, along with cost, drives the use of Commercial Off-The-Shelf (COTS) parts for military and space applications. We can thus anticipate that the aerospace industry will, at some point, be forced to use Pb-free components and subsystems as part of their standard business practices. In this paper we attempt to provide a snapshot of the commercial industry trends and how they may impact electronics in the aerospace environment. In addition, we also look at different strategies for implementation. Finally we present data collected on a recent NASA project to focus on finding suitable alternatives to eutectic tin-lead solders and solder pastes. The world is moving toward implementation of environmentally friendly manufacturing techniques. The aerospace industry will be forced to deal with issues related with Pb free assembly, either by availability or legislation. This paper provides some insight into some of the tradeoffs that should be considered.

Pb-free electronics manufacturing↗
NASA NTRS2006

Chromite-Plagioclase Assemblages as a New Shock Indicator; Implications for the Shock and Thermal Histories of Ordinary Chondrites

Chromite in ordinary chondrites (OC) can be used as a shock indicator. A survey of 76 equilibrated H, L and LL chondrites shows that unshocked chromite grains occur in equant, subhedral and rounded morphologies surrounded by silicate or intergrown with metallic Fe-Ni and/or troilite. Some unmelted chromite grains are fractured or crushed during whole-rock brecciation. Others are transected by opaque veins; the veins form when impacts cause localized heating of metal-troilite intergrowths above the Fe-FeS eutectic (988 C), mobilization of metal-troilite melts, and penetration of the melt into fractures in chromite grains. Chromite-plagioclase assemblages occur in nearly every shock-stage S3-S6 OC; the assemblages range in size from 20-300 microns and consist of 0.2-20-micron-size euhedral, subhedral, anhedral and rounded chromite grains surrounded by plagioclase or glass of plagioclase composition. Plagioclase has a low impedance to shock compression. Heat from shock-melted plagioclase caused adjacent chromite grains to melt; chromite grains crystallized from this melt. Those chromite grains in the assemblages that are completely surrounded by plagioclase are generally richer in Al2O3, than unmelted, matrix chromite grains in the same meteorite. Chromite veinlets (typically 0.5-2 microns thick and 10-300 microns long) occur typically in the vicinity of chromite-plagioclase assemblages. The veinlets formed from chromite-plagioclase melts that were injected into fractures in neighboring silicate grains; chromite crystallized in the fractures and the residual plagioclase-rich melt continued to flow, eventually pooling to form plagioclase-rich melt pockets. Chromite-rich chondrules (consisting mainly of olivine, plagioclase-normative mesostasis, and 5-15 vol.% chromite) occur in many shocked OC and OC regolith breccias but they are absent from primitive type-3 OC. They may have formed by impact melting chromite, plagioclase and adjacent mafic silicates during higher-energy shock events. The melt was jetted from the impact site and formed droplets due to surface tension. Crystallization of these droplets may have commenced in flight, prior to landing on the parent-body surface. Chromite-plagioclase assemblages and chromite veinlets occur in 25 out of 25 shock-stage S1 OC of petrologic type 5 and 6 that I examined. Although these rocks contain unstrained olivine with sharp optical extinction, most possess other shock indicators such as extensive silicate darkening, numerous occurrences of metallic Cu, polycrystalline troilite, and opaque veins. It seems likely that these rocks were shocked to levels at least as high as shock-stage S3 and then annealed by heat generated during the shock event. During annealing, the olivine crystal lattices healed but other shock indicators survived. Published Ar-Ar age data for some SI OC indicate that many shock and annealing events occurred very early in the history of the parent asteroids. The common occurrence of shocked and annealed OC is consistent with collisions being a major mechanism responsible for metamorphosing OC.

Rubin, Alan E.↗
NASA NTRS2007

Assembly and Thermal Hydraulic Test of a Stainless Steel Sodium-Potassium Circuit

Early Flight Fission Test Facilities (EFF-TF) team has been tasked by the NASA Marshall Space Flight Center Nuclear Systems Office to design, fabricate, and test an actively pumped alkali metal flow circuit. The system was originally built for use with lithium, but due to a shift in focus, it was redesigned for use with a eutectic mixture of sodium potassium (NaK). Basic circuit components include: reactor segment, NaK to gas heat exchanger, electromagnetic (EM) liquid metal pump, load/drain reservoir, expansion reservoir, instrumentation, and a spill reservoir. A 37-pin partial-array core (pin and flow path dimensions are the same as those in a full design) was selected for fabrication and test. This paper summarizes the first fill and checkout testing of the Stainless Steel NaK-Cooled Circuit (SNaKC).

