Class Y: NEPP Championed Approach to Advanced Package Qualification
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flight parts procurement↗
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Actel Parts Usage in GSFC Projects
The purpose of this paper is to provide an overview of the Actel field programmable gate array (FPGA) issues and investigations to date, provide information to GSFC parts engineers on the risks associated with the use of these parts in flight, provide procurement options for their respective projects, and provide general guidance for use of these devices if no other acceptable options exist.
Sahu, Kusum↗
Characterization of Machine Variability and Progressive Heat Treatment in Selective Laser Melting of Inconel 718
The absence of an economy of scale in spaceflight hardware makes additive manufacturing an immensely attractive option for propulsion components. As additive manufacturing techniques are increasingly adopted by government and industry to produce propulsion hardware in human-rated systems, significant development efforts are needed to establish these methods as reliable alternatives to conventional subtractive manufacturing. One of the critical challenges facing powder bed fusion techniques in this application is variability between machines used to perform builds. Even with implementation of robust process controls, it is possible for two machines operating at identical parameters with equivalent base materials to produce specimens with slightly different material properties. The machine variability study presented here evaluates 60 specimens of identical geometry built using the same parameters. 30 samples were produced on machine 1 (M1) and the other 30 samples were built on machine 2 (M2). Each of the 30-sample sets were further subdivided into three subsets (with 10 specimens in each subset) to assess the effect of progressive heat treatment on machine variability. The three categories for post-processing were: stress relief, stress relief followed by hot isostatic press (HIP), and stress relief followed by HIP followed by heat treatment per AMS 5664. Each specimen (a round, smooth tensile) was mechanically tested per ASTM E8. Two formal statistical techniques, hypothesis testing for equivalency of means and one-way analysis of variance (ANOVA), were applied to characterize the impact of machine variability and heat treatment on six material properties: tensile stress, yield stress, modulus of elasticity, fracture elongation, and reduction of area. This work represents the type of development effort that is critical as NASA, academia, and the industrial base work collaboratively to establish a path to certification for additively manufactured parts. For future flight programs, NASA and its commercial partners will procure parts from vendors who will use a diverse range of machines to produce parts and, as such, it is essential that the AM community develop a sound understanding of the degree to which machine variability impacts material properties.
Prater, T.↗
Characterization of Machine Variability and Progressive Heat Treatment in Selective Laser Melting of Inconel 718
The absence of an economy of scale in spaceflight hardware makes additive manufacturing an immensely attractive option for propulsion components. As additive manufacturing techniques are increasingly adopted by government and industry to produce propulsion hardware in human‐rated systems, significant development efforts are needed to establish these methods as reliable alternatives to conventional subtractive manufacturing. One of the critical challenges facing powder bed fusion techniques in this application is variability between machines used to perform builds. Even with implementation of robust process controls, it is possible for two machines operating at identical parameters with equivalent base materials to produce specimens with slightly different material properties. The machine variability study presented here evaluates 60 specimens of identical geometry built using the same parameters. 30 samples were produced on machine 1 (M1) and the other 30 samples were built on machine 2 (M2). Each of the 30‐sample sets were further subdivided into three subsets (with 10 specimens in each subset) to assess the effect of progressive heat treatment on machine variability. The three categories for post‐processing were: stress relief, stress relief followed by hot isostatic press (HIP), and stress relief followed by HIP followed by heat treatment per AMS 5664. Each specimen (a round, smooth tensile) was mechanically tested per ASTM E8. Two formal statistical techniques, hypothesis testing for equivalency of means and one‐way analysis of variance (ANOVA), were applied to characterize the impact of machine variability and heat treatment on six material properties: tensile stress, yield stress, modulus of elasticity, fracture elongation, and reduction of area. This work represents the type of development effort that is critical as NASA, academia, and the industrial base work collaboratively to establish a path to certification for additively manufactured parts. For future flight programs, NASA and its commercial partners will procure parts from vendors who will use a diverse range of machines to produce parts and, as such, it is essential that the AM community develop a sound understanding of the degree to which machine variability impacts material properties.
