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At least 163 records · Page 9

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NASA NTRS2017

Thermal cycling testing to failure of a ceramic column grid array package for space applications

Ceramic column grid array (CCGA) packages have been used increasingly in logic and microprocessor functions, telecommunications, flight avionics boards, payload electronics boards, engineering navigational and science cameras, electronic assemblies, and other applications, because of their inherent advantages such as high electrical interconnect density, very good thermal and electrical performance, and compatibility with standard surface-mount technology (SMT) packaging assembly processes. Because these advanced electronic packages tend to have less solder-joint strain-relief than do leaded flat-pack electronic packages, the reliability of CCGA packages in challenging thermal environments is a very important consideration for their short- and long-term use in JPL-NASA space missions. In this study, we assembled daisy chains of polyimide printed wiring boards from CCGA-interconnect packages, inspected the boards nondestructively, and then subjected them to thermal cycling to assess their reliability in thermal environments from +125°C to -40°C±25°C. The test hardware consists of a CCGA 1752 package (CN version). The package was divided into four daisy-chained sections that were electrically monitored for their continuity during thermal cycling. The CCGA 1752 package is roughly 45 mm × 45 mm with a 42-mm × 42-mm array of 80%/20% Pb/Sn columns on a 1.00-mm pitch. The resistance of the daisy-chained CCGA interconnects was continuously monitored during thermal cycling in a gaseous nitrogen environment. Electrical continuity resistance measurements as a function of thermal cycling are reported here; tests to date have shown significant change to an open circuit in daisy-chain resistance as a function of thermal cycling. The change in interconnect resistance becomes increasingly noticeable with increasing number of thermal cycles. This paper describes the experimental thermal-cycling test results of CCGA 1752 package reliability testing under an extremely wide temperature range. The first failure was observed at 1479th thermal cycle. We report the thermal-cycle reliability test data for ~2500 thermal cycles.

Ramesham, Rajeshuni↗

NASA NTRS1990

Dynamic Characteristics of Space Station Freedom Mars and Lunar Evolution Reference Configurations

One concept for a manned mission to Mars uses an evolutionary version of Space Station Freedom (SSF) as a transportation node. The station is modified by the addition of dual keels, an upper and lower boom, additional laboratory and habitation modules, increased power and an assembly platform. With these modifications the station is called the Mars Evolution Reference Configuration (MERC). The mass of the station is 65 percent greater than the mass of SSF and its moments of inertia through the mass center are greater by approximately a factor of four. Over a period of months, several flights from Earth to low-Earth-orbit carry the components of a manned Mars piloted vehicle (MPV) to the MERC where the vehicle is constructed on the assembly platform. After each flight the station is reboosted to an appropriate altitude, such that the orbit decay due to atmospheric drag forces lowers the spacecraft to the proper altitude at the appropriate time for rendezvous with the next assembly flight. When the assembly process is completed, the MPV, which has a mass of approximately 200,000 lbm, is situated on the evolutionary station. The mass increase of the MERC with MPV system over SSF is 112 percent and the moments of inertia about axes through the mass center increase by up to a factor of 12. When the MPV is assembled, inspected and verified, the mission is ready to proceed and the MPV is moved from the station to a staging area and mated with fueled trans-Mars injection stages for the flight to Mars. This presentation describes a finite element model of the MERC formulated to investigate the expected low frequency modes and its variation with the addition of a large payload. A basic reboost procedure using near-continuous firing of reaction control system jets is proposed with off-modulation of the jets used to control flight attitude. The reboost procedure is described with the closed-loop attitude control dictating jet on/off cycling based on feedback signals which contain both the rigid body rotation information and the elastic rotations local to the attitude sensor. The presentation contains a description of the dynamic response at critical points of the station during the reboost and concludes with results of a brief study of the dynamic characteristics of a Lunar transportation node configuration.