Garber, A.↗
NASA NTRS2007

Processes in Early Planetesimals: Evidence from Ureilite Meteorites

Ureilites are primitive ultramafic achondrites composed largely of olivine and pigeonite, with minor augite, carbon, sulphide and metal. They represent very early material in the history of the Solar System and form a bridge between undifferentiated chondrites and fully differentiated asteroids. They show a mixture of chemical characteristics, some of which are considered to be nebula-derived (e.g. a negative correlation between Mg/Fe and Delta O-17 that resembles that of the ordinary chondrites but at lower Delta O-17 values) whereas others have been imposed by asteroidal differentiation. Carbon isotope data show a striking negative correlation of delta C-13 values with mg# in olivine. delta C-13 also correlates positively with Delta O-17, and therefore this isotopic variation was probably also nebula-derived. Thus, oxygen and carbon isotope compositions and Fe-Mg systematics of each monomict ureilite were established before differentiation processes began. Heated by decay of short-lived radioactive isotopes, the ureilite asteroid started to melt. Metal and sulphide would have melted first, forming a Fe-S eutectic liquid, which removed chalcophile elements and incompatible siderophile elements, and basaltic melts that removed Al, Ca and the LREE. Several elements show different abundances and/or correlations with Fo content in olivine, e.g. carbon shows a positive correlation in ferroan ureilites, and a weak or even negative correlation in more magnesian compositions. HSE such as Os and Ir also show different distributions, i.e. ureilites with Fo < 82 have very scattered Os and Ir concentrations, which reach high values, whereas ureilites with Fo > 82 tend to have much less scattered and overall lower Os and Ir abundances. A similar change in elemental behaviour is shown by the Fe-Mn relations in ureilitic olivines: those with Fo contents < 85 show a good negative correlation, whereas those with Fo > 85 show much greater scatter. This suggests that a major change affected the parent body at a time when melting had reached relatively magnesian bulk compositions. We consider that this event may have been a hit and run collision in which the ureilite parent body collided with a larger object. During the collision, the ureilite mantle broke up catastrophically but re-accreted in a jumbled state around the still-intact core. Mg-rich basaltic melts that were in the process of being formed at the time of break-up were retained in part as melt clasts that re-accreted to the regolith and are found in polymict ureilites.

Mittlefehldt, David W.↗
NASA NTRS2007

Solidification Behavior of gamma'-Ni3Al Containing Alloys in the Ni-Al-O System

The chemical activities of Al and Ni in gamma(prime)-Ni3Al-containing systems were measured using the multi-cell Knudsen effusion-cell mass spectrometry technique (multi-cell KEMS), over the composition range 8 - 32 at.%Al and temperature range T = 1400 - 1750 K. From these measurements a better understanding of the equilibrium solidification behaviour of gamma(prime)-Ni3Al-containing alloys in the Ni-Al-O system was established. Specifically, these measurements revealed that (1) gamma(prime)-Ni3Al forms via the peritectiod reaction, gamma + Beta (+ A12O3) = gamma (prime) (+ Al2O3), at 1633 +/- 1 K, (2) the {gamma + Beta + Al2O3} phase field is stable over the temperature range 1633 through 1640 K, and (3) equilibrium solidification occurs by the eutectic reaction, L (+ Al2O3) = gamma + Beta (+ Al2O3), at 1640 +/- 1 K and a liquid composition of 24.8 +/- 0.2 at.%Al (at an unknown oxygen content). When projected onto the Ni-Al binary, this behaviour is inconsistent with the current Ni-Al phase diagram and a new diagram is proposed. This new Ni-Al phase diagram explains a number of unusual steady-state solidification structures reported previously and provides a much simpler reaction scheme in the vicinity of the gamma(prime)-Ni3Al phase field.

