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Report details the test and inspection procedures for the mass production of high reliability integrated circuits. It covers configuration control, basic fundamentals of quality control, control charts, wafer process evaluation, general process evaluation, evaluation score system, and diffusion evaluation.
NASA has long supported research on intelligent control technologies that could allow space systems to operate autonomously or with reduced human supervision. Proposed uses range from automated control of entire space vehicles to mobile robots that assist or substitute for astronauts to vehicle systems such as life support that interact with other systems in complex ways and require constant vigilance. The potential for pervasive use of such technology to extend the kinds of missions that are possible in practice is well understood, as is its potential to radically improve the robustness, safety and productivity of diverse mission systems. Despite its acknowledged potential, intelligent control capabilities are rarely used in space flight systems. Perhaps the most famous example of intelligent control on a spacecraft is the Remote Agent system flown on the Deep Space One mission (1998 - 2001). However, even in this case, the role of the intelligent control element, originally intended to have full control of the spacecraft for the duration of the mission, was reduced to having partial control for a two-week non-critical period. Even this level of mission acceptance was exceptional. In most cases, mission managers consider intelligent control systems an unacceptable source of risk and elect not to fly them. Overall, the technology is not trusted. From the standpoint of those who need to decide whether to incorporate this technology, lack of trust is easy to understand. Intelligent high-level control means allowing software io make decisions that are too complex for conventional software. The decision-making behavior of these systems is often hard to understand and inspect, and thus hard to evaluate. Moreover, such software is typically designed and implemented either as a research product or custom-built for a particular mission. In the former case, software quality is unlikely to be adequate for flight qualification and the functionality provided by the system is likely driven largely by the need to publish innovative work. In the latter case, the mission represents the first use of the system, a risky proposition even for relatively simple software.
Topics covered include: Fully Integrated, Miniature, High-Frequency Flow Probe Utilizing MEMS Leadless SOI Technology; Nanoscale Surface Plasmonics Sensor With Nanofluidic Control; Advanced Dispersed Fringe Sensing Algorithm for Coarse Phasing Segmented Mirror Telescopes; Neural Network Back-Propagation Algorithm for Sensing Hypergols; Bulk Moisture and Salinity Sensor; Change-Based Satellite Monitoring Using Broad Coverage and Targetable Sensing; Circularly Polarized Microwave Antenna Element with Very Low Off-Axis Cross-Polarization; Ultra-Low Heat-Leak, High-Temperature Superconducting Current Leads for Space Applications; Flash Cracking Reactor for Waste Plastic Processing; An Automated Safe-to-Mate (ASTM) Tester; Wireless Chalcogenide Nanoionic-Based Radio-Frequency Switch; Compute Element and Interface Box for the Hazard Detection System; DOT Transmit Module; Composite Aerogel Multifoil Protective Shielding; Li-Ion Electrolytes with Improved Safety and Tolerance to High-Voltage Systems; Polymer-Reinforced, Non-Brittle, Lightweight Cryogenic Insulation; Controlled, Site-Specific Functionalization of Carbon Nanotubes with Diazonium Salts; Regenerable Sorbent for CO2 Removal; Sprayable Aerogel Bead Compositions With High Shear Flow Resistance and High Thermal Insulation Value; Lexan Linear Shaped Charge Holder with Magnets and Backing Plate; Robotic Ankle for Omnidirectional Rock Anchors; Wind, Wave, and Tidal Energy Without Power Conditioning; An Active Heater Control Concept to Meet IXO Type Mirror Module Thermal-Structural Distortion Requirement; Waterless Clothes-Cleaning Machine; Integrated Electrical Wire Insulation Repair System; LVGEMS Time-of-Flight Mass Spectrometry on Satellites; Surface Inspection Tool for Optical Detection of Surface Defects; Per-Pixel, Dual-Counter Scheme for Optical Communications; Certification-Based Process Analysis; Surface Navigation Using Optimized Waypoints and Particle Swarm Optimization; Smart-Divert Powered Descent Guidance to Avoid the Backshell Landing Dispersion Ellipse; Estimating Foreign-Object-Debris Density from Photogrammetry Data; Adaptive Sampling of Spatiotemporal Phenomena with Optimization Criteria; Building a 2.5D Digital Elevation Model From 2D Imagery; Eyes on the Earth 3D; Target Trailing With Safe Navigation for Maritime Autonomous Surface Vehicles; Adams-Based Rover Terramechanics and Mobility Simulator - ARTEMIS; ISTP CDF Skeleton Editor; Uplink Summary Generator (ULSGEN) Version 1.0; Robotics On-Board Trainer (ROBoT); Software Engineering Tools for Scientific Models; Automatic Data Filter Customization Using a Genetic Algorithm; Tracker Toolkit; Towards Efficient Scientific Data Management Using Cloud Storage; On a Formal Tool for Reasoning About Flight Software Cost Analysis; A Nanostructured Composites Thermal Switch Controls Internal and External Short Circuit in Lithium Ion Batteries; Spacecraft Crew Cabin Condensation Control; and Functional Near-Infrared Spectroscopy Signals Measure Neuronal Activity in the Cortex.