Ayers, J. Kirk↗

DOE OSTI2024

Formation of Linear Plasmonic Heterotrimers Using Nanoparticle Docking to DNA Origami Cages

The fabrication of complex assemblies with interesting collective properties from plasmonic nanoparticles (NPs) is often challenging. While DNA-directed self-assembly has emerged as one of the most promising approaches to forming such complex assemblies, the resulting structures tend to have large variability in gap sizes and shapes, as the DNA strands used to organize these particles are flexible, and the polydispersity of the NPs leads to variability in these critical structural features. Here, we use a new strategy termed docking to DNA origami cages (D-DOC) to organize spherical NPs into a linear heterotrimer with a precisely defined geometrical arrangement. Instead of binding NPs to the exterior of the DNA templates, D-DOC binds the NPs to either the interior or the opening of a 3D cage, which significantly reduces the variability of critical structural features by incorporating multiple diametrically arranged capture strands to tether NPs. Additionally, such a spatial arrangement of the capture strand can work synergistically with shape complementarity to achieve tighter confinement. To assemble NPs via D-DOC, we developed a multistep assembly process that first encapsulates an NP inside a cage and then binds two other NPs to the openings. Microscopic characterization shows low variability in the bond angles and gap sizes. Both UV–vis absorption and surface-enhanced Raman scattering (SERS) measurements showed strong plasmonic coupling that aligned with predictions by electrodynamic simulations, further confirming the precision of the assembly. These results suggest D-DOC could open new opportunities in biomolecular sensing, SERS and fluorescence spectroscopies, and energy harvesting through the self-assembly of NPs into more complex 3D assemblies.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

NASA NTRS2017

Direct-Write Printing on Three-Dimensional Geometries for Miniaturized Detector and Electronic Assemblies

Direct-write printing techniques will enable new detector assemblies that were not previously possible with traditional assembly processes. Detector concepts were manufactured using this technology to validate repeatability. Additional detector applications and printed wires on a 3-dimensional magnetometer bobbin will be designed for print. This effort focuses on evaluating performance for direct-write manufacturing techniques on 3-dimensional surfaces. Direct-write manufacturing has the potential to reduce mass and volume for fabrication and assembly of advanced detector concepts by reducing trace widths down to 10 microns, printing on complex geometries, allowing new electronic concept production, and reduced production times of complex those electronics.

Additive Manufacturing↗

NASA NTRS2018

Direct-Write Printing on Three-Dimensional Geometries for Miniaturized Detector and Electronic Assemblies

Direct-write printing↗

DOE OSTI2022

Low-Power, Flexible Sensor Arrays with Solderless Board-to-Board Connectors for Monitoring Soil Deformation and Temperature

Landslides are a global and frequent natural hazard, affecting many communities and infrastructure networks. Technological solutions are needed for long-term, large-scale condition monitoring of infrastructure earthworks or natural slopes. However, current instruments for slope stability monitoring are often costly, require a complex installation process and/or data processing schemes, or have poor resolution. Wireless sensor networks comprising low-power, low-cost sensors have been shown to be a crucial part of landslide early warning systems. Here, we present the development of a novel sensing approach that uses linear arrays of three-axis accelerometers for monitoring changes in sensor inclination, and thus the surrounding soil’s deformation. By combining these deformation measurements with depth-resolved temperature measurements, we can link our data to subsurface thermal–hydrological regimes where relevant. In this research, we present a configuration of cascaded I2C sensors that (i) have ultra-low power consumption and (ii) enable an adjustable probe length. From an electromechanical perspective, we developed a novel board-to-board connection method that enables narrow, semi-flexible sensor arrays and a streamlined assembly process. The low-cost connection method relies on a specific FR4 printed circuit board design that allows board-to-board press fitting without using electromechanical components or solder connections. The sensor assembly is placed in a thin, semi-flexible tube (inner diameter 6.35 mm) that is filled with an epoxy compound. The resulting sensor probe is connected to an AA-battery-powered data logger with wireless connectivity. We characterize the system’s electromechanical properties and investigate the accuracy of deformation measurements. Our experiments, performed with probes up to 1.8 m long, demonstrate long-term connector stability, as well as probe mechanical flexibility. Furthermore, our accuracy analysis indicates that deformation measurements can be performed with a 0.390 mm resolution and a 95% confidence interval of ±0.73 mm per meter of probe length. This research shows the suitability of low-cost accelerometer arrays for distributed soil stability monitoring. In comparison with emerging low-cost measurements of surface displacement, our approach provides depth-resolved deformation, which can inform about shallow sliding surfaces.