Copland, Evan↗
NASA NTRS2007

Intermediate Temperature Fluids Life Tests - Experiments

There are a number of different applications that could use heat pipes or loop heat pipes (LHPs) in the intermediate temperature range of 450 to 725 K (170 to 450 C), including space nuclear power system radiators, fuel cells, and high temperature electronics cooling. Historically, water has been used in heat pipes at temperatures up to about 425 K (150 C). Recent life tests, updated below, demonstrate that titanium/water and Monel/water heat pipes can be used at temperatures up to 550 K (277 C), due to water's favorable transport properties. At temperatures above roughly 570 K (300 C), water is no longer a suitable fluid, due to high vapor pressure and low surface tension as the critical point is approached. At higher temperatures, another working fluid/envelope combination is required, either an organic or halide working fluid. An electromotive force method was used to predict the compatibility of halide working fluids with envelope materials. This procedure was used to reject aluminum and aluminum alloys as envelope materials, due to their high decomposition potential. Titanium and three corrosion resistant superalloys were chosen as envelope materials. Life tests were conducted with these envelopes and six different working fluids: AlBr3, GaCl3, SnCl4, TiCl4, TiBr4, and eutectic diphenyl/diphenyl oxide (Therminol VP-1/Dowtherm A). All of the life tests except for the GaCl3 are ongoing; the GaCl3 was incompatible. As the temperature approaches 725 K (450 C), cesium is a potential heat pipe working fluid. Life tests results are also presented for cesium/Monel 400 and cesium/70-30 copper/nickel heat pipes operating near 750 K (477 C). These materials are not suitable for long term operation, due to copper transport from the condenser to the evaporator.

Anderson, William G.↗
NASA NTRS2007

Stainless Steel NaK-Cooled Circuit (SNaKC) Fabrication and Assembly

An actively pumped Stainless Steel NaK Circuit (SNaKC) has been designed and fabricated by the Early Flight Fission Test Facility (EFF-TF) team at NASA's Marshall Space Flight Center. This circuit uses the eutectic mixture of sodium and potassium (NaK) as the working fluid building upon the experience and accomplishments of the SNAP reactor program from the late 1960's The SNaKC enables valuable experience and liquid metal test capability to be gained toward the goal of designing and building an affordable surface power reactor. The basic circuit components include a simulated reactor core a NaK to gas heat exchanger, an electromagnetic (EM) liquid metal pump, a liquid metal flow meter, an expansion reservoir and a drain/fill reservoir To maintain an oxygen free environment in the presence of NaK, an argon system is utilized. A helium and nitrogen system are utilized for core, pump, and heat exchanger operation. An additional rest section is available to enable special component testing m an elevated temperature actively pumped liquid metal environment. This paper summarizes the physical build of the SNaKC the gas and pressurization systems, vacuum systems, as well as instrumentation and control methods.

Godfroy, Thomas J.↗
NASA NTRS1988

Carbide/fluoride/silver self-lubricating composite

A self-lubricating, friction and wear reducing composite material for use over a wide temperature spectrum from cryogenic temperature to about 900.degree. C. in a chemically reactive environment comprising silver, barium fluoride/calcium fluoride eutectic, and metal bonded chromium carbide.

Sliney, Harold E.↗
NASA NTRS2008

Imaging and Analysis of Void-defects in Solder Joints Formed in Reduced Gravity using High-Resolution Computed Tomography

As a part of efforts to develop an electronics repair capability for long duration space missions, techniques and materials for soldering components on a circuit board in reduced gravity must be developed. This paper presents results from testing solder joint formation in low gravity on a NASA Reduced Gravity Research Aircraft. The results presented include joints formed using eutectic tin-lead solder and one of the following fluxes: (1) a no-clean flux core, (2) a rosin flux core, and (3) a solid solder wire with external liquid no-clean flux. The solder joints are analyzed with a computed tomography (CT) technique which imaged the interior of the entire solder joint. This replaced an earlier technique that required the solder joint to be destructively ground down revealing a single plane which was subsequently analyzed. The CT analysis technique is described and results presented with implications for future testing as well as implications for the overall electronics repair effort discussed.