Prater, Tracie↗
The Goddard Space Flight Center preferred parts list, revision A
A listing is presented of preferred electronic parts, part upgrading procedures, part derating guidelines, and part screening procedures to be used in the selection, procurement, and application of parts for Goddard Space Flight Center space systems and ground support equipment.
Tyson, N. E.↗
GSFC Preferred Parts List PPL-15
A listing is presented of preferred electronic parts, part upgrading procedures, part derating guidelines, and part screening procedures to be used in the selection, procurement, and application of parts for Goddard Space Flight Center space systems and ground support equipment.
Adolphsen, J. W.↗
GSFC preferred parts lists PPL-17
A listing of preferred parts, part upgrading procedures, part derating guidelines, and part screening procedures to be used in the selection, procurement, and application of parts for Goddard Space Flight Center (GSFC) space systems and ground support equipment is contained.
Baldini, B. P.↗
The impact of the flight specifications on semiconductor failure rates.
Flight specifications effects on failure rates of semiconductor parts in Apollo Guidance Computer, detailing procurement, screen, burn-in and field history
Hanley, L. D.↗
FY23 Drone RFID (Final Report)
The Drone RFID project successfully completed proof-of-concept testing to demonstrate the potential of a drone-based inventory system for high value remote materials at Los Alamos National Laboratory. Multiple drone platforms were procured, flight authorizations were received, and the vehicles were flown demonstrating what was initially perceived as the most difficult part of the project, successfully flying drones at the lab. Three commercial RFID inventory systems were also purchased, and ground testing performed to determine their suitability. Ultimately, one system was chosen for flight testing and successfully demonstrated the drone's ability to execute inventory with great potential for a relatively low-cost implementation.
42 ENGINEERING↗
CompactPCI(Registered TradeMark) Connectors in Space Flight Applications
This report documents the current status of CompactPCI(Registered TradeMark) connectors in GSFC spaceflight applications. To the extent the information is known, this report summarizes to what component quality level each NASA contractor (referred to as OEM in this report) procured the parts, and what board level and system level testing was performed. The report also provides the current status of the reliability assessment for each GSFC project based on the results of testing and FMEA (Failure Mode Effects Analysis). This report addresses how the CompactPCI(Registered TradeMark) connectors came into existence, and how these became the connector style chosen by many designers of space flight hardware. It identifies the design philosophy and the lack of robustness which has led to several known failure modes. These failure modes include fretting of connector pins during vibration, shock and thermal cycling, exposure of underplating, and increased resistance, including brief excursions to very high resistance. Each of these are signs of aging, which becomes an increasing concern for long duration orbiting space flight applications. This report addresses the mitigation strategy to replace CompactPCI(Registered TradeMark) connectors with space qualified Hypertronics 2mm cPCI connectors. The Hypertronics 2mm cPCI connectors are pin-to-pin compatible with the CompactPCI(Registered TradeMark) connectors and meet all of the same technical requirements, except the ability to hot mate, and to mate directly with a CompactPCI of the opposite gender. A detailed comparison of the CompactPCI(Registered TradeMark) connector and the Hypertronics 2mm cPCI connector is provided to describe the ruggedness of Hypertronics connector for space flight applications. Finally, this report makes recommendations for flight hardware for the future missions where the hardware is yet to be built, as well as for the hardware which has already been built with CompactPCI(Registered TradeMark) connectors.
Williams, Richard↗
Evaluation of advanced microelectronics for inclusion in MIL-STD-975
The approach taken by NASA and JPL (Jet Propulsion Laboratory) in the development of a MIL-STD-975 section which contains advanced technology such as Large Scale Integration and Very Large Scale Integration (LSI/VLSI) microelectronic devices is described. The parts listed in this section are recommended as satisfactory for NASA flight applications, in the absence of alternate qualified devices, based on satisfactory results of a vendor capability audit, the availability of sufficient characterization and reliability data from the manufacturers and users and negotiated detail procurement specifications. The criteria used in the selection and evaluation of the vendors and candidate parts, the preparation of procurement specifications, and the status of this activity are discussed.