deformation monitoring↗

DOE OSTI2022

Reduced Graphene Oxide Aerogels with Functionalization-Mediated Disordered Stacking for Sodium-Ion Batteries

Surface modified reduced graphene oxide (rGO) aerogels were synthesized using the hydrothermal method. Ethylene diamine (EDA) and α-cyclodextrin (CD) were used to functionalize the surface of the graphene oxide layers. The oxygen reduction and surface modification occurred in-situ during the hydrothermal self-assembly process. The chemical functionality and structure of the resulting ethylene diamine modified (rGO-EDA) and cyclodextrin modified (rGO-CD) aerogels as well as of the pristine unmodified rGO aerogel were studied using XPS, SEM, XRD, and SANS techniques. The overall surface composition showed a significant decrease in the oxygen content for all synthesized aerogels. The surface modified aerogels were characterized by a disordered stacking of the assembled rGO layers. The surface functionalities resulted in a broad distribution of the interlayer spacing and introduced structural heterogeneities. Such disordered structures can enable a better adsorption mechanism of the sodium ions. Coin cells based on the synthesized aerogels and sodium metal were assembled and tested at several charge and discharge rates. The correlation between the surface functionality of the rGO, the induced structural heterogeneities due to the disordered stacking, and the electrochemical performance of sodium-ion batteries were investigated. Operando XRD measurements were carried out during the battery cycling to investigate the adsorption or intercalation nature of the sodiation mechanism.

25 ENERGY STORAGE↗

DOE OSTI2022

Solvent-Driven Transformation of Zn/Cd 2+ -Deoxycholate Assemblies

Deoxycholic acid (DOC) is a unique, biologically derived surfactant with facial amphiphilicity that has been exploited, albeit minimally, in supramolecular assembly of materials. Here, we present the synthesis and structural characterization of three hybrid metal (Zn 2+ and Cd 2+ )-DOC compounds. Analysis by single-crystal Xray diffraction reveals the many interactions that are possible between these facial surfactants and the influence of solvent molecules that drive the assembly of materials. These structures are the first metal- DOC complexes besides those obtained from alkali and alkaline earth metals. We isolated polymeric chains of both Cd and Zn (Zn poly -DOC and Cd poly -DOC) from water. Major interactions between DOC molecules in these phases are hydrophobic in nature. Cd poly -DOC exhibits unique P1 symmetry, with complete interdigitation of the amphiphiles between neighboring polymeric chains. Zn 4 -DOC, obtained from methanol dissolution of Zn poly -DOC, features the OZn 4 tetrahedron, widely known in basic zinc acetate and MOF-5 (metal organic framework). We document a solvent-driven, roomtemperature transition between Zn poly -DOC and Zn 4 -DOC (in both directions) by scanning and transmission electron microscopies in addition to small-angle X-ray scattering, powder X-ray diffraction, and infrared spectroscopy. These studies show the methanoldriven transition of Zn poly -DOC to Zn 4 -DOC occurs via an intermediate with no long-range order of the Zn 4 clusters, indicating the strongest interactions driving assembly are intramolecular. On the contrary, water-driven solid-to-solid transformation from Zn 4 -DOC to Zn poly -DOC exhibits crystal-to-crystal transformation. Zn poly -DOC is robust, easy to synthesize, and comprised of biologically benign components, so we demonstrate dye absorption as a proxy for water treatment applications. It favors absorption of positively charged dyes. These studies advance molecular level knowledge of the supramolecular assembly of facial surfactants that can be exploited in the design of organic-inorganic hybrid materials. This research also highlights the potential of solvent for tuning supramolecular assembly processes, leading to new hybrid materials featuring facial surfactants.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

