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NASA NTRSDate not supplied

Strategies Toward Lunar Dust Adhesion Mitigation

Recently, the NASA Space Technology Mission Directorate solicited feedback to prioritize shortfalls, which were defined as technology areas needed to enable future exploration missions. Lunar dust mitigation emerged as a critical area and is cross-cutting with many of the highest ranked shortfalls with passive dust mitigation technologies being directly ranked in the top 50. Hazards associated with lunar dust are ubiquitous across all aspects of long duration lunar surface missions, whether crewed or robotic, due to the abrasive, electrostatically charged, and chemically reactive properties of lunar dust. Compounding the issue, lunar dust moves across the lunar surface due to levitation, twilight craters, and plume-surface interactions, which can result in particle velocities exceeding 1 km/h. To address lunar dust challenges, NASA is developing active and passive adhesion mitigation technologies to address specific mission needs, including electrodynamic dust screens, piezoelectric materials, biomimetic engineered surfaces, among many others. Additionally, abrasion-resistant materials are being evaluated for applications for use near landing sites and in surface manipulation and excavation equipment. These approaches, as well as test methodologies both in the laboratory and on the lunar surface to evaluate technology efficacy, will be described.

Dust Mitigation↗

DOE OSTI2022

Layer-wise Imaging Dataset from Powder Bed Additive Manufacturing Processes for Machine Learning Applications (Peregrine v2022-10)

36 MATERIALS SCIENCE↗

NASA NTRS2004

Deep Space Test Bed

The DSTB Facility provides a new capability for the National Aeronautics and Space Administration s (NASA s) Space Radiation Shielding Project (SRSP). The objective of the DSTB is to provide a platform to conduct radiation shielding investigations in an environment more similar to deep space than most Low Earth orbits or is achievable at a particle accelerator. The DSTB provides a means to experimentally test radiation shielding effectiveness of various materials and to test the accuracy of radiation transport code predictions in the deep space cosmic ray environment more frequently and at a lower cost compared to space flight missions. New spectrometers, dosimeters and other techniques may be exercised and verified using the DSTB before space flight. The DSTB will be implemented through NASA s National Scientific Balloon Facility (NSBF) which provides polar balloon flights that lift science payloads to high altitude (120,000 A. (36.58km)) to escape much of the shielding effects of the Earth s atmosphere and magnetosphere. Polar flights are conducted through NSBF in coordination with the United States Polar Program. The DSTB will be launched on a Long Duration Balloon (LDB) from McMurdo, Antarctica (77.86 degrees south latitude) for circumpolar flights, nominally 20 days, traveling to the west and typically bounded between 73 to 82 degrees south latitude. Float altitudes for these balloons with payload are 115,000 to 130,000 feet (35.05 to 39.62km). The DSTB will be able to accommodate up to 20 investigations per flight. Annual flight opportunities are planned starting in December 2005. Balloon campaigns in Antarctica occur in December and January during the Austral summer. Since a key goal of the DSTB facility is to efficiently serve the varied needs of the radiation shielding community; it must be designed with a flexible architecture. By implementing the DSTB facility with NASA s balloon program, which operates under reduced formalities compared to space flight, the DSTB facility can adjust for different investigation priorities on successive flights. This flexibility in the DSTB will be applied at several levels; in the distribution of the shared resources for each flight; addressing the payload configuration on a system level for each flight; and utilizing a selection process for investigations that considers yearly flight opportunities as well as the possibility for repeated flights. This approach for operating the DSTB facility will allow it to handle a wide range of investigations.