Easton, John W.↗
NASA NTRS2008

Formation of gamma(sup prime)-Ni3Al via the Peritectoid Reaction: gamma + beta (+ Al2O3)=gamma(sup prime)(+ Al2O3)

The activities of Al and Ni were measured using multi-cell Knudsen effusion-cell mass spectrometry (multi-cell KEMS), over the composition range 8-32 at.%Al and temperature range T=1400-1750 K in the Ni-Al-O system. These measurements establish that equilibrium solidification of gamma(sup prime)-Ni3Al-containing alloys occurs by the eutectic reaction, L (+ Al2O3)=gamma + Beta(+ Al2O3), at 1640 +/- 1 K and a liquid composition of 24.8 +/- 0.2 at.%al (at an unknown oxygen content). The {gamma + Beta (+Al2O3} phase field is stable over the temperature range 1633-1640 K, and gamma(sup prime)-Ni3Al forms via the peritectoid, gamma + Beta (+ Al2O3)=gamma(sup prime) (+ Al2O3), at 1633 +/- 1 K. This behavior is consistent with the current Ni-Al phase diagram and a new diagram is proposed. This new Ni-Al phase diagram explains a number of unusual steady-state solidification structures reported previously and provides a much simpler reaction scheme in the vicinity of the gamma(sup prime)-Ni2Al phase field.

Copeland, Evan↗
NASA NTRS2008

Solid-State High-Temperature Power Cells

All-solid-state electrochemical power cells have been fabricated and tested in a continuing effort to develop batteries for instruments for use in environments as hot as 500 C. Batteries of this type are needed for exploration of Venus, and could be used on Earth for such applications as measuring physical and chemical conditions in geothermal and oil wells, processing furnaces, and combustion engines. In the state-of-the-art predecessors of the present solid-state power cells, fully packaged molten eutectic salts are used as electrolytes. The molten-salt-based cells can be susceptible to significant amounts of self-discharge and corrosion when used for extended times at elevated temperatures. In contrast, all-solid-state cells such as the present ones are expected to be capable of operating for many days at temperatures up to 500 C, without significant self-discharge. The solid-state cell described here includes a cathode made of FeS2, an electrolyte consisting of a crystalline solid solution of equimolar amounts of Li3PO4 and Li4SiO4, and an anode made of an alloy of Li and Si (see figure). The starting material for making the solid electrolyte is a stoichiometric mixture of Li3PO4, SiO2, and Li3CO2. This mixture is ball-milled, then calcined for two hours at a temperature of 1,100 C, then placed in a die atop the cathode material. Next, the layers in the die are squeezed together at a pressure between 60 and 120 MPa for one hour at a temperature of 600 C to form a unitary structure comprising the solid electrolyte and cathode bonded together. Finally, the lithium-alloy anode is pressure-bonded to the solid electrolyte layer, using an intermediate layer of pure lithium. In one test of a cell of this type, a discharge rate of about 1 mA per gram of cathode material was sustained for 72 hours at a temperature of about 460 C. This is about three times the discharge rate required to support some of the longer duration Venus-exploration mission scenarios.

Whitacre, Jay↗
NASA NTRS1947

Cyclic Engine Test of Cast Vitallium Turbine Buckets - I

An investigation was conducted to correlate the engine service performance of cast Vitallium turbine buckets with standard laboratory metallurgical data. Data were obtained from four I-40 turbine wheels of Timken alloy with cast Vitallium buckets. In order to accelerate bucket deterioration, the turbine wheels were subjected to 20-minute cycles consisting of 5 minutes at idle and 15 minutes at rated speed. A bucket broke on the first wheel during cycle 22 after 7 hours and 20 minutes. The broken bucket was replaced and during the third cycle after the replacement a second bucket broke after a total running time of 8 hours and 12 minutes, The first bucket failure on the second wheel occurred during cycle 29 after 9 hours and 28 minutes; no further failure occurred during 66 additional cycles. Total running time on this wheel was 31 hours and 40 minutes. The third wheel was run for 229 cycles (76 hr and 20 min, total running time) without a. failure. The fourth wheel was operated for 105 cycles (35 hr, total running time) without a failure. Examination of the bro?en buckets indicated that the failures were probably due to fatigue, Massive eutectic areas that existed near the trailing edge probably contributed to the low fatigue strength.

