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NASA Standards Update: Electrical, Electronic, Electromechanical, and Electro-optical (EEEE or Quad-E) Parts Selection, Testing and Derating Standard (NASA-STD-8739.11)
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Historical Evolution of NASA Standard Materials Testing with Hypergolic Propellants and Ammonia (NASA Standard 6001 Test 15)
The NASA Johnson Space Center White Sands Test Facility (WSTF) has performed testing of hazardous and reactive aerospace fluids, including hypergolic propellants, with materials since the 1960s with the Apollo program. Amongst other test activities, Test 15 is a NASA standard test for evaluating the reactivity of materials with selected aerospace fluids, in particular hydrazine, monomethylhydrazine, uns-dimethylhydrazine, Aerozine 50, dinitrogen tetroxide oxidizers, and ammonia. This manuscript provides an overview of the history of Test 15 over a timeline ranging from prior to its development and first implementation as a NASA standard test in 1974 to its current refinement. Precursor documents to NASA standard tests, as they are currently known, are reviewed. A related supplementary test, international standardization, and enhancements to Test 15 are also discussed. Because WSTF was instrumental in the development and implementation of Test 15, WSTF experience and practices are referred to in this manuscript.
Status of a NASA Standard and Three NASA Handbooks
NASA-STD-7003 Pyroshock Test Criteria, May 18, 1999, has been revised per direction of NASA Headquarters to make it a mandatory standard and to update it for advances in the discipline since it's initial release. NASA-HDBK-7004B Force Limited Vibration Testing, January 31, 2003, and NASA-HDBK-7005 Dynamic Environmental Criteria, March 13, 2001, are being updated to reflect advances in the disciplines since their last release. Additionally, a new NASA handbook, NASA-HDBK-7008 Spacecraft Structural Dynamics Testing is currently being prepared. This paper provides an overview of each document, summarizes the major revisions for the documents undergoing update, and provides the development schedules.
Reflections on the NASA standardization effort
The NASA standardization effort which has been in existence for four years is described. A significant number of equipments have been declared standard in order to achieve multimission utilization with the consequent avoidance of high nonrecurring development costs. The small numbers of equipments and significant gaps in time before the next user requires the item raise questions of the value of maintaining a standard, how to assure its producibility economically in the future, and how to prevent its technical obsolescence. Increasing pressures to broaden the participation of industry in the space program have also contributed to a reexamination of the philosophy of standardization.
Development of a NASA standard gas generator
The goals of the NASA Standard Gas Generator (NSGG) Program are to create a NASA standard gas generating cartridge, characterize its performance, and make it readily available to users. A cartridge within the same envelope as the NASA Standard Initiator (NSI) has the greatest potential use. This potential use is described in viewgraph form. Our approach for NSGG development and qualification was planned to be conducted in several phases. Test methods were developed to evaluate output performance for a variety of potential applications. A feasibility study using modified NSI's was accomplished. Preliminary and final development will be conducted with a delta qualification to evaluate the effects of manufacturing lots and environments. Feasibility study results, feasibility study conclusions, and future plans are presented.
NASA specification for manufacturing and performance requirements of NASA standard aerospace nickel-cadmium cells
On November 25, 1985, the NASA Chief Engineer established a NASA-wide policy to maintain and to require the use of the NASA standard for aerospace nickel-cadmium cells and batteries. The Associate Administrator for Safety, Reliability, Maintainability, and Quality Assurance stated on December 29, 1986, the intent to retain the NASA standard cell usage policy established by the Office of the Chief Engineer. The current NASA policy is also to incorporate technological advances as they are tested and proven for spaceflight applications. This policy will be implemented by modifying the existing standard cells or by developing new NASA standards and their specifications in accordance with the NASA's Aerospace Battery Systems Program Plan. This NASA Specification for Manufacturing and Performance Requirements of NASA Standard Aerospace Nickel-Cadmium Cells is prepared to provide requirements for the NASA standard nickel-cadmium cell. It is an interim specification pending resolution of the separator material availability. This specification has evolved from over 15 years of nickel-cadmium cell experience by NASA. Consequently, considerable experience has been collected and cell performance has been well characterized from many years of ground testing and from in-flight operations in both geosynchronous (GEO) and low earth orbit (LEO) applications. NASA has developed and successfully used two standard flight qualified cell designs.