Milton, Martha E.↗

NASA NTRS2008

Development of a Prototype Water Pump for Future Space Suit Applications

NASA s next generation of space suit systems will place new demands on the pump used to circulate cooling water through the life support system and the crew s liquid cooling garment. Long duration missions and frequent EVA require increased durability and reliability; limited resupply mass requirements demand compatibility with recycled water, and changing system design concepts demand increased tolerance for dissolved and free gas and the ability to operate over a broader range of flow rates and discharge pressure conditions. This paper describes the development of a positive displacement prototype pump to meet these needs. A gerotor based design has been adapted to meet pump performance, gas tolerance, and durability requirements while providing a small, lightweight pump assembly. This design has been detailed and implemented using materials selected to address anticipated water quality and mission needs as a prototype unit for testing in NASA laboratories. Design requirements, pump technology selection and design, performance testing and test results will be discussed.

Hartman, David↗

NASA NTRS2009

Development of a Prototype Water Pump for Future Space Suit Applications

NASA's next generation of space suit systems will place new demands on the pump used to circulate cooling water through the life support system and the crew's liquid cooling garment. Long duration missions and frequent EVA require increased durability and reliability; limited resupply mass requirements demand compatibility with recycled water, and changing system design concepts demand increased tolerance for dissolved and free gas and the ability to operate over a broader range of flow rates and discharge pressure conditions. This paper describes the development of a positive displacement prototype pump to meet these needs. A gerotor based design has been adapted to meet pump performance, gas tolerance, and durability requirements while providing a small, lightweight pump assembly. This design has been detailed and implemented using materials selected to address anticipated water quality and mission needs as a prototype unit for testing in NASA laboratories. Design requirements, pump technology selection and design, performance testing and test results will be discussed.

Hartman, David↗

NASA NTRS2019

Inserting New Technologies into Human-Computer Interfaces for Future Lunar and Mars Missions

Plans call for human cislunar operations and lunar surface access, to prepare for eventual Mars missions. NASA will also develop new opportunities in lunar orbit that provide the foundation and act as a gateway for human exploration deeper into the solar system. Current human spaceflight is complex and requires as many as fifty people to support the International Space Station (ISS) Mission Control Center (MCC) in Houston, Texas. These flight controllers in the front and back rooms of the MCC, serve as an extra pair of eyes overseeing the numerous station systems. Deep space missions - to the moon, Mars, and beyond - will be more complex and place challenging mission constraints on the crew. As the round-trip communication delays increase in deep space exploration, more on-board systems autonomy and functionality will be needed to maintain and control the vehicle. These mission constraints will change the Earth-based ground control approach and will demand efficient and effective human-computer interfaces (HCI) to control a highly complex vehicle or habitat system. All of this necessitates a different approach to designing and developing spacecraft and habitats. In the beginning of new human spaceflight programs, focus is typically on launch vehicle and uncrewed spacecraft design and development. The reasoning behind this focus to enable flight testing of an integrated launch vehicle and spacecraft system to ensure it will be safe enough to allow humans on board. This is an essential process for new spacecraft, however, the practical effect is a lack of funding for the spacecraft’s human interfaces development. It can be many years before the human interface development begins, putting it late in the spacecraft lifecycle, when almost all other spacecraft systems and subsystems are already in place. This forces the usage of existing and proven technologies for the HCI interfaces. We posit that putting the human first in a spacecraft design process will yield a more effective spacecraft for exploration and long duration missions. NASA Human Research Program (HRP) has identified inadequate HCI as a risk for future missions. New tools and procedures to aid the crew in operating a complex spacecraft will be required. This paper discusses ongoing activities in the development of the next generation HCI components and systems, and a new approach toward human interfaces for spacecraft.