Farmer, Elmo↗
NASA NTRS2009

Long Term Measurement of the Vapor Pressure of Gold in the Au-C System

Incorporating the {Au(s,l) + graphite} reference in component activity measurements made with the multiple effusion-cell vapor source mass spectrometry (multicell KEMS) technique provides a fixed temperature defining ITS-90 (T(sub mp)(Au) = 1337.33K) and a systematic method to check accuracy. Over a 2 year period delta H sub(298)Au was determined by the 2nd and 3rd law methods in 25 separate experiments and were in the ranges 362.2 plus or minus 3.3 kJmol(sup -1) and 367.8 plus or minus 1.1 kJmol(sup -1), respectively. This 5 kJmol-1 discrepancy is transferred directly to the measured activities. This is unacceptable and the source of this discrepancy needs to be understood and corrected. Accepting the 2nd law value increases p(Au) by about 50 percent, brings the 2nd and 3rd law values into agreement and removes the T dependence in the 3rd law values. While compelling, there is no way to independently determine instrument sensitivities, S(sub Au), with T in a single experiment with KEMS. This lack of capability is stopping a deeper understanding of this problem. In addition, the Au-C phase diagram suggests a eutectic invariant reaction: L-Au(4.7at%C) = FCC-Au(0.08at%C) + C(graphite) at T(sub e) approximately 1323K. This high C concentration in Au(l) must reduce p(Au) in equilibrium with {Au(s,l) + graphite} and raises some critical questions about the Gibbs free energy functions of Au(s,l) and the Au fixed point (T(sub mp)(Au) = 1337.33K) which is always measured in graphite.

Copland, Evan H.↗
NASA NTRS2009

NASA PS400: A New Temperature Solid Lubricant Coating for High Temperature Wear Applications

A new solid lubricant coating, NASA PS400, has been developed for high temperature tribological applications. This plasma sprayed coating is a variant of the patented PS304 coating and has been formulated to provide higher density, smoother surface finish and better dimensional stability than PS304. PS400 is comprised of a nickel-molybdenum binder that provides strength, creep resistance and extreme oxidative and dimensional stability. Chromium oxide, silver and barium-calcium fluoride eutectic are added to the binder to form PS400.Tribological properties were evaluated with a pin-on-disk test rig in sliding contact to 650 C. Coating material samples were exposed to air, argon and vacuum at 760 C followed by cross section microscopic analysis to assess microstructure stability. Oil-Free microturbine engine hot section foil bearing tests were undertaken to assess PS400 s suitability for hot foil gas bearing applications. The preliminary results indicate that PS400 exhibits tribological characteristics comparable to the PS304 coating but with enhanced creep resistance and dimensional stability suitable for demanding, dynamic applications.

DellaCorte, C.↗
NASA NTRS2009

NiF2/NaF:CaF2/Ca Solid-State High-Temperature Battery Cells

Experiments and theoretical study have demonstrated the promise of all-solid-state, high-temperature electrochemical battery cells based on NiF2 as the active cathode material, CaF2 doped with NaF as the electrolyte material, and Ca as the active anode material. These and other all-solid-state cells have been investigated in a continuing effort to develop batteries for instruments that must operate in environments much hotter than can be withstood by ordinary commercially available batteries. Batteries of this type are needed for exploration of Venus (where the mean surface temperature is about 450 C), and could be used on Earth for such applications as measuring physical and chemical conditions in geothermal wells and oil wells. All-solid-state high-temperature power cells are sought as alternatives to other high-temperature power cells based, variously, on molten anodes and cathodes or molten eutectic salt electrolytes. Among the all-solid-state predecessors of the present NiF2/NaF:CaF2/Ca cells are those described in "Solid-State High-Temperature Power Cells" (NPO-44396), NASA Tech Briefs, Vol. 32, No. 5 (May 2008), page 40. In those cells, the active cathode material is FeS2, the electrolyte material is a crystalline solid solution of equimolar amounts of Li3PO4 and LiSiO4, and the active anode material is Li contained within an alloy that remains solid in the intended high operational temperature range.