NASA NTRS2012

Analyzers Provide Water Security in Space and on Earth

Resourcefulness is a key quality for living in space, and on the International Space Station (ISS), that means making the most of water supplies. In 2008, the installation of the Water Processing Assembly (WPA) onboard the ISS allowed the space station s crew to do just that. The WPA purifies moisture from nearly every possible source - sweat, water vapor, wastewater, and even urine - for drinking and oxygen generation. Capable of producing 35 gallons of potable, recycled water a day, the system has reduced the need for water delivered to the ISS by over 1,000 gallons a year, saving significant payload costs in the process. As with any drinking water, quality is a concern, particularly when that water has been recycled. This is an issue of particular interest in space, where ISS crewmembers would have to deal with any illness far from the nearest medical personnel and facilities. The WPA employs sensors that monitor water quality by measuring its conductivity, and rounding out the system s quality assurance methods is a device developed for NASA by a private industry partner. That company has now made the technology available for ensuring the purity of water for consumption and industrial uses on Earth.

Source record↗

NASA NTRS1983

Hermetic edge sealing of photovoltaic modules

The feasibility of using an electrostatic bonding (ESB) and ultrasonic welding process to produce hermetic edge seals on terrestrial solar cell modules was investigated. The fabrication sequence is to attach an aluminum foil "gasket' to the perimeter of a glass sheet. A cell circuit is next encapsulated inside the gasket, and its aluminum foil back cover is seam welded ultrasonically to the gasket. An ESB process for sealing aluminum to glass was developed in an ambient air atmosphere, which eliminates the requirement for a vacuum or pressure vessel. An ultrasonic seam welding process was also developed which did not degrade the quality of the ESB seal. Good quality welds with minimal deformation were produced. The effectiveness of the above described sealing techniques was tested by constructing 400 sq cm (8 x 8 s64 sq in) sample modules, and then subjecting them to nondestructive fine and gross leak tests. The gross leak tests identified several different causes of leaks which were then eliminated by modifying the assembly process.

Nowlan, M. J.↗

DOE OSTI2023

Ultrastrong Ionotronic Films Showing Electrochemical Osmotic Actuation

Abstract A multifunctional soft material with high ionic and electrical conductivity, combined with high mechanical properties and the ability to change shape can enable bioinspired responsive devices and systems. The incorporation of all these characteristics in a single material is very challenging, as the improvement of one property tends to reduce other properties. Here, a nanocomposite film based on charged, high‐aspect‐ratio 1D flexible nanocellulose fibrils, and 2D Ti 3 C 2 T x MXene is presented. The self‐assembly process results in a stratified structure with the nanoparticles aligned in‐plane, providing high ionotronic conductivity and mechanical strength, as well as large water uptake. In hydrogel form with 20 wt% liquid, the electrical conductivity is over 200 S cm −1 and the in‐plane tensile strength is close to 100 MPa. This multifunctional performance results from the uniquely layered composite structure at nano‐ and mesoscales. A new type of electrical soft actuator is assembled where voltage as low as ±1 V resulted in osmotic effects and giant reversible out‐of‐plane swelling, reaching 85% strain.

Chemistry↗

DOE OSTI2020

Visualizing a viral genome with contrast variation small angle X-ray scattering

Despite the threat to human health posed by some single-stranded RNA viruses, little is understood about their assembly. The goal of this work is to introduce a new tool for watching an RNA genome direct its own packaging and encapsidation by proteins. Contrast variation small-angle X-ray scattering (CV-SAXS) is a powerful tool with the potential to monitor the changing structure of a viral RNA through this assembly process. The proteins, though present, do not contribute to the measured signal. As a first step in assessing the feasibility of viral genome studies, the structure of encapsidated MS2 RNA was exclusively detected with CV-SAXS and compared with a structure derived from asymmetric cryo-EM reconstructions. Additional comparisons with free RNA highlight the significant structural rearrangements induced by capsid proteins and invite the application of time-resolved CV-SAXS to reveal interactions that result in efficient viral assembly.

