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At least 199 records · Page 11

Characterization and recovery of Deep Sub Micron (DSM) technologies behavior under radiation

This paper serves a twofold purpose: characterize the behavior of a reconfigurable chip exposed to radiation; and demonstrate a method for functionality recovery due to Total Ionizing Dose (TID) effects. The experiments are performed using a PL developed reconfigurable device, a Field Programmable Transistor Array (FPTA). The paper initially describes experiments on the characterization of the NMOS transistor behavior for TID values up to 300krad. The behavior of analog and digital circuits downloaded onto the FPTA chip is also assessed for TID effects. This paper also presents a novel approach for circuit functionality recovery due to radiation effects based on Evolvable Hardware. The key idea is to reconfigure a programmable device, in-situ, to compensate, or bypass its degraded or damaged components. Experiments with total radiation dose up to 300kRad show that while the functionality of a variety of circuits, including digital gates, a rectifier and a Digital to Analog Converter implemented on a FPTA-2 chip is degraded/lost at levels before 200kRad, the correct functionality can be recovered through the proposed evolutionary approach and the chips are able to survive higher radiation, for several functions in excess of total radiation dose of 250kRad.

evolvable hardware↗

Liquid Bismuth Propellant Management System for the Very High Specific Impulse Thruster with Anode Layer

Two prototype bismuth propellant feed systems were constructed and operated in conjunction with a propellant vaporizer. One system provided bismuth to a vaporizer using gas pressurization but did not include a means to measure the flow rate. The second system incorporated an electromagnetic pump to provide fine control of the hydrostatic pressure and a new type of in-line flow sensor that was developed for accurate, real-time measurement of the mass flow rate. High-temperature material compatibility was a driving design requirement for the pump and flow sensor, leading to the selection of Macor for the main body of both components. Posttest inspections of both components revealed no degradation of the material. The gas pressurization system demonstrated continuous pressure control over a range from zero to 200 torr. In separate proof-of-concept experiments, the electromagnetic pump produced a linear pressure rise as a function of current that compared favorably with theoretical pump pressure predictions, producing a pressure rise of 10 kPa at 30 A. Preliminary flow sensor operation indicated a bismuth flow rate of 6 mg/s with an uncertainty of plus or minus 6%. An electronics suite containing a real-time controller was successfully used to control the entire system, simultaneously monitoring all power supplies and performing data acquisition duties.

Polzin, K. A.↗

Method and system for detecting a failure or performance degradation in a dynamic system such as a flight vehicle

A method and system for detecting a failure or performance degradation in a dynamic system having sensors for measuring state variables and providing corresponding output signals in response to one or more system input signals are provided. The method includes calculating estimated gains of a filter and selecting an appropriate linear model for processing the output signals based on the input signals. The step of calculating utilizes one or more models of the dynamic system to obtain estimated signals. The method further includes calculating output error residuals based on the output signals and the estimated signals. The method also includes detecting one or more hypothesized failures or performance degradations of a component or subsystem of the dynamic system based on the error residuals. The step of calculating the estimated values is performed optimally with respect to one or more of: noise, uncertainty of parameters of the models and un-modeled dynamics of the dynamic system which may be a flight vehicle or financial market or modeled financial system.

Miller, Robert H.↗

Soil Moisture Data Assimilation in the NASA Land Information System for Local Modeling Applications and Improved Situational Awareness