West, William↗
NASA NTRS2010

Modeling of the Orbital Debris Population of RORSAT Sodium-Potassium Droplets

A large population resident in the orbital debris environment is composed of eutectic sodium-potassium (NaK) droplets, released during the reactor core ejection of 16 nuclear-powered Radar Ocean Reconnaissance Satellites (RORSATs) launched in the 1980s by the former Soviet Union. These electrically conducting RORSAT debris objects are spherical in shape, generating highly polarized radar returns. Their diameters are mostly in the centimeter and millimeter size regimes. Since the Space Surveillance Network catalog is limited to objects greater than 5 cm in low Earth orbit, our current knowledge about this special class of orbital debris relies largely on the analysis of Haystack radar data. This paper elaborates the simulation of the RORSAT debris populations in the new NASA Orbital Debris Engineering Model ORDEM2010, which replaces ORDEM2000. The estimation of the NaK populations uses the NASA NaK-module as a benchmark. It follows the general statistical approach to developing all other ORDEM2010-required LEO populations (for various types of debris and across a wide range of object sizes). This paper describes, in detail, each major step in the NaK-population derivation, including a specific discussion on the conversion between Haystack-measured radar-cross-sections and object-size distribution for the NaK droplets. Modeling results show that the RORSAT debris population is stable for the time period under study and that Haystack data sets are fairly consistent over the observations of multiple years.

Xu, Y.-L.↗
NASA NTRS2010

Testing of Liquid Metal Components for Nuclear Surface Power Systems

The Early Flight Fission Test Facility (EFF-TF) was established by the Marshall Space Flight Center (MSFC) to provide a capability for performing hardware-directed activities to support multiple in-space nuclear reactor concepts by using a non-nuclear test methodology. This includes fabrication and testing at both the module/component level and near prototypic reactor configurations. The EFF-TF is currently supporting an effort to develop an affordable fission surface power (AFSP) system that could be deployed on the Lunar surface. The AFSP system is presently based on a pumped liquid metal-cooled (Sodium-Potassium eutectic, NaK-78) reactor design. This design was derived from the only fission system that the United States has deployed for space operation, the Systems for Nuclear Auxiliary Power (SNAP) 10A reactor, which was launched in 1965. Two prototypical components recently tested at MSFC were a pair of Stirling power conversion units that would be used in a reactor system to convert heat to electricity, and an annular linear induction pump (ALIP) that uses travelling electromagnetic fields to pump the liquid metal coolant through the reactor loop. First ever tests were conducted at MSFC to determine baseline performance of a pair of 1 kW Stirling convertors using NaK as the hot side working fluid. A special test rig was designed and constructed and testing was conducted inside a vacuum chamber at MSFC. This test rig delivered pumped NaK for the hot end temperature to the Stirlings and water as the working fluid on the cold end temperature. These test were conducted through a hot end temperature range between 400 to 550C in increments of 50 C and a cold end temperature range from 30 to 70 C in 20 C increments. Piston amplitudes were varied from 6 to 1 1mm in .5 mm increments. A maximum of 2240 Watts electric was produced at the design point of 550 hot end, 40 C cold end with a piston amplitude of 10.5mm. This power level was reached at a gross thermal efficiency of 28%. A baseline performance map was established for the pair of 1kW Stirling convertors. The performance data will then be used for design modification to the Stirling convertors. The ALIP tested at MSFC has no moving parts and no direct electrical connections to the liquid metal containing components. Pressure is developed by the interaction of the magnetic field produced by the stator and the current which flows as a result of the voltage induced in the liquid metal contained in the pump duct. Flow is controlled by variation of the voltage supplied to the pump windings. Under steady-state conditions, pump performance is measured for flow rates from 0.5-4.3 kg/s. The pressure rise developed by the pump to support these flow rates is roughly 5-65 kPa. The RMS input voltage (phase-to-phase voltage) ranges from 5-120 V, while the frequency can be varied arbitrarily up to 60 Hz. Performance is quantified at different loop temperature levels from 50 C up to 650 C, which is the peak operating temperature of the proposed AFSP reactor. The transient response of the pump is also evaluated to determine its behavior during startup and shut-down procedures.

Polzin, Kurt A.↗