59 BASIC BIOLOGICAL SCIENCES↗

NASA NTRS2012

Hardy Bacterium Isolated From Two Geographically Distinct Spacecraft Assembly Cleanroom Facilities

Earlier studies have confirmed that a tenacious hardy bacterial population manages to persist and survive throughout a spacecraft assembly process. The widespread detection of these organisms underscores the challenges in eliminating them completely. Only comprehensive and repetitive microbial diversity studies of geographically distinct cleanroom facilities will bolster the understanding of planetary protection relevant microbes. Extensive characterizations of the physiological traits demonstrated by cleanroom microbes will aid NASA in gauging the forward contamination risk that hardy bacteria (such as Tersicoccus phoenicis) pose to spacecraft. This study reports on the isolation and identification of two gram-positive, non-motile, non-spore-forming bacterial strains from the spacecraft assembly facilities at Kennedy Space Center, Florida, USA and Centre Spatial Guyanais, Kourou, French Guiana. DNA-DNA relatedness values between the novel strains indicates that these novel strains were indeed members of a same species. Phylogenetic evidence derived from a 16S ribosomal DNA analysis indicated that both the novel strains are less closely related to all other Arthrobacter species.

Vaisham-payan, Parag A.↗

DOE OSTI2020

Self-Assembly of Metallo-Supramolecules under Kinetic or Thermodynamic Control: Characterization of Positional Isomers Using Scanning Tunneling Spectroscopy

Coordination-driven self-assembly has been extensively employed to construct a variety of discrete structures as a bottom-up strategy. However, mechanistic understanding regarding whether self-assembly is under kinetic or thermodynamic control is less explored. To date, such mechanistic investigation has been limited to distinct, assembled structures. It still remains a formidable challenge to study the kinetic and thermodynamic behavior of self-assembly systems with multiple assembled isomers due to the lack of characterization methods. Herein, we use a stepwise strategy which combined self-recognition and self-assembly processes to construct giant metallo-supramolecules with 8 positional isomers in solution. With the help of ultrahigh-vacuum, low-temperature scanning tunneling microscopy and scanning tunneling spectroscopy, we were able to unambiguously differentiate 14 isomers on the substrate which correspond to 8 isomers in solution. Through measurement of 162 structures, the experimental probability of each isomer was obtained and compared with the theoretical probability. Finally, such a comparison along with density functional theory (DFT) calculation suggested that although both kinetic and thermodynamic control existed in this self-assembly, the increased experimental probabilities of isomers compared to theoretical probabilities should be attributed to thermodynamic control.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

NASA NTRS2021

Machine Learning to Predict Joint Performance in Epoxy Composites Based on Process Parameters

Polymer matrix composites are gaining popularity in the aerospace industry due to their high specific strength, fatigue properties, and processability. However, based on current FAA certification guidelines, manufacturers utilizing current state-of-the-art composites made with adhesive bonds commonly install redundant fasteners to guarantee the strength of these adhesively bonded composite parts. The number of fasteners in a single-aisle commercial transport aircraft is typically on the order of 105, which reduces manufacturing rate, increases cost tremendously, and reduces the advantage of the specific strength composites provide. Due to this, the Adhesive Free Bonding of Composites (AERoBOND) project at NASA Langley Research Center has developed a novel assembly process to manufacture complex composite parts without the use of adhesives and fasteners. However, optimization of the process is currently challenging due to the complex and interdependent process parameters. To assist with the optimization, four machine learning algorithms utilizing gradient boosting decision trees were created to provide predictions for the mechanical and characterization properties of the composite parts. Approximately 200 random states from each algorithm were tested, and the models from each state were isolated and analyzed based on their accuracy, a validation process, and their feature importance. This analysis concluded that the models created from the machine learning algorithms could accelerate a parametric study for the AERoBOND process by rapidly optimizing process parameters to achieve desired performance characteristics.