Scott, W. Richard↗
Cryogenic fluid management experiment
The cryogenic fluid management experiment (CFME), designed to characterize subcritical liquid hydrogen storage and expulsion in the low-q space environment, is discussed. The experiment utilizes a fine mesh screen fluid management device to accomplish gas-free liquid expulsion and a thermodynamic vent system to intercept heat leak and control tank pressure. The experiment design evolved from a single flight prototype to provision for a multimission (up to 7) capability. A detailed design of the CFME, a dynamic test article, and dedicated ground support equipment were generated. All materials and parts were identified, and components were selected and specifications prepared. Long lead titanium pressurant spheres and the flight tape recorder and ground reproduce unit were procured. Experiment integration with the shuttle orbiter, Spacelab, and KSC ground operations was coordinated with the appropriate NASA centers, and experiment interfaces were defined. Phase 1 ground and flight safety reviews were conducted. Costs were estimated for fabrication and assembly of the CFME, which will become the storage and supply tank for a cryogenic fluid management facility to investigate fluid management in space.
Eberhardt, R. N.↗
V/STOL tilt rotor aircraft study. Volume 2: Preliminary design of research aircraft
A preliminary design study was conducted to establish a minimum sized, low cost V/STOL tilt-rotor research aircraft with the capability of performing proof-of-concept flight research investigations applicable to a wide range of useful military and commercial configurations. The analysis and design approach was based on state-of-the-art methods and maximum use of off-the-shelf hardware and systems to reduce development risk, procurement cost and schedules impact. The rotors to be used are of 26 foot diameter and are the same as currently under construction and test as part of NASA Tilt-Rotor Contract NAS2-6505. The aircraft has a design gross weight of 12,000 lbs. The proposed engines to be used are Lycoming T53-L-13B rated at 1550 shaft horsepower which are fully qualified. A flight test investigation is recommended which will determine the capabilities and limitations of the research aircraft.
Source record↗
A programmable heater control circuit for spacecraft
Spacecraft thermal control is accomplished for many components through use of multilayer insulation systems, electrical heaters, and radiator systems. The heaters are commanded to maintain component temperatures within design specifications. The programmable heater control circuit (PHCC) was designed to obtain an effective and efficient means of spacecraft thermal control. The hybrid circuit provides use of control instrumentation as temperature data, available to the spacecraft central data system, reprogramming capability of the local microprocessor during the spacecraft's mission, and the elimination of significant spacecraft wiring. The hybrid integrated circuit has a temperature sensing and conditioning circuit, a microprocessor, and a heater power and control circuit. The device is miniature and housed in a volume which allows physical integration with the component to be controlled. Applications might include alternate battery-powered logic-circuit configurations. A prototype unit with appropriate physical and functional interfaces was procured for testing. The physical functionality and the feasibility of fabrication of the hybrid integrated circuit were successfully verified. The remaining work to develop a flight-qualified device includes fabrication and testing of a Mil-certified part. An option for completing the PHCC flight qualification testing is to enter into a joint venture with industry.