Salazar, George A.↗

NASA NTRSDate not supplied

Integrated Logistics and Supportability Challenges of Sustained Human Lunar Exploration

NASA’s Artemis program plans to establish a sustained human presence on the lunar surface. The International Space Station other space station programs have demonstrated long-duration human spaceflight operations that reuse infrastructure in Low Earth Orbit, sometimes including long uncrewed “dormant” periods. In contrast, human lunar exploration to date has consisted solely of relatively short sortie missions, rather than a sustained presence. A sustained human outpost on the Moon that can support month-long crewed exploration missions and be reused by multiple crews will be more challenging than past operations, particularly from the perspective of logistics, supportability, and risk. This paper examines the integrated logistics and supportability challenges of sustained human lunar exploration and provides a review of historical spaceflight experience in terms of crewed mission endurance, uncrewed duration, transportation overhead, and access to abort. Planned Artemis Base Camp crewed mission endurance is approximately 2.5 times longer than past lunar surface crewed mission endurance, but similar to average time between resupply for the International Space Station. Sustained human spacecraft have only twice experienced uncrewed durations longer than the planned interval between Artemis Base Camp missions, and Artemis surface assets will face long uncrewed periods more regularly than any past sustained human spacecraft. Transportation of crew and cargo to and from the Moon will be more difficult and time-consuming than transportation to and from Low Earth Orbit, and crew access to abort will be more limited. The implications of Artemis lunar operations for crewed Mars mission planning are also discussed. Historical approaches to risk management—including logistics, supportability, and abort strategies—should be reexamined and re-optimized for this new mission context. Sustained lunar operations will provide a valuable proving ground for testing new approaches to crewed space exploration.

logistics↗

NASA NTRSDate not supplied

Integrated Logistics and Supportability Challenges of Sustained Human Lunar Exploration

NASA’s Artemis program plans to establish a sustained human presence on the lunar surface. The International Space Station and other space station programs have demonstrated long-duration human spaceflight operations that reuse infrastructure in Low Earth Orbit, sometimes including long uncrewed “dormant” periods. In contrast, all human exploration beyond Low Earth Orbit to date has consisted solely of relatively short sortie missions, rather than a sustained presence. A sustained human outpost on the Moon that can support month-long crewed exploration missions and be reused by multiple crews will be more challenging than past operations, particularly from the perspective of logistics, supportability, and risk. This paper examines the integrated logistics and supportability challenges of sustained human lunar exploration and provides a review of historical spaceflight experience in terms of crewed mission endurance, uncrewed duration, transportation overhead, and access to abort. Planned Artemis Base Camp crewed mission endurance is approximately 2.5 times longer than past lunar surface crewed mission endurance, but similar to the average time between resupply for the International Space Station. Sustained human spacecraft have only twice experienced uncrewed durations longer than the planned interval between Artemis Base Camp missions, and Artemis surface assets will face long uncrewed periods more regularly than any past sustained human spacecraft. Transportation of crew and cargo to and from the Moon will be more difficult and time-consuming than transportation to and from Low Earth Orbit, and crew access to abort will be more limited. The implications of Artemis lunar operations for crewed Mars mission planning are also discussed. Historical approaches to risk management—including logistics, supportability, and abort strategies—should be reexamined and re-optimized for this new mission context. Sustained lunar operations will provide a valuable proving ground for testing new approaches to crewed space exploration.

logistics↗

DOE OSTI2015

Performance of low smeared density sodium-cooled fast reactor metal fuel

An experiment was performed in the Experimental Breeder Rector-II (EBR-II) in the 1990s to show that metallic fast reactor fuel could be used in reactors with a single, once-through core. To prove the long duration, high burnup, high neutron exposure capability an experiment where the fuel pin was designed with a very large fission gas plenum and very low fuel smeared density (SD). The experiment, X496, operated to only 8.3 at. % burnup because the EBR-II reactor was scheduled for shut-down at that time. Many of the examinations of the fuel pins only funded recently with the resurgence of reactor designs using very high-burnup fuel. The results showed that, despite the low smeared density of 59% the fuel swelled radially to contact the cladding, fission gas release appeared to be slightly higher than demonstrated in conventional 75%SD fuel tests and axial growth was about the same as 75% SD fuel. There were axial positions in some of the fuel pins which showed evidence of fuel restructuring and an absence of fission products with low metaling points and gaseous precursors (Cs and Rb). Lastly, a model to investigate whether these areas may have overheated due to a loss of bond sodium indicates that it is a possible explanation for the fuel restructuring and something to be considered for fuel performance modeling of low SD fuel.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2023

