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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 19 records
All sourcesNASA NTRSDOE OSTI
NASA NTRS1993

Role of failure-mechanism identification in accelerated testing

Accelerated life testing techniques provide a short-cut method to investigate the reliability of electronic devices with respect to certain dominant failure mechanisms that occur under normal operating conditions. However, accelerated tests have often been conducted without knowledge of the failure mechanisms and without ensuring that the test accelerated the same mechanism as that observed under normal operating conditions. This paper summarizes common failure mechanisms in electronic devices and packages and investigates possible failure mechanism shifting during accelerated testing.

Hu, J. M.↗
DOE OSTI2015

A Statistical Perspective on Highly Accelerated Testing

Highly accelerated life testing has been heavily promoted at Sandia (and elsewhere) as a means to rapidly identify product weaknesses caused by flaws in the product's design or manufacturing process. During product development, a small number of units are forced to fail at high stress. The failed units are then examined to determine the root causes of failure. The identification of the root causes of product failures exposed by highly accelerated life testing can instigate changes to the product's design and/or manufacturing process that result in a product with increased reliability. It is widely viewed that this qualitative use of highly accelerated life testing (often associated with the acronym HALT) can be useful. However, highly accelerated life testing has also been proposed as a quantitative means for "demonstrating" the reliability of a product where unreliability is associated with loss of margin via an identified and dominating failure mechanism. It is assumed that the dominant failure mechanism can be accelerated by changing the level of a stress factor that is assumed to be related to the dominant failure mode. In extreme cases, a minimal number of units (often from a pre-production lot) are subjected to a single highly accelerated stress relative to normal use. If no (or, sufficiently few) units fail at this high stress level, some might claim that a certain level of reliability has been demonstrated (relative to normal use conditions). Underlying this claim are assumptions regarding the level of knowledge associated with the relationship between the stress level and the probability of failure. The primary purpose of this document is to discuss (from a statistical perspective) the efficacy of using accelerated life testing protocols (and, in particular, "highly accelerated" protocols) to make quantitative inferences concerning the performance of a product (e.g., reliability) when in fact there is lack-of-knowledge and uncertainty concerning the assumed relationship between the stress level and performance. In addition, this document contains recommendations for conducting more informative accelerated tests.

42 ENGINEERING↗
DOE OSTI2020

Characterizing photovoltaic backsheet adhesion degradation using the wedge and single cantilever beam tests, Part II: Accelerated tests

Photovoltaic (PV) backsheets provide critical moisture, mechanical, and electrical insulation to the backside of PV modules, but their continued functionality depends upon their ability to remain well adhered over years of harsh environmental exposure. A study of adhesive strength was conducted on several PV backsheet types exposed to indoor accelerated weathering. Two adhesion tests – the wedge test and single cantilever beam test – were used to measure adhesion energy in four backsheets: two with fluoropolymer-based outer (airside) layers – polyvinyl fluoride (PVF), polyvinylidene fluoride (PVDF) – and two with non-fluoropolymer-based outer layers–polyamide (PA) and polyethylene terephthalate (PET). The effects of changes in temperature, ultraviolet (UV) irradiance, relative humidity, and a periodic water spray were studied. The PET-, PVF- and PVDF-based backsheets all showed instances of debonding in an adhesive layer, which is commonly reported. Furthermore, for the PA-, PET-, and PVDF-based backsheets, adhesion energy dropped fairly rapidly with exposure, reaching very low levels by 4000 h. The PVF-based backsheet was relatively robust to weathering. Pull-off of an outer chalking layer in the PA- and PET-based backsheets suggested a sensitivity to UV. Adhesion in these two backsheets was also highly sensitive to changes in moisture level. Changes in UV irradiance and temperature did not show a statistically significant effect on adhesion loss for the exposure levels used. The present work is part of a two-part adhesion study on both field-weathered and indoor-exposed backsheets, and forms a basis for understanding adhesion degradation across a variety of backsheet types and degradation factors.

14 SOLAR ENERGY↗
DOE OSTI2014

Advanced Beamline Design for Fermilab's Advanced Superconducting Test Accelerator

The Advanced Superconducting Test Accelerator (ASTA) at Fermilab is a new electron accelerator currently in the commissioning stage. In addition to testing superconducting accelerating cavities for future accelerators, it is foreseen to support a variety of Advanced Accelerator R&D (AARD) experiments. Producing the required electron bunches with the expected flexibility is challenging. The goal of this dissertation is to explore via numerical simulations new accelerator beamlines that can enable the advanced manipulation of electron bunches. The work especially includes the design of a low-energy bunch compressor and a study of transverse-to-longitudinal phase space exchangers.