Preliminary results: Root cause investigation of orbital anomalies and failures in NASA standard 50 ampere-hour nickel-cadmium batteries
Two lots of NASA standard 50 A.H. Ni-Cd battery cells, manufactured by Gates Aerospace Batteries and built into batteries by McDonnell Douglas, have experienced significant performance problems. The two lots were used on the Compton Gamma Ray Observatory and the Upper Atmosphere Research Satellite. Both of these satellites are Low Earth Orbital (LEO) satellites containing batteries on a parallel bus charged to NASA standard V/T curves using a NASA standard power regulator. The following preliminary conclusions were reached: (1) several plate and cell parameters have migrated within their spec limits over the years (in some cases, from one extreme to the other); (2) several parametric relationships, not generally monitored and therefore not under specification control, have also migrated over the years; (3) many of these changes appear to have taken place as a natural consequence of changes in GE/GAB materials and processes; (4) several of these factors may be 'conspiring' to aggravate known cell failure mechanisms (factors such as heavier plate, less teflon and/or less-uniform teflon, and less electrolyte) but all are still in spec (where specs exist); (5) the weight of the evidence collected to characterize the anomalies and to characterize the negative electrode itself, strongly suggests that alterations to the structure, composition, uniformity, and efficiency of the negative electrode are at the heart of the battery performance problems currently being experienced; and (6) further investigation at all levels (plate, cell, battery, and system) continues to be warranted.
Development of NASA Standards for Enabling Certification of Additively Manufactured Parts
There are currently no NASA standards providing specific design and construction requirements for certification of additively manufactured parts. Several international standards organizations are developing standards for additive manufacturing; however, NASA mission schedules preclude the Agency from relying on these organizations to develop standards that are both timely and applicable. NASA and its partners in human spaceflight (Commercial Crew, Space Launch System, and Orion Multi-Purpose Crew Vehicle Programs) are actively developing additively manufactured parts for flight as early as 2018. To bridge this gap, NASA Marshall Space Flight Center (MSFC) is authoring a Center-level standard (MSFC-STD-3716) 1 to establish standard practices for the Laser Powder Bed Fusion (L-PBF) process. In its draft form, the MSFC standard has been used as a basis for L-PBF process implementation for each of the human spaceflight programs. The development of an Agency-level standard is proposed, based upon the principles of MSFC-STD-3716, which would have application to multiple additive manufacturing processes and be readily adaptable to all NASA programs.
Method of Fabricating NASA-Standard Macro-Fiber Composite Piezoelectric Actuators
The NASA Macro-Fiber Composite actuator is a flexible piezoelectric composite device designed for controlling vibrations and shape deformations in high performance aerospace structures. A complete method for fabricating the standard NASA Macro-Fiber Composite actuator is presented in this document. When followed precisely, these procedures will yield devices with electromechanical properties identical to the standard actuator manufactured by NASA Langley Research Center.
Analysis of the DebriSat Fragments and Comparison to the NASA Standard Satellite Breakup Model
Existing DOD and NASA satellite breakup models are based on a key laboratory test, the 1992 Satellite Orbital debris Characterization Impact Test, which has supported many applications and matched on-orbit events involving older satellite designs reasonably well over the years. In 2014, the NASA Orbital Debris Program Office, in collaboration with the Air Force Space and Missile Systems Center, The Aerospace Corporation, and the University of Florida, conducted a hypervelocity impact test using a high-fidelity, mock-up satellite, DebriSat, in controlled and instrumented laboratory conditions to update and improve these models. DebriSat is representative of present-day, low Earth orbit satellites, having been constructed with modern spacecraft materials and techniques. The DebriSat fragment ensemble provided a variety of shapes, bulk densities, and dimensions. Fragments down to 2 mm in size are being characterized by their physical and derived properties. The data will inform updates to the current NASA Standard Satellite Breakup Model (SSBM), which was formulated using laboratory and ground-based measurements of on-orbit fragmentation events to describe an average breakup for spacecraft and upper-stage collisions and explosions. Although individual fragment collection and characterization is still ongoing, this paper will present the status of the DebriSat fragment data analysis including cumulative characteristic length and cumulative mass distributions, area-to-mass distributions, and characteristic length versus mass distributions. Additionally, comparisons to the NASA SSBM will be presented.