Seeker 1.0 is a prototype free flying robot that will one day be capable of inspecting human-rated spacecraft. Building off previous free flyer experience, this technology will eventually improve safety of human spacecraft by offering a variety of inspection capabilities for both routine and emergency scenarios providing increased capability and safety over current inspection methods. Seeker 1.0 is capable of 6 degree of freedom flight via a cold gas propulsion system and can operate up to 1 hour via a semi-autonomous guidance, navigation, and control system. The prototype spacecraft is capable of capturing still images at a variety of resolutions up to 13 MP. The initial test flight utilizes a command and data relay box called Kenobi. Kenobi is a derivative of the Seeker design and will communicate between Cygnus and Seeker and store data for post-mission downlink. Seeker and Kenobi have launched inside a NanoRacks External CubeSat Deployer (NRCSD-E) attached to the NG-11 Cygnus ISS resupply vehicle and will operate after Cygnus departs ISS and moves to a safe altitude. Operations will last approximately 30 minutes and will consist of basic vehicle maneuvers while capturing high-resolution still images. With any remaining time and propellant, Seeker will demonstrate additional safety capabilities and maneuvers required for operations around a crewed spacecraft. The Seeker project utilized the Class IE process that allows for streamlined flight hardware development and increased mission risk tolerance.
The goal of this research is to develop a viable NDE technique for the inspection of orbiter thermal protection system (TPS) tile bonds. Phase 2, discussed here, concentrated on developing an empirical understanding of the bonded and unbonded vibration signatures of acreage tiles. Controlled experiments in the laboratory have provided useful information on the dynamic response of TPS tiles. It has been shown that several signatures are common to all the pedigree tiles. This degree of consistency in the tile-SIP (strain isolation pad) dynamic response proves that an unbond can be detected for a known tile and establish the basis for extending the analysis capability to arbitrary tiles for which there are no historical data. The field tests of the noncontacting laser acoustic sensor system, conducted at the Kennedy Space Center (KSC), investigated the vibrational environment of the Orbiter Processing Facility (OPF) and its effect on the measurement and analysis techniques being developed. The data collected showed that for orbiter locations, such as the body flap and elevon, the data analysis scheme, and/or the sensor, will require modification to accommodate the ambient motion. Several methods were identified for accomplishing this, and a solution is seen as readily achievable. It was established that the tile response was similar to that observed in the laboratory. Of most importance, however, is that the field environment will not affect the physics of the dynamic response that is related to bond condition. All of this information is fundamental to any future design and development of a prototype system.
The nuclear industry is experiencing renewed interest in autonomous robotics, yet most deployed systems remain teleoperated with limited autonomy. This work presents two contributions toward fully autonomous nuclear robotic systems: autonomous waste inspection at the Hanford Site and an autonomous hot cell laboratory framework. Inspections of Hanford's underground waste storage tanks are performed manually at significant cost and personnel exposure. We developed a reinforcement-learning (RL) training pipeline for a custom-built inspection arm. In parallel, we are designing an autonomous laboratory framework for post-irradiation examination in hot cells at the Specimen Preparation Laboratory (SPL) that integrates computer vision, task and motion planning, hardware execution, and operator-in-the-loop control. These systems demonstrate a path toward safer, more efficient nuclear operations by reducing human exposure while maintaining rigorous human oversight at critical decision points.