Layer-wise Imaging Dataset from Powder Bed Additive Manufacturing Processes for Machine Learning Applications (Peregrine v2022-10.1)

This release consists of six datasets which together include multi-modal layer-wise powder bed images from two different powder bed printing technologies. These datasets are designed primarily to facilitate the development and testing of new computer vision and machine learning based anomaly and defect detection algorithms. The authors provide both training data with corresponding ground truth pixel masks and evaluation data with corresponding baseline prediction pixel masks made by a trained neural network. The laser powder bed fusion (L-PBF) datasets are sourced from EOS M290 and AddUp FormUp 350 printers and the binder jet (BJ) dataset is sourced from an ExOne M-Flex printer. The materials represented in these datasets include 17-4 PH Stainless Steel, GammaPrint-700, Inconel 718, Maraging Steel, and H13 Steel. The sensor imaging modalities represented include visible-light (VL), temporally-integrated (i.e., long duration exposure) near-infrared (TI-NIR), and wide-band infrared (IR). To download the dataset: (1) Create a Globus account. (2) Create a Globus Endpoint on your computer. (3) Transfer the dataset from the OLCF DOI-DOWNLOADS Collection to your Collection. Common troubleshooting steps: (a) Confirm that the transfer is going from OLCF DOI-DOWNLOADS to your Collection. (b) Create an exception for Globus in your antivirus software so that it can create an Endpoint. (c) Manually create a Globus access directory (where the data will be downloaded) by going to the Preferences > Access tab.

36 MATERIALS SCIENCE↗

NASA NTRS1993

Evaluation of seals, lubricants, and adhesives used on LDEF

A wide variety of seals, lubricants, and adhesives were used on the Long Duration Exposure Facility (LDEF). The results, to date, of the Systems Special Investigation Group (SIG) and the Materials SIG investigation into the effect of the long term low Earth orbit (LEO) exposure on these materials is discussed. Results of this investigation show that if the material was shielded from exposure to LDEF's external environment, the 69 month exposure to LEO had minimal effect on the material. However, if the material was on LDEF's exterior surface, a variety of events occurred ranging from no material change, to changes in mechanical or physical properties, to complete disappearance of the material. The results are from the following sources: (1) visual examinations and/or testing of materials performed by various LDEF experimenters, (2) testing done at Boeing in support of the Materials or Systems SIG investigations, (3) testing done at Boeing on Boeing hardware flown on LDEF.

Dursch, Harry↗

NASA NTRS1993

Physics of debris clouds from hypervelocity impacts

The protection scheme developed for long duration space platforms relies primarily upon placing thin metal plates or 'bumpers' around flight critical components. The effectiveness of this system is highly dependent upon its ability to break up and redistribute the momentum of any particle which might otherwise strike the outer surface of the spacecraft. Therefore it is of critical importance to design the bumpers such that maximum dispersion of momentum is achieved. This report is devoted to an in-depth study into the design and development of a laboratory instrument which would permit the in-situ monitoring of the momentum distribution as the impact event occurs. A series of four designs were developed, constructed and tested culminating with the working instrument which is currently in use. Each design was individually tested using the Space Environmental Effects Facility (SEEF) at the Marshall Space Flight Center in Huntsville, Alabama. Along with the development of the device, an experimental procedure was developed to assist in the investigation of various bumper materials and designs at the SEEF. Preliminary results were used to compute data which otherwise were not experimentally obtainable. These results were shown to be in relative agreement with previously obtained values derived through other methods. The results of this investigation indicated that momentum distribution could in fact be measured in-situ as the impact event occurred thus giving a more accurate determination of the effects of experimental parameters on the momentum spread. Data produced by the instrument indicated a Gaussian-type momentum distribution. A second apparatus was developed and it was placed before the shield in the line of travel utilized a plate to collect impact debris scattered backwards. This plate had a passage hole in the center to allow the particle to travel through it and impact the proposed shield material. Applying the law of conservation of angular momentum a backward momentum vector was determined from the angular velocity of the plate. The forward scattered and backward scattered momentum values were then analyzed to judge the distribution of debris. Loss of momentum was attributed to the inaccuracies of the means of measurement. Assumptions of symmetrical debris for the forward and backward scattered directions also contributed to this loss.