43 PARTICLE ACCELERATORS↗
DOE OSTI2018

Robustness of Asymptotic Optimal Accelerated Test Plans to Small-Sample Settings

Accelerated testing is a form of testing commonly employed in industry, especially at Sandia National Laboratories, in order to extract information about product lifetime behavior that cannot be acquired under normal operating conditions due to the extensive durations of the intended life- times. As of the writing of this report, there is no known guideline for the design of accelerated tests at the laboratories and yet there is an entire field in the statistical literature on the optimal design of accelerated tests covering a wide range of limitations and constraints available for reference. A potential roadblock to incorporating this knowledge is the common difficulty at Sandia of having severely limited data available for such testing. Nearly all of the methodology presented in the statistical literature is based on asymptotic or large-sample theory and so may not be appropriate for the testing conditions present at Sandia. This report investigates optimal accelerated test plans derived based on small-sample or exact methodology for both a basic test setting as well as a more realistic setting and compares the resulting test plans to those derived based on the large- sample methodology from the literature. It is shown that the large-sample test plans are actually quite robust to the presence of limited data and are generally more flexible than the small-sample test plans.

36 MATERIALS SCIENCE↗
DOE OSTI2013

Proposal for an Accelerator R&D User Facility at Fermilab's Advanced Superconducting Test Accelerator (ASTA)

Fermilab is the nation’s particle physics laboratory, supported by the DOE Office of High Energy Physics (OHEP). Fermilab is a world leader in accelerators, with a demonstrated track-record— spanning four decades—of excellence in accelerator science and technology. We describe the significant opportunity to complete, in a highly leveraged manner, a unique accelerator research facility that supports the broad strategic goals in accelerator science and technology within the OHEP. While the US accelerator-based HEP program is oriented toward the Intensity Frontier, which requires modern superconducting linear accelerators and advanced highintensity storage rings, there are no accelerator test facilities that support the accelerator science of the Intensity Frontier. Further, nearly all proposed future accelerators for Discovery Science will rely on superconducting radiofrequency (SRF) acceleration, yet there are no dedicated test facilities to study SRF capabilities for beam acceleration and manipulation in prototypic conditions. Finally, there are a wide range of experiments and research programs beyond particle physics that require the unique beam parameters that will only be available at Fermilab’s Advanced Superconducting Test Accelerator (ASTA). To address these needs we submit this proposal for an Accelerator R&D User Facility at ASTA. The ASTA program is based on the capability provided by an SRF linac (which provides electron beams from 50 MeV to nearly 1 GeV) and a small storage ring (with the ability to store either electrons or protons) to enable a broad range of beam-based experiments to study fundamental limitations to beam intensity and to develop transformative approaches to particle-beam generation, acceleration and manipulation which cannot be done elsewhere. It will also establish a unique resource for R&D towards Energy Frontier facilities and a test-bed for SRF accelerators and high brightness beam applications in support of the OHEP mission of Accelerator Stewardship.

43 PARTICLE ACCELERATORS↗
NASA NTRS1976

Accelerated test techniques for micro-circuits: Evaluation of high temperature (473 k - 573 K) accelerated life test techniques as effective microcircuit screening methods

The application of high temperature accelerated test techniques was shown to be an effective method of microcircuit defect screening. Comprehensive microcircuit evaluations and a series of high temperature (473 K to 573 K) life tests demonstrated that a freak or early failure population of surface contaminated devices could be completely screened in thirty two hours of test at an ambient temperature of 523 K. Equivalent screening at 398 K, as prescribed by current Military and NASA specifications, would have required in excess of 1,500 hours of test. All testing was accomplished with a Texas Instruments' 54L10, low power triple-3 input NAND gate manufactured with a titanium- tungsten (Ti-W), Gold (Au) metallization system. A number of design and/or manufacturing anomalies were also noted with the Ti-W, Au metallization system. Further study of the exact nature and cause(s) of these anomalies is recommended prior to the use of microcircuits with Ti-W, Au metallization in long life/high reliability applications. Photomicrographs of tested circuits are included.

Johnson, G. M.↗
DOE OSTI2018

Synchrotron Radiation Beam Diagnostics for the Integrable Optics Test Accelerator

The Integrable Optics Test Accelerator (IOTA) is a research electron and proton storage ring currently being commissioned at Fermilab's Accelerator Science and Technology (FAST) facility. An extensive beam physics research program is planned, including tests of novel techniques for improving beam intensity, stability, and emittance. A key part of IOTA beam diagnostics suite are synchrotron light beam monitors, mounted onto each dipole. In this paper, we present the hardware and software design of this system. Mechanical layout and actuator control electronics are described. High throughput image acquisition and analysis architecture is outlined, and its preliminary performance is explored. Integration of the system within accelerator control network and possible user applications, such as camera auto-focusing, are discussed.

43 PARTICLE ACCELERATORS↗
DOE OSTI2015

First Beam and High-Gradient Cryomodule Commissioning Results of the Advanced Superconducting Test Accelerator at Fermilab

The advanced superconducting test accelerator at Fermilab has accelerated electrons to 20 MeV and, separately, the International Linear Collider (ILC) style 8-cavity cryomodule has achieved the ILC performance milestone of 31.5 MV/m per cavity. When fully completed, the accelerator will consist of a photoinjector, one ILC-type cryomodule, multiple accelerator R&D beamlines, and a downstream beamline to inject 300 MeV electrons into the Integrable Optics Test Accelerator (IOTA). We report on the results of first beam, the achievement of our cryomodule to ILC gradient specifications, and near-term future plans for the facility.