Brennen Michael Middleton↗

NASA NTRSDate not supplied

Machine Learning to Predict Joint Performance in Epoxy Composites Based on Process Parameters

Polymer matrix composites are gaining popularity in the aerospace industry due to their high specific strength, fatigue properties, and processability. However, based on current FAA certification guidelines, manufacturers utilizing current state-of-the art composites made with adhesive bonds commonly install redundant fasteners to guarantee the strength of these adhesively bonded composite parts.1,2 The number of fasteners in a single-aisle commercial transport aircraft is typically on the order of 105, which reduces manufacturing rate, increases cost tremendously, and reduces the advantage of the specific strength composites provide. Due to this, the Adhesive Free Bonding of Composites (AERoBOND) project at NASA Langley Research Center has developed a novel assembly process to manufacture complex composite parts without the use of adhesives and fasteners.1 However, optimization of the process is currently challenging due to the complex and interdependent process parameters. To assist with the optimization, four machine learning algorithms utilizing gradient boosting decision trees were created to provide predictions for the mechanical and characterization properties of the composite parts. Approximately 200 random states from each algorithm were tested, and the models from each state were isolated and analyzed based on their accuracy, a validation process, and their feature importance. This analysis concluded that the models created from the machine learning algorithms could accelerate a parametric study for the AERoBOND process by rapidly optimizing process parameters to achieve desired performance characteristics.

Brennen M Middleton↗

DOE OSTI2021

Structural insight into host plasma membrane association and assembly of HIV-1 matrix protein

Oligomerization of Pr55 Gag is a critical step of the late stage of the HIV life cycle. It has been known that the binding of IP6, an abundant endogenous cyclitol molecule at the MA domain, has been linked to the oligomerization of Pr55 Gag . However, the exact binding site of IP6 on MA remains unknown and the structural details of this interaction are missing. Here, we present three high-resolution crystal structures of the MA domain in complex with IP6 molecules to reveal its binding mode. Additionally, extensive Differential Scanning Fluorimetry analysis combined with cryo- and ambient-temperature X-ray crystallography and GNM-based transfer entropy calculations identify the key residues that participate in IP6 binding. Our data provide novel insights about the multilayered HIV-1 virion assembly process that involves the interplay of IP6 with PIP2, a phosphoinositide essential for the binding of Pr55 Gag to membrane. IP6 and PIP2 have neighboring alternate binding sites within the same highly basic region (residues 18–33). This indicates that IP6 and PIP2 bindings are not mutually exclusive and may play a key role in coordinating virion particles’ membrane localization. Based on our three different IP6-MA complex crystal structures, we propose a new model that involves IP6 coordination of the oligomerization of outer MA and inner CA domain’s 2D layers during assembly and budding.

60 APPLIED LIFE SCIENCES↗

NASA NTRS1975

Development of beam lead RF integrated circuits

This paper describes the design and development of a set of multifunction VHF/UHF integrated circuits aimed at providing a major improvement in spacecraft radio reliability through low stress operation and the processing of these circuits in beam-lead form. The methods evolved for the high frequency characterization of the devices are discussed together with the design of suitable test fixtures. Typical test results and the distribution of test parameters are presented. A unique carrier for beam-lead devices is described, and the need for such a device is discussed. The application of the carrier to device screening, burn-in and drift measurements is discussed together with the incentives for providing these capabilities. An overview of the integration of the devices into the spacecraft radio is given and candidate assembly processes are discussed. The technology impact of this approach upon future spacecraft radio systems is qualitatively examined.

Kline, A. J.↗