Zee, Ralph↗

NASA NTRS1997

Investigation of Teflon FEP Embrittlement on Spacecraft in Low Earth Orbit

Teflon(registered trademark) FEP (fluorinated ethylene-propylene) is commonly used on exterior spacecraft surfaces in the low Earth orbit (LEO) environment for thermal control. Silverized or aluminized FEP is used for the outer layer of thermal control blankets because of its low solar absorptance and high thermal emittance. FEP is also preferred over other spacecraft polymers because of its relatively high resistance to atomic oxygen erosion. Because of its low atomic oxygen erosion yield, FEP has not been protected in the space environment. Recent, long term space exposures such as on the Long Duration Exposure Facility (LDEF, 5.8 years in space), and the Hubble Space Telescope (HST, after 3.6 years in space) have provided evidence of LEO environmental degradation of FEP. These exposures provide unique opportunities for studying environmental degradation because of the long durations and the different conditions (such as differences in altitude) of the exposures. Samples of FEP from LDEF and from HST (retrieved during its first servicing mission) have been evaluated for solar induced embrittlement and for synergistic effects of solar degradation and atomic oxygen. Micro-indenter results indicate that the surface hardness increased as the ratio of atomic oxygen fluence to solar fluence decreased for the LDEF samples. FEP multilayer insulation (MLI) retrieved from HST provided evidence of severe embrittlement on solar facing surfaces. Micro-indenter measurements indicated higher surface hardness values for these samples than LDEF samples, but the solar exposures were higher. Cracks induced during bend testing were significantly deeper for the HST samples with the highest solar exposure than for LDEF samples with similar atomic oxygen fluence to solar fluence ratios. If solar fluences are compared, the LDEF samples appear as damaged as HST samples, except that HST had deeper induced cracks. The results illustrate difficulties in comparing LEO exposed materials from different missions. Because the HST FEP appears more damaged than LDEF FEP based on depth of embrittlement, other causes for FEP embrittlement in addition to atomic oxygen and ultraviolet (UV) radiation, such as thermal effects and the possible role of soft x-ray radiation, need to be considered. FEP that was exposed to soft x-rays in a ground test facility, showed embrittlement similar to that witnessed in LEO, which indicates that the observed differences between LDEF and HST FEP might be attributed to the different soft x-ray fluences during these two missions.

deGroh, Kim K.↗

NASA NTRS2013

FRET-Aptamer Assays for Bone Marker Assessment, C-Telopeptide, Creatinine, and Vitamin D