As part of the NASA Soil Moisture Active Passive (SMAP) Early Adopter (EA) program, the NASA Shortterm Prediction Research and Transition (SPoRT) Center has implemented a data assimilation (DA) routine into the NASA Land Information System (LIS) for soil moisture retrievals from the European Space Agency's Soil Moisture Ocean Salinity (SMOS) satellite. The SMAP EA program promotes application‐driven research to provide a fundamental understanding of how SMAP data products will be used to improve decision‐making at operational agencies. SPoRT has partnered with select NOAA/NWS Weather Forecast Offices (WFOs) that use output from a real‐time regional configuration of LIS, without soil moisture DA, to initialize local numerical weather prediction (NWP) models and enhance situational awareness. Improvements to local NWP with the current LIS have been demonstrated; however, a better representation of the land surface through assimilation of SMOS (and eventually SMAP) retrievals is expected to lead to further model improvement, particularly during warm‐season months. SPoRT will collaborate with select WFOs to assess the impact of soil moisture DA on operational forecast situations. Assimilation of the legacy SMOS instrument data provides an opportunity to develop expertise in preparation for using SMAP data products shortly after the scheduled launch on 5 November 2014. SMOS contains a passive L‐band radiometer that is used to retrieve surface soil moisture at 35‐km resolution with an accuracy of 0.04 cu cm cm (exp -3). SMAP will feature a comparable passive L‐band instrument in conjunction with a 3‐km resolution active radar component of slightly degraded accuracy. A combined radar‐radiometer product will offer unprecedented global coverage of soil moisture at high spatial resolution (9 km) for hydrometeorological applications, balancing the resolution and accuracy of the active and passive instruments, respectively. The LIS software framework manages land surface model (LSM) simulations and includes an Ensemble Kalman Filter for conducting land surface DA. SPoRT has added a module to read, quality‐control and bias‐correct swaths of Level II SMOS soil moisture retrievals prior to assimilation within LIS. The impact of SMOS DA is being tested using the Noah LSM. Experiments are being conducted to examine the impacts of SMOS soil moisture DA on the resulting LISNoah fields and subsequent NWP simulations using the Weather Research and Forecasting (WRF) model initialized with LIS‐Noah output. LIS‐Noah soil moisture will be validated against in situ observations from Texas A&M's North American Soil Moisture Database to reveal the impact and possible improvement in soil moisture trends through DA. WRF model NWP case studies will test the impacts of DA on the simulated near‐surface and boundary‐layer environments, and precipitation during both quiescent and disturbed weather scenarios. Emphasis will be placed on cases with large analysis increments, especially due to contributions from regional irrigation patterns that are not represented by precipitation input in the baseline LIS‐Noah run. This poster presentation will describe the soil moisture DA methodology and highlight LIS‐Noah and WRF simulation results with and without assimilation.

Case, Jonathan L.↗

Operating Modes and Cooling Capabilities of the Flight ADR for the SXS Instrument on Astro-H

The microcalorimeter array on the Soft X-ray Spectrometer instrument on Astro-H requires cooling to 50 mK, which will be accomplished by a 3-stage adiabatic demagnetization refrigerator (ADR). The ADR is surrounded by a cryogenic system consisting of a superfluid helium tank, a 4.5 K Joule-Thomson (JT) cryocooler, and additional 2-stage Stirling cryocoolers that pre-cool the JT cooler and radiation shields within the cryostat. The unique ADR design allows the instrument to meet all of its science requirements using either the stored cryogen or the JT cryocooler as its heat sink, giving the instrument an unusual degree of tolerance for component failures or degradation in the cryogenic system. The flight detector assembly, ADR and dewar were integrated in early 2014, and have since been extensively characterized and calibrated. At present, the four instruments are being integrated with the spacecraft in preparation for an early 2016 launch. This presentation summarizes the operation and performance of the ADR in all of its operating modes.