Nguyen, D. D.↗
Upset Simulation and Training Initiatives for U.S. Navy Commercial Derived Aircraft
Militarized versions of commercial platforms are growing in popularity due to many logistical benefits in the form of commercial off-the-shelf (COTS) parts, established production methods, and commonality for different certifications. Commercial data and best practices are often leveraged to reduce procurement and engineering development costs. While the developmental and cost reduction benefits are clear, these militarized aircraft are routinely operated in flight at significantly different conditions and in significantly different manners than for routine commercial flight. Therefore they are at a higher risk of flight envelope exceedance. This risk may lead to departure from controlled flight and/or aircraft loss1. Historically, the risk of departure from controlled flight for military aircraft has been mitigated by piloted simulation training and engineering analysis of typical aircraft response. High-agility military aircraft simulation databases are typically developed to include high angles of attack (AoA) and sideslip due to the dynamic nature of their missions and have been developed for many tactical configurations over the previous decades. These aircraft simulations allow for a more thorough understanding of the vehicle flight dynamics characteristics at high AoA and sideslip. In recent years, government sponsored research on transport airplane aerodynamic characteristics at high angles of attack has produced a growing understanding of stall/post-stall behavior. This research along with recent commercial airline training initiatives has resulted in improved understanding of simulator-based training requirements and simulator model fidelity.2-5 In addition, inflight training research over the past decade has produced a database of pilot performance and recurrency metrics6. Innovative solutions to aerodynamically model large commercial aircraft for upset conditions such as high AoA, high sideslip, and ballistic damage, as well as capability to accurately account for scaling factors, is necessary to develop realistic engineering and training simulations. Such simulations should significantly reduce the risk of departure from controlled flight, loss of aircraft, and ease the airworthiness certification process. The characteristics of commercial derivative aircraft are exemplified by the P-8A Multi-mission Maritime Aircraft (MMA) aircraft, and the largest benefits of initial investigation are likely to be yielded from this platform. The database produced would also be utilized by flight dynamics engineers as a means to further develop and investigate vehicle flight characteristics as mission tactics evolve through the years ahead. This paper will describe ongoing efforts by the U.S. Navy to develop a methodology for simulation and training for large commercial-derived transport aircraft at unusual attitudes, typically experienced during an aircraft upset. This methodology will be applied to a representative Navy aircraft (P-8A) and utilized to develop a robust simulation that should accurately represent aircraft response in these extremes. Simulation capabilities would then extend to flight dynamics analysis and simulation, as well as potential training applications. Recent evaluations of integrated academic, ground-based simulation, and in-flight upset training will be described along with important lessons learned, specific to military requirements.
Donaldson, Steven↗
Critical concerns, solutions and guidelines for use of plastic encapsulated microcircuits for space flight applications
Some of the concerns and risk mitigation procedures for using plastic encapsulated microcircuits (PEMs) for space applications are discussed. Despite their advantages, PEMs cannot be implemented in all space applications by replacing military parts numbers with their commercial counterparts in product designs and part lists. The technical and procurement concerns are summarized, and suggestions for high reliability procurements are given. The ability to withstand deleterious environmental effects and to meet mission critical reliability is the key to the successful use of PEMs for space applications.
Virmani, Nick↗
Airborne Doppler lidar activities
During August and September 1984, 20 research flights were conducted by the CV990 with airborne doppler lidar installed. Nine of these flights were dedicated to the Lidar project. Excellent data were obtained in the Carquenez Strait downwind of San Francisco Bay, showing the divergence of the flow as it passes into the Central Valley. The data clearly show the horizontal and vertical structure of the wind flow in the pass region and adjoining parts of the Central Valley. Data were also obtained in the vicinity of Mount Shasta in northern California, showing the flow in the lee of the isolated mountain. Preliminary analyses of these flights using the McIdas interactive graphics system have been accomplished, and procurements have been initiated for detailed scientific analyses. A partial failure of a crucial optical component resulted in contamination of a portion of the wind data that were obtained in the Mount Shasta and subsequent flights. Analyses are underway to attempt reconstruction of the data to minimize the effects of the failure. Data were obtained in conjunction with a microwave wind profiler at Penn State University. It is expected that data reconstruction will be of use in this case. Procurement has been initiated for scientific analyses of these results. The improved airborne Lidar system performed well. In most of the research flights a large number of different scan angles were used to obtain the vertical structure of the wind fields being investigated.
Fitzjarrald, D. R.↗
NASA Aerospace Flight Battery Program: Recommendations for Technical Requirements for Inclusion in Aerospace Battery Procurements
This NASA Aerospace Flight Battery Systems Working Group was chartered within the NASA Engineering and Safety Center (NESC). The Battery Working Group was tasked to complete tasks and to propose proactive work to address battery related, agency-wide issues on an annual basis. In its first year of operation, this proactive program addressed various aspects of the validation and verification of aerospace battery systems for NASA missions. Studies were performed, issues were discussed and in many cases, test programs were executed to generate recommendations and guidelines to reduce risk associated with various aspects of implementing battery technology in the aerospace industry. This document contains Part 2 - Volume I: Recommendations for Technical Requirements for Inclusion in Aerospace Battery Procurements of the program's operations.
Jung, David S.↗