Astronauts lose 1.0 to 1.5% of their bone mass per month on long-duration spaceflights. NASA wishes to monitor the bone loss onboard spacecraft to develop nutritional and exercise countermeasures, and make adjustments during long space missions. On Earth, the same technology could be used to monitor osteoporosis and its therapy. Aptamers bind to targets against which they are developed, much like antibodies. However, aptamers do not require animal hosts or cell culture and are therefore easier, faster, and less expensive to produce. In addition, aptamers sometimes exhibit greater affinity and specificity vs. comparable antibodies. In this work, fluorescent dyes and quenchers were added to the aptamers to enable pushbutton, one-step, bind-and-detect fluorescence resonance energy transfer (FRET) assays or tests that can be freeze-dried, rehydrated with body fluids, and used to quantitate bone loss of vitamin D levels with a handheld fluorometer in the spacecraft environment. This work generated specific, rapid, one-step FRET assays for the bone loss marker C-telopeptide (CTx) when extracted from urine, creatinine from urine, and vitamin D congeners in diluted serum. The assays were quantified in nanograms/mL using a handheld fluorometer connected to a laptop computer to convert the raw fluorescence values into concentrations of each analyte according to linear standard curves. DNA aptamers were selected and amplified for several rounds against a 26- amino acid form of CTx, creatinine, and vitamin D. The commonalities between loop structures were studied, and several common loop structures were converted into aptamer beacons with a fluorophore and quencher on each end. In theory, when the aptamer beacon binds its cognate target (CTx bone peptide, creatinine, or vitamin D), it is forced open and no longer quenched, so it gives off fluorescent light (when excited) in proportion to the amount of target present in a sample. This proportional increase in fluorescence is called a "lights on" FRET response. The vitamin D aptamer beacon gives a "lights off" or inversely proportional fluorescence response to the amount of vitamin D present in diluted serum. These FRET-aptamer assays are rapid (<30 minutes), sensitive (low ng/mL detection limits), and quite easy to carry out (add sample, mix, and detect in the handheld reader). Benefits include the speed of the assays as well as the small amount of space taken up by the handheld reader and cuvette assays. The aptamer DNA sequences represent novel additional features of the existing (patent-pending) FRET-aptamer assay platform.

Bruno, John G.↗

NASA NTRS2017

NASA Advanced Explorations Systems: 2017 Advancements in Life Support Systems

The NASA Advanced Exploration Systems (AES) Life Support Systems (LSS) project strives to develop reliable, energy-efficient, and low-mass spacecraft systems to provide environmental control and life support systems (ECLSS) critical to enabling long duration human missions beyond low Earth orbit (LEO). Highly reliable, closed-loop life support systems are among the capabilities required for the longer duration human space exploration missions planned in the mid-2020s and beyond. The LSS Project is focused on four are-as-architecture and systems engineering for life support systems, environmental monitoring, air revitalization, and wastewater processing and water management. Starting with the International Space Station (ISS) LSS systems as a point of departure where applicable, the three-fold mission of the LSS Project is to address discrete LSS technology gaps, to improve the reliability of LSS systems, and to advance LSS systems toward integrated testing aboard the ISS. This paper is a follow on to the AES LSS development status reported in 2016 and provides additional details on the progress made since that paper was published with specific attention to the status of the Aerosol Sampler ISS Flight Experiment, the Spacecraft Atmosphere Monitor (SAM) Flight Experiment, the Brine Processor Assembly (BPA) Flight Experiment, the CO2 removal technology development tasks, and the work investigating the impacts of dormancy on LSS systems.

Schneider, Walter F.↗

DOE OSTI2024

Unconventional Wells Interference: Supervised Machine Learning for Detecting Fracture Hits

The primary objective of the study was development of a machine learning (ML)-based workflow for fracture hit (“frac hit”) detection and monitoring using shale oil-field data such as drilling surveys, production history (oil and produced water), pressure, and fracking start time and duration records. The ML method takes advantage of long short-term memory (LSTM) and multilayer perceptron (MLP) neural networks to identify the frac hits due to hydraulic communication between the fracking child well(s) and the producing parent well(s) within the same pad (intra-pad interaction) and/or on different pads (inter-pad interaction). It utilizes time series of pressure and production data from within a pad and from adjacent pads. The workflow can capture time variable features of frac hits when the model architecture is deep and wide enough, with enough trainable parameters for deep learning and feature extraction, as demonstrated in this paper by using training and testing subsets of the field data from selected neighboring pads with over a couple of hundred wells. The study was focused on frac-hit interaction among paired wells and demonstrated that the ML model, once trained, can predict the frac-hit probability.

