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Presentation for Reliability and Maintainability Symposium in January 2026. This is a ROUGH DRAFT that will be blind peer reviewed.
The fulfillment of the new US. National Vision for Space Exploration requires many new enabling technologies to accomplish the goal of utilizing space for commercial activities and for returning humans to the moon and extraterrestrial environments. Traditionally, flight structures are manufactured as complete systems and require humans to complete the integration and assembly in orbit. These structures are bulky and require the use of heavy launch vehicles to send the units to the desired location, e.g. International Space Station (ISS). This method requires a high degree of safety, numerous space walks and significant cost for the humans to perform the assembly in orbit. For example, for assembly and maintenance of the ISS, 52 Extravehicular Activities (EVA's) have been performed so far with a total EVA time of approximately 322 hours. Sixteen (16) shuttle flights haw been to the ISS to perform these activities with an approximate cost of $450M per mission. For future space missions, costs have to be reduced to reasonably achieve the exploration goals. One concept that has been proposed is the autonomous assembly of space structures. This concept is an affordable, reliable solution to in-space and extraterrestrial assembly operations. Assembly is autonomously performed when two components containing onboard electronics join after recognizing that the joint is appropriate and in the precise position and orientation required for assembly. The mechanism only activates when the specifications are correct and m a nominal range. After assembly, local sensors and electronics monitor the integrity of the joint for feedback to a master controller. To achieve this concept will require a shift in the methods for designing space structures. In addition, innovative techniques will be required to perform the assembly autonomously. Monitoring of the assembled joint will be necessary for safety and structural integrity. If a very large structure is to be assembled in orbit, then the number of integrity sensors will be significant. Thus simple, low cost sensors are integral to the success of this concept. This paper will address these issues and will propose a novel concept for assembling space structures autonomously. The paper will present Several autonomous assembly methods. Core technologies required to achieve in space assembly will be discussed and novel techniques for communicating, sensing, docking and assembly will be detailed. These core technologies are critical to the goal of utilizing space in a cost efficient and safe manner. Finally, these technologies can also be applied to other systems both on earth and extraterrestrial environments.
Flip-chip architectures have recently enabled significant scaling-up of multi-qubit circuits and have been used to assemble hybrid quantum systems that combine different substrates, for example, for quantum acoustics experiments. The standard flip-chip method uses superconducting galvanic connections between two substrates, typically implemented using sophisticated indium wafer-bonding systems, which give highly reliable and temperature-cyclable assemblies, but are expensive, somewhat inflexible in design, and require robust substrates that can sustain the large compressive forces required to cold-weld the indium bonds. A much simpler method is to assemble dies using very low-force contacts and air-dried adhesives, although this does not provide a galvanic contact between the dies. In this work, we demonstrate that the latter technique can be used to reliably couple superconducting qubit circuits, in which the qubits are on separate dies, without the need for a galvanic connection. We demonstrate full vector qubit control of each qubit on each of the two dies, with high-fidelity single-shot readout, and further demonstrate entanglement-generating excitation swaps as well as benchmark a controlled-Z entangling gate between the two qubits on the two dies. This exemplifies a simple and inexpensive assembly method for two-plus-one-dimensional quantum circuit integration that supports the use of delicate or unusually shaped substrates.
Critical high-pressure sealing joints on the Space Shuttle reusable solid rocket motor require precise control of bolt preload to ensure proper joint function. As the reusable solid rocket motor experiences rapid internal pressurization, correct bolt preloads maintain the sealing capability and structural integrity of the hardware. The angle-of-twist process provides the right combination of preload accuracy, reliability, process control, and assembly-friendly design. It improves significantly over previous methods. The sophisticated angle-of-twist process controls have yielded answers to all discrepancies encountered while the simplicity of the root process has assured joint preload reliability.