This IR is a follow-up conference Paper to the IR approved abstract; PNNL-SA-194096. --- Verification that equipment is authentic and not changed; even at the circuit card assembly (CCA) level will likely be an important component of future arms control treaties. This effort was an initial evaluation of the potential for laser-based ultrasound (LBU) as an inspection tool for Unique Identification (UID) of Circuit Card Assembly (CCA) boards and CCA components. The LBU system used a laser pulse for ultrasound generation and an Optical Microphone for ultrasound detection to image subsurface structures without physical contact and in a dry state. This paper described the selected CCA surrogate, CCA components that were examined, the LBU system, LBU images of the CCA components, and the initial development of UID algorithms. Receiver operating characteristics (ROC) curves indicated good performance for two algorithms as a potential means for UID of CCA boards and CCA components.
Topics include: Simulation Testing of Embedded Flight Software; Improved Indentation Test for Measuring Nonlinear Elasticity; Ultraviolet-Absorption Spectroscopic Biofilm Monitor; Electronic Tongue for Quantitation of Contaminants in Water; Radar for Measuring Soil Moisture Under Vegetation; Modular Wireless Data-Acquisition and Control System; Microwave System for Detecting Ice on Aircraft; Routing Algorithm Exploits Spatial Relations; Two-Finger EKG Method of Detecting Evasive Responses; Updated System-Availability and Resource-Allocation Program; Routines for Computing Pressure Drops in Venturis; Software for Fault-Tolerant Matrix Multiplication; Reproducible Growth of High-Quality Cubic-SiC Layers; Nonlinear Thermoelastic Model for SMAs and SMA Hybrid Composites; Liquid-Crystal Thermosets, a New Generation of High-Performance Liquid-Crystal Polymers; Formulations for Stronger Solid Oxide Fuel-Cell Electrolytes; Simulation of Hazards and Poses for a Rocker-Bogie Rover; Autonomous Formation Flight; Expandable Purge Chambers Would Protect Cryogenic Fittings; Wavy-Planform Helicopter Blades Make Less Noise; Miniature Robotic Spacecraft for Inspecting Other Spacecraft; Miniature Ring-Shaped Peristaltic Pump; Compact Plasma Accelerator; Improved Electrohydraulic Linear Actuators; A Software Architecture for Semiautonomous Robot Control; Fabrication of Channels for Nanobiotechnological Devices; Improved Thin, Flexible Heat Pipes; Miniature Radioisotope Thermoelectric Power Cubes; Permanent Sequestration of Emitted Gases in the Form of Clathrate Hydrates; Electrochemical, H2O2-Boosted Catalytic Oxidation System; Electrokinetic In Situ Treatment of Metal-Contaminated Soil; Pumping Liquid Oxygen by Use of Pulsed Magnetic Fields; Magnetocaloric Pumping of Liquid Oxygen; Tailoring Ion-Thruster Grid Apertures for Greater Efficiency; and Lidar for Guidance of a Spacecraft or Exploratory Robot.
This Equipment Self-Assessment Checklist is designed for asset owners and operators (AOOs) responsible for the deployment, operation, maintenance, or cybersecurity oversight of grid systems and digital energy technologies. It provides a structured inspection checklist for evaluating the security, integrity, and operational trustworthiness of equipment across substations, generation sites, distributed energy resources (DERs), and control environments.