58 GEOSCIENCES↗

NASA NTRS2018

Evaluation of the Danish Aerospace Corporation Portable Pulmonary Function System

A research project designed to investigate changes in maximal oxygen consumption (VO2max) during and following long duration flight on the International Space Station (ISS) has recently been completed. The device used to measure VO2 on board ISS, the Portable Pulmonary Function System (PPFS) manufactured by the Danish Aerospace Corporation (DAC), is based on previous-generation devices manufactured by DAC, but the PPFS has not been validated for analyzing metabolic gases or measuring cardiac output (Qc). The purpose of the present evaluation is to compare PPFS metabolic gas analysis measurements to measurements obtained using a clinically-validated system (ParvoMedics TrueOne(c) 2400 system; Parvo). In addition, Qc data collected with the PPFS were compared to Qc measurements from echocardiography. METHODS: Ten subjects completed three cycle exercise tests to maximal exertion. The first test was conducted to determine each subject's VO2max and set the work rates for the second and third (comparison) tests. The protocol for the two comparison tests consisted of three 5-minute stages designed to elicit 25%, 50%, and 75% VO2max (based upon results from the initial test), followed by 1-minute stages of increasing work rate (25 watt/minute) until the subject reached maximal effort. During one of the two comparison tests, metabolic gases and Qc were assessed with the PPFS; metabolic gases and Qc were assessed with the Parvo and by echocardiography, respectively, during the other test. The order of the comparison tests was counterbalanced. VO2max and maximal work rate during the comparison tests were compared using t tests. Mixed-effects regression modeling was used to analyze submaximal data. RESULTS: All of the data were within normal physiological ranges. The PPFS-measured values for VO2max were 6% lower than values obtained with the Parvo (PPFS: 3.11 +/- 0.75 L/min; Parvo: 3.32 +/- 0.87 L/min; mean +/- standard deviation; P = 0.02); this difference is probably due to flow restriction imposed by the PPFS Qc accessories. Submaximal VO2 values were slightly lower when measured with the PPFS, although differences were not physiologically relevant. The PPFS-measured values of submaximal carbon dioxide production (VCO2) were lower than the data obtained from Parvo, which could be attributed to lower fractions of expired carbon dioxide measured by the PPFS. The PPFS Qc values tended to be lower than echocardiography-derived values. CONCLUSIONS: The results of the present study indicate a need to further examine the PPFS and to better quantify its reproducibility; however, none of the findings of the current evaluation indicate that the PPFS needs to be replaced or modified.

Portable Pulmonary Function System (PPFS)↗

NASA NTRS2019

High Reliability Requires More than Providing Spares

It is sometimes optimistically hoped that a space life support system can be kept working throughout a long duration mission by repairing failed components, as long as sufficient spares are flown. It is usually assumed that the components have constant known failure rates. Then the needed numbers of spares can be computed to have any particular probability that all failed components can be replaced by available spares. This approach can provide high reliability if its favorable assumptions, including constant known failure rates, are satisfied. Other favorable assumptions are that the failures are statistically independent, repair will be successful without causing further failures, and all failures are due to internal component failures. These assumptions are not usually justified. The failure rates may be estimates that are inadequately verified because of insufficient testing. Failure rates may change due to materials substitutions, manufacturing changes, redesigns to fix failures, and new failures caused by redesigns. Failures that are not statistically independent may result from one common cause, such as a design or manufacturing error or a cascade of cause and effect, possibly caused by an external event such as a power outage. Repair may be unsuccessful or cause damage. Many failures occur at component interfaces or at the overall systems level, not within isolated components. Other failures causes are completely external to the system, due to assembly, maintenance, and operational errors or to unexpected environmental challenges. Replacement with sufficient spares can compensate for expected internal component failures but may not be able to cope with unpredictable design and manufacturing flaws, human errors, and environmental impacts. Reliability estimates based on providing sufficient spares to compensate for expected failures may be far too high. They are essentially upper bounds on reliability that might be approached if many frequent but often unconsidered failure causes can be eliminated.

spares↗