The space shuttle utilizes several rocket engine systems, all of which must function with a high degree of reliability for successful mission completion. The space shuttle main engine (SSME) is by far the most complex of the rocket engine systems and is designed to be reusable. The reusability of spacecraft systems introduces many problems related to testing, reliability, and logistics. Components must be assembled from parts inventories in a manner which will most effectively utilize the available parts. Assembly must be scheduled to efficiently utilize available assembly benches while still maintaining flight schedules. Assembled components must be assigned to as many contiguous flights as possible, to minimize component changes. Each component must undergo a rigorous testing program prior to flight. In addition, testing and assembly of flight engines and components must be done in conjunction with the assembly and testing of developmental engines and components. The development, testing, manufacture, and flight assignments of the engine fleet involves the satisfaction of many logistical and operational requirements, subject to many constraints. The purpose of the SSME Component Assembly and Life Management Expert System (CALMES) is to assist the engine assembly and scheduling process, and to insure that these activities utilize available resources as efficiently as possible.
Materials aging is a high-consequence failure mode in electronic systems. Such mechanisms can degrade the electrical properties of connectors, relays, wire bonds, and other interconnections. Lost performance will impact, not only that of the device, but also the function and reliability of next-level assemblies and the weapons system as a whole. The detections of changes to materials surfaces at the nanometer-scale resolution, provides a means to identify aging processes at their early stages before they manifest into latent failures that affect system-level performance and reliability. Diffusion will be studied on thin films that undergo accelerated aging using the nanometer scale characterization technique of Frequency Modulated Kelvin Probe Force Microscopy (FM-KPFM). The KPFM provides a relatively easy, non-destructive methodology that does not require high-vacuum facilities to obtain nanometer spatial resolution of surface chemistry changes. The KPFM method can provide the means to measure surface, and near-surface, elemental concentrations that allow the determination of diffusion rate kinetics. These attributes will be illustrated by assessing diffusion in a thin film couple. Validation data will obtained from traditional techniques: (a) Auger electron spectroscopy (AES), x-ray fluorescence (XRF), and xray photoelectron spectroscopy (XPS).
Materials aging is a high-consequence failure mode in electronic systems. Such mechanisms can degrade the electrical properties of connectors, relays, wire bonds, and other interconnections. Lost performance will impact, not only that of the device, but also the function and reliability of next-level assemblies and the weapons system as a whole. The detections of changes to materials surfaces at the nanometer-scale resolution, provides a means to identify aging processes at their early stages before they manifest into latent failures that affect system-level performance and reliability. Diffusion will be studied on thin films that undergo accelerated aging using the nanometer scale characterization technique of Frequency Modulated Kelvin Probe Force Microscopy (FM-KPFM). The KPFM provides a relatively easy, non-destructive methodology that does not require high-vacuum facilities to obtain nanometer spatial resolution of surface chemistry changes. The KPFM method can provide the means to measure surface, and near-surface, elemental concentrations that allow the determination of diffusion rate kinetics. These attributes will be illustrated by assessing diffusion in a thin film couple. Validation data will obtained from traditional techniques: (a) Auger electron spectroscopy (AES), x-ray fluorescence (XRF), and xray photoelectron spectroscopy (XPS).
TPG-core IMS concept was jointly explored in this study. Integrating high thermally conductive TPG graphite core into IMS is expected to simultaneously achieve high thermal conductivity from TPG and electrical functionalities from IMS. Nearly 2x thermal conductivity and 30% weight saving was demonstrated on TPG-core IMS compared to conventional Cu-core IMS. Significant junction temperature reduction (11°C) in steady state and power cycling was revealed by the thermal analysis as the result of improved thermal spreading in plane and through the thickness. The study also proved the manufacturability and compatibility of this TPG-core IMS structure to the existing IMS production and power module assembling. Finally, the integration of TPG and IMS paves a new packaging route to increase heat load, improve reliability, simplify module design and reduce assembling cost and number of steps.
Developments to improve system efficiency and reliability for water and carbon dioxide separation systems on crewed vehicles combine sub-scale systems testing and multi-physics simulations. This paper describes the development of COMSOL simulations in support of the Life Support Systems (LSS) project within NASA's Advanced Exploration Systems (AES) program. Specifically, we model the 4 Bed Molecular Sieve (4BMS) of the Carbon Dioxide Removal Assembly (CDRA) operating on the International Space Station (ISS).
