Rapid qualification of area array package assemblies by increase of ramp rates and temperature ranges
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Chip scale package CSP area array package microvia↗
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Rapid qualification of CSP assemblies by increase of ramp rates and cycling temperature ranges
Team members representing government agencies and private companies have joined together to pool in-kind resources for developing the quality and reliability of chip scale packages (CSPs) for a variety of projects.
chip scale package solder joint reliability BGA th↗
Rapid qualification of fused filament fabrication thermoplastics for cryogenic applications
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Louis Vaught↗
Automated Testing Experience of the Linear Aerospike SR-71 Experiment (LASRE) Controller
System controllers must be fail-safe, low cost, flexible to software changes, able to output health and status words, and permit rapid retest qualification. The system controller designed and tested for the aerospike engine program was an attempt to meet these requirements. This paper describes (1) the aerospike controller design, (2) the automated simulation testing techniques, and (3) the real time monitoring data visualization structure. Controller cost was minimized by design of a single-string system that used an off-the-shelf 486 central processing unit (CPU). A linked-list architecture, with states (nodes) defined in a user-friendly state table, accomplished software changes to the controller. Proven to be fail-safe, this system reported the abort cause and automatically reverted to a safe condition for any first failure. A real time simulation and test system automated the software checkout and retest requirements. A program requirement to decode all abort causes in real time during all ground and flight tests assured the safety of flight decisions and the proper execution of mission rules. The design also included health and status words, and provided a real time analysis interpretation for all health and status data.
Larson, Richard R.↗
The SeaWinds Scatterometer Antenna Subsystem on the QuikScat Spacecraft
In today's environment of "Better, Faster, Cheaper", the ability to produce reliable, flight-proven mechanisms for mission critical applications is more important than ever. Such a mechanism was produced for the QuikScat satellite. The Scatterometer Antenna Subsystem (SAS) is a spin mechanism that continuously rotates a scatterometer antenna, and includes the necessary features (rotary interfaces, drives, launch locks, etc) to allow collection of the scatterometry data that will insure mission success. This paper will discuss the evolution of the SAS from its design heritage on the GGS Polar mission to qualification on the ADEOS II satellite to being a key enabler for the rapid development of the QuikScat Satellite.
Workman, Brian J.↗
FPGA development for high altitude subsonic parachute testing
This paper describes a rapid, top down requirements-driven design of an FPGA used in an Earth qualification test program for a new Mars subsonic parachute. The FPGA is used to process and store data from multiple sensors at multiple rates during launch, ascent, deployment and descent phases of the subsonic parachute test.
telemetry↗
High altitude subsonic parachute field programmable gate array
This paper describes a rapid, top down requirements-driven design of an FPGA used in an Earth qualification test program for a new Mars subsonic parachute. The FPGA is used to process and control storage of telemetry data from multiple sensors throughout; launch, ascent, deployment and descent phases of the subsonic parachute test.
FPGA methodology↗
X-57 Maxwell High Lift Motor Controller Electromagnetic Interference Test Results
During research and development for NASA’s X-57 Maxwell all-electric aircraft project, the efficiency and power density requirements of its electric propulsion subsystem components were met, but aspects of integrating its powertrain subsystems proved problematic. Electromagnetic interference (EMI) from the cruise motor controller (CMC) was a significant challenge for the project. This problem was exacerbated by the lack of EMI requirements imposed on subsystem powertrain components. This report presents the results of EMI testing of the X-57 high lift motor controller (HLMC) at the NASA Glenn Research Center’s EMI Laboratory. For reference, the conducted emissions are compared to DO–160G and MIL–STD–61G conducted emissions limits. After the EMI test, mitigation of the conducted emissions using lightweight EMI chokes produced at NASA Glenn was evaluated using the Fast Fourier Transform (FFT) capability of an oscilloscope in the hardware development laboratory. This process can contribute to the rapid prototyping of electric powertrain components and EMI filters and improve the likelihood of successful EMI qualification at the component and system levels.
Silicon carbide↗
International Space Station (ISS) Internal Active Thermal Control System (IATCS) New Biocide Selection, Qualification and Implementation
The Internal Active Thermal Control System (IATCS) aboard the International Space Station (ISS) is primarily responsible for the removal of heat loads from payload and system racks. The IATCS is a water based system which works in conjunction with the EATCS (External ATCS), an ammonia based system, which are interfaced through a heat exchanger to facilitate heat transfer. On-orbit issues associated with the aqueous coolant chemistry began to occur with unexpected increases in CO2 levels in the cabin. This caused an increase in total inorganic carbon (TIC), a reduction in coolant pH, increased corrosion, and precipitation of nickel phosphate. These chemical changes were also accompanied by the growth of heterotrophic bacteria that increased risk to the system and could potentially impact crew health and safety. Studies were conducted to select a biocide to control microbial growth in the system based on requirements for disinfection at low chemical concentration (effectiveness), solubility and stability, material compatibility, low toxicity to humans, compatibility with vehicle environmental control and life support systems (ECLSS), ease of application, rapid on-orbit measurement, and removal capability. Based on these requirements, ortho-phthalaldehyde (OPA), an aromatic dialdehyde compound, was selected for qualification testing. This paper presents the OPA qualification test results, development of hardware and methodology to safely apply OPA to the system, development of a means to remove OPA, development of a rapid colorimetric test for measurement of OPA, and the OPA on-orbit performance for controlling the growth of microorganisms in the ISS IATCS since November 3, 2007.