Topics include: Hidden Identification on Parts: Magnetic Machine-Readable Matrix Symbols; System for Processing Coded OFDM Under Doppler and Fading; Multipurpose Hyperspectral Imaging System; Magnetic-Flux-Compensated Voltage Divider; High-Performance Satellite/Terrestrial-Network Gateway; Internet-Based System for Voice Communication With the ISS; Stripline/Microstrip Transition in Multilayer Circuit Board; Dual-Band Feed for a Microwave Reflector Antenna; Quadratic Programming for Allocating Control Effort; Range Process Simulation Tool; Simulator of Space Communication Networks; Computing Q-D Relationships for Storage of Rocket Fuels; Contour Error Map Algorithm; Portfolio Analysis Tool; Glass Frit Filters for Collecting Metal Oxide Nanoparticles; Anhydrous Proton-Conducting Membranes for Fuel Cells; Portable Electron-Beam Free-Form Fabrication System; Miniature Laboratory for Detecting Sparse Biomolecules; Multicompartment Liquid-Cooling/Warming Protective Garments; Laser Metrology for an Optical-Path-Length Modulator; PCM Passive Cooling System Containing Active Subsystems; Automated Electrostatics Environmental Chamber; Estimating Aeroheating of a 3D Body Using a 2D Flow Solver; Artificial Immune System for Recognizing Patterns; Computing the Thermodynamic State of a Cryogenic Fluid; Safety and Mission Assurance Performance Metric; Magnetic Control of Concentration Gradient in Microgravity; Avionics for a Small Robotic Inspection Spacecraft; and Simulation of Dynamics of a Flexible Miniature Airplane.
On 4 December 2002, a failure of the Refurbished Manipulator Arm System (RMAS) occurred in the Manipulator Development Facility (MDF) at Johnson Space Center. When the Test Director commanded a should pitch maneuver to lift the arm from its payload bay pedestal, the yaw controls failed. This, coupled with a gravitational forces (due to the angle of the shoulder joint with respect to vertical), resulted in uncontrolled arm motion. The shoulder yaw joint moved approximately 20 degrees, causing the extended arm to strike and severely damage the port side MDF catwalk handrails. The arm motion stopped after impact with the handrails. On 10-12 January 2001, inspections were performed on the port face of the lower and upper arms of the RMAS using a infrared thermography developed at Langley Research Center. This paper presents the results of those nondestructive inspections and provides a complete description of the anomalies found and their locations.
Purpose: This document provides guidance on the design and analysis of a NASA Standard nondestructive evaluation (NDE) probability of detection (POD) study. A Standard NDE flaw size is considered to be conservative such that most inspectors, trained and certified in the specific NDE method, are expected to provide at least 90/95 POD for that flaw size to inspect fracture-critical hardware. Scope: This document is specifically applicable to NASA Technical Standards that establish the NDE requirements for any NASA system or component, flight or ground, where fracture control and a quantitative demonstration of POD is a requirement, including NASA-STD-5009B, Nondestructive Evaluation Requirements for Fracture-Critical Metallic Components, and NASA-STD-5019A,Fracture Control Requirements for Spaceflight Hardware.
The capability of modern fighter airplanes to sustain flight at high angles of attack and/or moderate angles of sideslip often results in immersion of part of such an airplane in unsteady, separated, vortical flow emanating from its forebody or wings. The flows from these surfaces become turbulent and separated during flight under these conditions. These flows contain significant levels of energy over a frequency band coincident with that of low-order structural vibration modes of wings, fins, and control surfaces. The unsteady pressures applied to these lifting surfaces as a result of the turbulent flows are commonly denoted buffet loads, and the resulting vibrations of the affected structures are known as buffeting. Prolonged exposure to buffet loads has resulted in fatigue of structures on several airplanes. Damage to airplanes caused by buffeting has led to redesigns of airplane structures and increased support costs for the United States Air Force and Navy as well as the armed forces of other countries. Time spent inspecting, repairing, and replacing structures adversely affects availability of aircraft for missions. A blend of rudder-control and piezoelectric- actuator engineering concepts was selected as a basis for the design of a vertical-tail buffet-load-alleviation system for the F/A-18 airplane. In this system, the rudder actuator is used to control the response of the first tail vibrational mode (bending at a frequency near 15 Hz), while directional patch piezoelectric actuators are used to control the second tail vibrational mode (tip torsion at a frequency near 45 Hz). This blend of two types of actuator utilizes the most effective features of each. An analytical model of the aeroservoelastic behavior of the airplane equipped with this system was validated by good agreement with measured results from a full-scale ground test, flight-test measurement of buffet response, and an in-flight commanded rudder frequency sweep. The overall performance of the system was found to be characterized by reductions, ranging from 70 to 30 percent, in vertical-tail buffeting under buffet loads ranging from moderate to severe. These reductions were accomplished with a maximum commanded rudder angle of +/-2deg at 15 Hz and about 10 lb (.4.5 kg) of piezoelectric actuators attached to the vertical tail skin and operating at a peak power level of 2 kW. By meeting the design objective, this system would extend the vertical-tail fatigue life beyond two aircraft lifetimes. This system is also adaptable to other aircraft surfaces and other aircraft
Video system designed for examining interiors of burrows of gopher tortoises, 5 in. (13 cm) in diameter or greater, to depth of 18 ft. (about 5.5 m), includes video camera, video cassette recorder (VCR), television monitor, control unit, and power supply, all carried in backpack. Polyvinyl chloride (PVC) poles used to maneuver camera into (and out of) burrows, stiff enough to push camera into burrow, but flexible enough to bend around curves. Adult tortoises and other burrow inhabitants observable, young tortoises and such small animals as mice obscured by sand or debris.