SHINE Medical Technologies is working towards producing a reliable, domestic supply of medical isotopes, including molybdenum-99 (Mo-99), xenon-133, and iodine 131, without using highly enriched uranium. Approximately 88% of Mo-99 decays to technetium-99m, which is the most widely used medical isotope in the world, accounting for approximately 80% of all nuclear medicine procedures. A novel aqueous, subcritical nuclear assembly has been designed by SHINE Medical Technologies. The assembly can produce medical radioisotopes in significant quantities for U.S. and foreign needs. The assembly produces isotopes without using a reactor, instead using a fusion-based neutron source coupled to a fission-based aqueous assembly. The subcritical nature of the aqueous assembly has safety and licensing benefits, including the elimination of the reactor control system and elimination of high level waste. SHINE plans to construct eight subcritical assemblies with a plant capacity of greater than 3000 6-day Curies, which is more than one-quarter of the world's Mo-99 requirements. From a nuclear design standpoint, the aqueous subcritical assembly needs to be able to generate sufficient fission power to meet the production capacity requirements while remaining subcritical at all times with an acceptable margin. To address these conflicting design goals, a simple nuclear design and reactivity control philosophy has been developed that allows for high power operation with a high degree of safety. A fusion-driven subcritical fission assembly has been designed by SHINE Medical Technologies to provide a reliable, domestic supply of medical isotopes. Nuclear models have been created and show that the assembly can be started up, operated, and shutdown in a safe manner without active reactivity control systems. A unique reactivity control strategy allows SHINE to operate the aqueous subcritical assembly at much higher power levels than would otherwise be practical, while still retaining the benefits of subcritical operation and avoiding the need for complex subcritical measurement techniques. Based on the current design, the subcritical target is capable of generating significant fission power (on the order of 100 kW) when being driven by a simple, low-cost deuterium-tritium accelerator, enabling the SHINE facility to supply over one-fourth of the worldwide demand of Mo- 99. SHINE has recently been issued a construction permit by the U.S. Nuclear Regulatory Commission to build the commercial facility in Janesville, WI, with eight subcritical assemblies and the associated production equipment. (authors)
A total of twelve (12) preproduction modules were constructed, tested, and delivered. A concept to the frame assembly was designed and proven to be quite reliable. This frame design, as well as the rest of the assembly, was designed with future high volume production and the use of automated equipment in mind.
The ISS Urine Processor Assembly (UPA) began operations in November 2008. Though the UPA has successfully generated distillate from crew urine, several modifications and upgrades have been implemented to improve overall system performance throughout the years. Current and future upgrades to the UPA will continue to focus on improved system performance and reliability, focusing primarily on the Distillation Assembly and upgrades to the UPA vacuum pump. Work towards a flight demonstration experiment of a vacuum pump utilizing scroll pump technologies has also continued forward. The following paper discusses progress on these various concepts, including the implementation of a more reliable drive belt, improved methods for managing condensate in the stationary bowl of the Distillation Assembly, installation of improved centrifuge bearings, implementation of a liquid level sensor, and upgrades to the UPA vacuum pump.
Fiber optic assemblies have been used on spaceflight missions for many years as an enabling technology for routing, transmitting, and detecting optical signals. Due to the overwhelming success of NASA in implementing fiber optic assemblies on spaceflight science-based instruments, system scientists increasingly request fibers that perform in extreme environments while still maintaining very high optical transmission, stability, and reliability. Many new applications require fiber optic assemblies that will operate down to cryogenic temperatures as low as 20 Kelvin. In order for the fiber assemblies to operate with little loss in optical throughput at these extreme temperatures requires a system level approach all the way from how the fiber assembly is manufactured to how it is held, routed, and integrated. The NASA Goddard Code 562 Photonics Group has been designing, manufacturing, testing, and integrating fiber optics for spaceflight and other high reliability applications for nearly 20 years. Design techniques and lessons learned over the years are consistently applied to developing new fiber optic assemblies that meet these demanding environments. System level trades, fiber assembly design methods, manufacturing, testing, and integration will be discussed. Specific recent examples of ground support equipment for the James Webb Space Telescope (JWST); the Ice, Cloud and Land Elevation Satellite-2 (ICESat-2); and others will be included.
The paper describes a simple method developed to use and combine subsystem or assembly level accelerated test results withthe system level test results to estimate achieved overall system reliability.