Wilson, Mark E.↗
International Space Station (ISS) Internal Active Thermal Control System (IATCS) New Biocide Selection, Qualification and Implementation
The Internal Active Thermal Control System (IATCS) aboard the International Space Station (ISS) is primarily responsible for the removal of heat loads from payload and system racks. The IATCS is a water based system which works in conjunction with the EATCS (External ATCS), an ammonia based system, which are interfaced through a heat exchanger to facilitate heat transfer. On-orbit issues associated with the aqueous coolant chemistry began to occur with unexpected increases in CO2 levels in the cabin. This caused an increase in total inorganic carbon (TIC), a reduction in coolant pH, increased corrosion, and precipitation of nickel phosphate. These chemical changes were also accompanied by the growth of heterotrophic bacteria that increased risk to the system and could potentially impact crew health and safety. Studies were conducted to select a biocide to control microbial growth in the system based on requirements for disinfection at low chemical concentration (effectiveness), solubility and stability, material compatibility, low toxicity to humans, compatibility with vehicle environmental control and life support systems (ECLSS), ease of application, rapid on-orbit measurement, and removal capability. Based on these requirements, ortho-phthalaldehyde (OPA), an aromatic dialdehyde compound, was selected for qualification testing. This paper presents the OPA qualification test results, development of hardware and methodology to safely apply OPA to the system, development of a means to remove OPA, development of a rapid colorimetric test for measurement of OPA, and the OPA on-orbit performance for controlling the growth of microorganisms in the ISS IATCS since November 3, 2007.
Wilson, Mark E.↗
Combined vibration/temperature/sideload environmental testing of UHF blade antennas
Service problems encountered on the F-4 aircraft showed that the environmental qualification requirements for the UHF blade antenna were not adequate. Although the individual environmental levels were stringent enough, only combined environmental testing could duplicate the conditions in which service problems occurred. Techniques for applying static side load simultaneously with vibration and temperature were developed. The combined environment testing was instrumental in the rapid assessment of antenna modifications and resulted in a final configuration which proved satisfactory in service. A need to include combined environmental testing for qualification of blade antennas was established.
Volker, R.↗
FPGA development for high altitude subsonic parachute testing
This paper describes a rapid, top down requirements-driven design of a Field Programmable Gate Array (FPGA) used in an Earth qualification test program for a new Mars subsonic parachute. The FPGA is used to process and control storage of telemetry data from multiple sensors throughout launch, ascent, deployment and descent phases of the subsonic parachute test.
Field Programmable Gate Array (FPGA)↗
270V Battery Using COTS NiCd Cells For Manned Spacecraft
A high power (>35 kW at 215V), low capacity (5.2 Ah), and compact (45L) NiCd battery was developed for the X-38 Crew Return Vehicle (CRV), which is an experimental version of the lifeboat for the International Space Station (ISS). A simple design and innovative approach using a commercial-off-the-shelf (COTS) NiCd cell design enabled the design, qualification, and production of 4 flight units of this highly reliable and safe spacecraft battery to be achieved rapidly (2 years) and cheaply ($13M).
Darcy, Eric↗
Unintended Consequences: How Qualification Constrains Innovation
The development and implementation of new materials and manufacturing processes for aerospace application is often hindered by the high cost and long time span associated with current qualification procedures. The data requirements necessary for material and process qualification are extensive and often require millions of dollars and multiple years to complete. Furthermore, these qualification data can become obsolete for even minor changes to the processing route. This burden is a serious impediment to the pursuit of revolutionary new materials and more affordable processing methods for air vehicle structures. The application of integrated computational materials engineering methods to this problem can help to reduce the barriers to rapid insertion of new materials and processes. By establishing predictive capability for the development of microstructural features in relation to processing and relating this to critical property characteristics, a streamlined approach to qualification is possible. This paper critically examines the advantages and challenges to a modeling-assisted qualification approach for aerospace structural materials. An example of how this approach might apply towards the emerging field of additive manufacturing is discussed in detail.