The trend of teleoperator development is toward digital computer controlled systems which utilize local sensor-computer-actuator loops to avoid obstacles and to sense manipulator grip-and-slip. The potential applications of advanced teleoperator technology to manned aerospace systems include long manipulator booms to be mounted on the shuttle. These can transfer cargo from the space shuttle and can acquire and retrieve objects in space. Free-flying teleoperators capable of acquiring, inspecting, repairing or refurbishing satellites in orbit are another space application. Another potential application of teleoperator technology is the concept of using an anthropomorphous teleoperator in lieu of man to control aircraft or spacecraft normally controlled by a human pilot.
Recent advancements in the areas of tracking, communications, and robotics vision sensors being pursued within NASA, as applicable to space programs, are presented. Optical and laser-based communications and tracking systems and applications to space programs are discussed. Communication systems for multiple access, broadband, high data rate, and efficient operations are given. Current efforts at 20/30 GHz and millimeter wave bands are summarized. The use of optical data processing in control system applications for rendezvous and docking is presented. Robotics vision, based on television, laser, and microwave sensors for space applications, is discussed. The fusion of these technologies for remote control, station keeping, tracking, inspection, and satellite repair is detailed.
Inspection of space station windows for micrometeorite damage would be a difficult task insitu using current inspection techniques. Commercially available optical profilometers and inspection systems are relatively large, about the size of a desktop computer tower, and require a stable platform to inspect the test object. Also, many devices currently available are designed for a laboratory or controlled environments requiring external computer control. This paper presents an approach using a highly developed optical interferometer to inspect the windows from inside the space station itself using a self- contained hand held device. The interferometer would be capable as a minimum of detecting damage as small as one ten thousands of an inch in diameter and depth while interrogating a relatively large area. The current developmental state of this device is still in the proof of concept stage. The background section of this paper will discuss the current state of the art of profilometers as well as the desired configuration of the self-contained, hand held device. Then, a discussion of the developments and findings that will allow the configuration change with suggested approaches appearing in the proof of concept section.
Current composite manufacturing rates need to be improved to meet the projected demand of on-demand mobility (ODM) and commercial aircraft transports. Some processes in the composite manufacturing chain require touch labor such as manual sanding of surfaces prior to bonding and installing thousands of mechanical fasteners in bonded primary structures to achieve Federal Aviation Administration (FAA) certification. The consequences are insufficient repeatability in bond quality resulting in increased manufacturing time. The FAA has indicated that robust process control is one potential means of certifying bondlines in primary structure. This work describes an integrated closed-loop control system between a laser machining system and laser induced breakdown spectroscopy (LIBS) instrumentation as a means of assuring bond performance and achieving certified composite bondlines. Preliminary results from in-situ treatment and inspection are presented. Results indicate that LIBS inspection and laser treatment can be conducted simultaneously to achieve high quality, reliable adhesive bonds.