In a search for a high-performance joint, a Cu-based filler was developed to braze MGH956 alloy (Fe-20Cr-5Al-0.5Ti-0.5Y{sub 2}O{sub 3}, wt.%), and a reliable joint was obtained by assembly and welding under a high-purity argon atmosphere. The optimal joint was obtained by brazing at 1050 °C for 20 min. The microstructure, microhardness and tensile strength were investigated. The microhardness distribution across the joint was evaluated. The tensile strength of the joint mainly decreased linearly with an increase in test temperature in the range of room temperature (RT) to 700 °C. An interesting phenomenon was found: The joint strength at RT was 557.8 MPa and reached approximately 75% of the value of the base material. However, at 500 °C, the joint (428.7 MPa) achieved 95% of the strength of the base material (450.7 MPa). The fractography of a specimen tensile-tested at 500 °C indicates a higher percentage of intergranular fracture than that at RT.
Solid-state optical refrigeration uses anti-Stokes fluorescence to cool macroscopic objects to cryogenic temperatures without vibrations. Crystals such as Yb 3+ -doped YLiF 4 (YLF:Yb) have previously been laser-cooled to 91 K. In this study, we show for the first time laser cooling of a payload connected to a cooling crystal. A YLF:Yb crystal was placed inside a Herriott cell and pumped with a 1020-nm laser (47 W) to cool a HgCdTe sensor that is part of a working Fourier Transform Infrared (FTIR) spectrometer to 135 K. This first demonstration of an all-solid-state optical cryocooler was enabled by careful control of the various desired and undesired heat flows. Fluorescence heating of the payload was minimized by using a single-kink YLF thermal link between the YLF:Yb cooling crystal and the copper coldfinger that held the HgCdTe sensor. The adhesive-free bond between YLF and YLF:Yb showed excellent thermal reliability. This laser-cooled assembly was then supported by silica aerogel cylinders inside a vacuum clamshell to minimize undesired conductive and radiative heat loads from the warm surroundings. Our structure can serve as a baseline for future optical cryocooler devices.
ABSTRACT We implement a model for the two-point statistics of biased tracers that combines dark matter dynamics from N-body simulations with an analytic Lagrangian bias expansion. Using Aemulus, a suite of N-body simulations built for emulation of cosmological observables, we emulate the cosmology dependence of these non-linear spectra from redshifts z = 0 to z = 2. We quantify the accuracy of our emulation procedure, which is sub-per cent at $k=1\, h \,{\rm Mpc}^{-1}$ for the redshifts probed by upcoming surveys and improves at higher redshifts. We demonstrate its ability to describe the statistics of complex tracer samples, including those with assembly bias and baryonic effects, reliably fitting the clustering and lensing statistics of such samples at redshift z ≃ 0.4 to scales of $k_{\rm max} \approx 0.6\, h\,\mathrm{Mpc}^{-1}$. We show that the emulator can be used for unbiased cosmological parameter inference in simulated joint clustering and galaxy–galaxy lensing analyses with data drawn from an independent N-body simulation. These results indicate that our emulator is a promising tool that can be readily applied to the analysis of current and upcoming data sets from galaxy surveys.
The High-Luminosity Large Hadron Collider (HL-LHC) will produce a higher rate of particle collisions than the current Large Hadron Collider (LHC), requiring important upgrades to the Compact Muon Solenoid (CMS) to handle an increased amount of data. An important upgrade is the Phase-2 Outer Tracker Upgrade, which consists of 13,000 silicon sensor modules made of two parallel silicon sensors and readout electronics. These modules undergo careful quality control checks both during and after module assembly to ensure precise and reliable detector performance. This project focuses on precision testing for quality control of silicon sensor modules at Fermilab. Hands-on work includes visual inspection, current-voltage testing, module testing, and ultraviolet (UV) light exposure of modules showing abnormal current-voltage behavior. The ultraviolet exposure process improves the abnormal sensor readout data by placing the selected sensor side of the module directly under the UV light inside a controlled box. In addition to laboratory testing and ultraviolet experiments, I developed a Python-based data tool that connects to a module database and allows selected testing conditions and module information to be retrieved and displayed efficiently. These different testing procedures, experimental processes, and computational tools support the broader goal of identifying module issues and improving modules that will be used in the CMS Outer Tracker Phase-2 Upgrade.