43 PARTICLE ACCELERATORS↗
DOE OSTI2019

The Integrable Optics Test Accelerator

The Integrable Optics Test Accelerator (IOTA) at the Fermilab Accelerator Science & Technology (FAST) Facility is beginning operations, with an experimental program aimed at developing technology to enable future high intensity particle beams. The results garnered from IOTA should allow for better control of beam losses, leading to higher safely achievable beam power. This will be particularly useful for future accelerator based neutrino experiments. Two of the R&D efforts at IOTA, Nonlinear Integrable Optics and Electron Column-based space charge compensation, are discussed here.

43 PARTICLE ACCELERATORS↗
NASA NTRS1973

Fatigue-test acceleration with flight-by-flight loading and heating to simulate supersonic-transport operation

Possibilities for reducing fatigue-test time for supersonic-transport materials and structures were studied in tests with simulated flight-by-flight loading. In order to determine whether short-time tests were feasible, the results of accelerated tests (2 sec per flight) were compared with the results of real-time tests (96 min per flight). The effects of design mean stress, the stress range for ground-air-ground cycles, simulated thermal stress, the number of stress cycles in each flight, and salt corrosion were studied. The flight-by-flight stress sequences were applied to notched sheet specimens of Ti-8Al-1Mo-1V and Ti-6Al-4V titanium alloys. A linear cumulative-damage analysis accounted for large changes in stress range of the simulated flights but did not account for the differences between real-time and accelerated tests. The fatigue lives from accelerated tests were generally within a factor of two of the lives from real-time tests; thus, within the scope of the investigation, accelerated testing seems feasible.

Imig, L. A.↗
DOE OSTI2015

Proton Injection into the Fermilab Integrable Optics Test Accelerator (IOTA)

The Integrable Optics Test Accelerator (IOTA) is an experimental synchrotron being built at Fermilab to test the concept of non-linear "integrable optics". These optics are based on a lattice including non-linear elements that satisfies particular conditions on the Hamiltonian. The resulting particle motion is predicted to be stable but without a unique tune. The system is therefore insensitive to resonant instabilities and can in principle store very intense beams, with space charge tune shifts larger than those which are possible in conventional linear synchrotrons. The ring will initially be tested with pencil electron beams, but this poster describes the ultimate plan to install a 2.5 MeV RFQ to inject protons, which will produce tune shifts on the order of unity. Technical details will be presented, as well as simulations of protons in the ring.

43 PARTICLE ACCELERATORS↗
DOE OSTI2023

Accelerated test protocols to predict service life and durability of solid oxide fuel cells

Reliable accelerated test protocols are needed for solid oxide fuel cell research to facilitate rapid learning on key durability issues, identify potential modes of failure expeditiously, and eventually predict the calendar lifetime of an electrochemical cell. In this work, solid oxide fuel cells operated at a constant current density were compared to cells undergoing accelerated measurements, which are composed of intermittent current injection to the cell. A general accelerated test profile was developed by cycling a solid oxide fuel cell from open circuit to a predetermined operating current density that is the same as the current density during a steady-state operation, to accelerate the local redox environment. The following parameters were studied: current density, operation temperature, moist level, sintering temperature, cycling current, cycling frequency, and operation time. Up to 1,320,000 cycles were generated in this work. The cell degradation was accelerated by nearly 10 times, suggesting the feasibility of using this protocol for acceleration test to predict life performance and durability of solid oxide fuel cells.

08 HYDROGEN↗
NASA NTRS1973

Accelerated test plan for nickel cadmium spacecraft batteries

An accelerated test matrix is outlined that includes acceptance, baseline and post-cycling tests, chemical and physical analyses, and the data analysis procedures to be used in determining the feasibility of an accelerated test for sealed, nickel cadmium cells.

Hennigan, T. J.↗
DOE OSTI2016

Design of Octupole Channel for Integrable Optics Test Accelerator

We present the design of octupole channel for Integrable Optics Test Accelerator (IOTA). IOTA is a test accelerator at Fermilab, aimed to conduct research towards high-intensity machines. One of the goals of the project is to demonstrate high nonlinear betatron tune shifts while retaining large dynamic aperture in a realistic accelerator design. At the first stage the tune shift will be attained with a special channel of octupoles, which creates a variable octupole potential over a 1.8 m length. The channel consists of 18 identical air-cooled octupole magnets. The magnets feature a simple low-cost design, while meeting the requirements on maximum gradient - up to 1.4 kG/cm³, and field quality - strength of harmonics below 1%. Numerical simulations show that the channel is capable of producing a nonlinear tune shift of 0.08 without restriction of dynamic aperture of the ring.

43 PARTICLE ACCELERATORS↗
NASA NTRS1978

Accelerated test modeling

Cycle life regression model, cycle life prediction model, and acceleration factors are discussed. A method was presented to: (1) select a mathematical model; (2) determine model coefficients using accelerated test data; (3) test model fit of the accelerated test data; and (4) predict normal packs.

Schwartz, D.↗