Brice, Craig A.↗
Development of an Additive Manufacturing Ecosystem for Qualification of Additive Manufacturing Processes and Materials in Aviation
The major challenges associated with additive manufacturing (AM) are an ability to qualify parts and the costs associated with the technology. Our team will study and mature technologies as detailed below to develop an ecosystem for the qualification of AM machines, which in turn supports the certification of part production. Additive manufacturing offers unique opportunities for the aviation industry in the fabrication of original components and replacement parts. Aggressive use of metals AM has, for example, allowed the rapid development and production of new launch vehicle designs, at substantially reduced costs. Aviation has unique challenges, such as higher production volumes, but the potential value of integrating AM into aviation manufacturing is clear. To implement the ecosystem for AM qualification, the team will run a set of six multi-disciplinary projects. Each of these projects will address a current barrier to AM process qualification, and efficient production.
Koushik Datta↗
Photovoltaic Engineering Testbed: A Facility for Space Calibration and Measurement of Solar Cells on the International Space Station
The Photovoltaic Engineering Testbed ("PET") is a facility to be flown on the International Space Station to perform calibration, measurement, and qualification of solar cells in the space environment and then returning the cells to Earth for laboratory use. PET will allow rapid turnaround testing of new photovoltaic technology under AM0 conditions.
Landis, Geoffrey A.↗
New Millennium EO3
The New Millennium Program (NMP) is a NASA technology program that focuses on the validation of advanced spacecraft and instrumentation technologies in space. This program specifically seeks technologies that could significantly benefit future space and Earth science missions by enabling new science capabilities and reducing life cycle costs. These technologies must also require a validation in space to mitigate risks to the first science users, and provide cross-cutting benefits to both NASA's Earth and Space Science enterprises. The NASA Office of Earth Science (OES) directed the NMP to focus the third Earth Observing mission, E03, on innovative measurement concepts that would facilitate remote sensing observations from orbits beyond conventional low-Earth orbit (LEO). These orbits include geosynchronous orbits, highly elliptical orbits, mid-Earth and high-Earth orbits, and other unique vantage points such as L1 and L2. To maximize the input from the Earth science community, a NASA Research Announcement (NRA) was released to solicit innovative measurement concepts for this NMP flight. Because the NMP is a technology validation program, rather than a conventional science program, the NRA required that these measurement concepts employ revolutionary technologies and/or measurement strategies that will enable future science missions from orbits beyond LEO. Another requirement was that a validation in space was needed to reduce real or perceived risks of this concept to future science users. The proposals submitted in response to this NRA were peer reviewed by the NASA OES. The measurement concepts selected through this process will be summarized in this presentation. The E03 measurement concept NRA did not solicit complete mission concepts or flight hardware. Instead, the selected investigators will join integrated project formulation teams to define the mission for the demonstration of the measurement technique and participate in mission design trades and implementation planning. The teams will define and document the measurement approach, the required technologies, the validation plan, the scalability of the design to future science missions, and the infusion path for the completely validated instrument. During this project formulation phase, the specific technologies required to implement each measurement concept will be solicited through an open technology solicitation, and the technology providers will be added to the integrated teams. Once a complete candidate mission concept has been formulated for each measurement concept, these concepts will be subjected to a comprehensive review. The Associate Administrator of the OES will use the results of this review to select a single concept for the E03 flight opportunity. That mission concept will enter its implementation phase, which is expected to last for less than 36 months before launch. During this phase, and after launch, the implementation team will work with the NMP to document and disseminate the information gathered during the flight qualification testing and operations of the measurement concept and its component technologies. This information will be archived and published, where appropriate, to encourage the rapid infusion of these validated technologies into future space and Earth science missions. I
Li, Fuk K.↗
Instructions for Plastic Encapsulated Microcircuit(PEM) Selection, Screening and Qualification.
The use of Plastic Encapsulated Microcircuits (PEMs) is permitted on NASA Goddard Space Flight Center (GSFC) spaceflight applications, provided each use is thoroughly evaluated for thermal, mechanical, and radiation implications of the specific application and found to meet mission requirements. PEMs shall be selected for their functional advantage and availability, not for cost saving; the steps necessary to ensure reliability usually negate any initial apparent cost advantage. A PEM shall not be substituted for a form, fit and functional equivalent, high reliability, hermetic device in spaceflight applications. Due to the rapid change in wafer-level designs typical of commercial parts and the unknown traceability between packaging lots and wafer lots, lot specific testing is required for PEMs, unless specifically excepted by the Mission Assurance Requirements (MAR) for the project. Lot specific qualification, screening, radiation hardness assurance analysis and/or testing, shall be consistent with the required reliability level as defined in the MAR. Developers proposing to use PEMs shall address the following items in their Performance Assurance Implementation Plan: source selection (manufacturers and distributors), storage conditions for all stages of use, packing, shipping and handling, electrostatic discharge (ESD), screening and qualification testing, derating, radiation hardness assurance, test house selection and control, data collection and retention.
King, Terry↗