Propellant for the NASA Standard Initiator
This paper discusses processes employed in manufacturing zirconium-potassium perchlorate propellant for the NASA standard initiator. It provides both a historical background on the NSI device-detailing problem areas and their resolution--and on propellant blending techniques. Emphasis is placed on the precipitation blending method. The findings on mixing equipment, processing, and raw materials are described. Also detailed are findings on the bridgewire slurry operation, one of the critical steps in the production of the NASA standard initiator.
NASA Standards Inform Comfortable Car Seats
NASA developed standards, which included the neutral body posture (NBP), to specify ways to design flight systems that support human health and safety. Nissan Motor Company, with US offices in Franklin, Tennessee, turned to NASA's NBP research for the development of a new driver's seat. The 2013 Altima now features the new seat, and the company plans to incorporate the seats in upcoming vehicles.
Leo Spacecraft Charging Design Guidelines: A Proposed NASA Standard
Over the past decade, Low Earth Orbiting (LEO) spacecraft have gradually required ever-increasing power levels. As a rule, this has been accomplished through the use of high voltage systems. Recent failures and anomalies on such spacecraft have been traced to various design practices and materials choices related to the high voltage solar arrays. NASA Glenn has studied these anomalies including plasma chamber testing on arrays similar to those that experienced difficulties on orbit. Many others in the community have been involved in a comprehensive effort to understand the problems and to develop practices to avoid them. The NASA Space Environments and Effects program, recognizing the timeliness of this effort, commissioned and funded a design guidelines document intended to capture the current state of understanding. This document, which was completed in the spring of 2003, has been submitted as a proposed NASA standard. We present here an overview of this document and discuss the effort to develop it as a NASA standard.
Guidebook for the Design and Analysis of a NASA Standard Nondestructive Evaluation (NDE) Probability of Detection (POD) Study
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 NASA Standard 20 Ampere Hour Nickel-Cadmium Battery Manual
The NASA standard 20 ampere hour spacecraft nickel-cadmium battery in described. Mechanical electrical and thermal data are supplied. Both qualification and acceptance tests are described. Information on handling and storage is given.
Development and verification of NASA Standard Initiator-2 (NSI-2)
The results of verification testing under NASA Contract NAS9-17249 are summarized in this Final Report. An Appendix is published separately. The report contains a brief discussion of design elements, test results, and a discussion of the latter. The contract was awarded for development and demonstration of design modifications to the NASA Standard Initiator-1 (NSI-1), resulting in the development of NSI-2. The intent of the project was to develop and prove the following design features: (1) Protection from premature initiation due to electrostatic potential by means other than a spark gap; (2) Development of an integral insulated charge cup for use with a zirconium/potassium perchlorate type mixture; (3) Improved cost and reliability figures by the use of a deposited ridge; and (4) Elimination of dudding as a result of the pyrotechnic shock effect, the movement of the primer composition away from the bridge circuit.
Investigation and Comparison between New Satellite Impact Test Results and NASA Standard Breakup Model
This paper summarizes two new satellite impact tests conducted in order to investigate on the outcome of low- and hyper-velocity impacts on two identical target satellites. The first experiment was performed at a low velocity of 1.5 km/s using a 40-gram aluminum alloy sphere, whereas the second experiment was performed at a hyper-velocity of 4.4 km/s using a 4-gram aluminum alloy sphere by two-stage light gas gun in Kyushu Institute of Technology. To date, approximately 1,500 fragments from each impact test have been collected for detailed analysis. Each piece was analyzed based on the method used in the NASA Standard Breakup Model 2000 revision. The detailed analysis will conclude: 1) the similarity in mass distribution of fragments between low and hyper-velocity impacts encourages the development of a general-purpose distribution model applicable for a wide impact velocity range, and 2) the difference in area-to-mass ratio distribution between the impact experiments and the NASA standard breakup model suggests to describe the area-to-mass ratio by a bi-normal distribution.