adiabatic demagnetization refrigerator↗

Food Fortification Stability Study

NASA has established the goal of traveling beyond low-Earth orbit and extending manned exploration to Mars. The length of proposed Mars missions and the lack of resupply missions increases the importance of nutritional content in the food system, which will need a five year shelf life. The purpose of this research is to assess the stability of vitamin supplementation in traditionally processed spaceflight foods. It is expected that commercially available fortification nutrients will remain stable through a long duration exploration mission at sufficient levels if compatible formulation, processing, and storage temperatures are achieved. Five vitamins (vitamin E, vitamin K, pantothenic acid, folic acid, and thiamin) were blended into a vitamin premix (DSM, Freeport, TX) such that the vitamin concentration per serving equaled 25% of the recommended daily intake after two years of ambient storage. Four freeze-dried foods (Scrambled Eggs, Italian Vegetables, Potatoes Au Gratin, Noodles and Chicken) and four thermostabilized foods (Curry Sauce with Vegetables, Chicken Noodle Soup, Grilled Pork Chop, Rice with Butter) were produced, with and without the vitamin premix, to assess the impact of the added fortification on color and taste and to determine the stability of supplemental vitamins in spaceflight foods. The addition of fortification to spaceflight foods did not greatly alter the organoleptic properties of most products. In most cases, overall acceptability scores remained above 6.0 (minimum acceptable score) following six months and one year of low-temperature storage. Likewise, the color of fortified products appears to be preserved over one year of storage. The only exception was Grilled pork Chop and Chicken Noodle Soup whose individual components appear to degrade rapidly over one year of storage. Finally, most vitamins appear to be stable during long-term storage. The only exception was thiamin, which degraded rapidly during the first year of storage at 35˚C. It was previously believed that the imprecise method of fortification would prove problematic for nutrient quantification; however this was only an issue in stored samples of Grilled Pork Chop, Italian Vegetables and Curry Sauce with Vegetables. Year two data may further reveal the extent to which this is a problem, as well as identify overall quality changes over time.

Sirmons, T.↗

Operating Modes and Cooling Capabilities of the 3-Stage ADR Developed for the Soft-X-Ray Spectrometer Instrument on Astro-H

A 3-stage adiabatic demagnetization refrigerator (ADR) is used on the Soft X-ray Spectrometer instrument on Astro-H to cool a 6x6 array of x-ray microcalorimeters to 50 mK. The ADR is supported by a cryogenic system consisting of a superfluid helium tank, a 4.5 K Joule-Thomson (JT) cryocooler, and additional 2-stage Stirling cryocoolers that pre-cool the JT cooler and cool radiation shields within the cryostat. The ADR is configured so that it can use either the liquid helium or the JT cryocooler as its heat sink, giving the instrument an unusual degree of tolerance for component failures or degradation in the cryogenic system. The flight detector assembly, ADR and dewar were integrated into the flight dewar in early 2014, and have since been extensively characterized and calibrated. This paper summarizes the operation and performance of the ADR in all of its operating modes

x-ray astronomy↗

Atomic Oxygen Interactions and the Design of MISSE-9 and MISSE-10 Experiments

Spacecraft in low Earth orbit (LEO) are subjected to harsh environmental conditions, including radiation (cosmic rays, ultraviolet, x-ray, and charged particle radiation), micrometeoroids and orbital debris, temperature extremes, thermal cycling, and atomic oxygen (AO). These environmental exposures can result in erosion, embrittlement and optical property degradation, threatening spacecraft performance and durability. While all of these environmental exposures can cause degradation to spacecraft components, AO is a particularly serious structural, thermal, and optical threat, to exterior oxidizable spacecraft components.

Atomic Oxygen↗

Durability of Polymers in the Space Environment

Spacecraft in low Earth orbit (LEO) are subjected to harsh environmental conditions, including radiation (cosmic rays, ultraviolet, x-ray, and charged particle radiation), micrometeoroids and orbital debris, temperature extremes, thermal cycling, and atomic oxygen (AO). These environmental exposures can result in erosion, embrittlement and optical property degradation, threatening spacecraft performance and durability. While all of these environmental exposures can cause degradation to spacecraft components, AO is a particularly serious structural, thermal, and optical threat, to exterior oxidizable spacecraft materials, such as polymers. To further our understanding of AO erosion and radiation embrittlement of spacecraft materials, NASA Glenn Research Center has developed and flown a series of experiments as part of the Materials International Space Station Experiment (MISSE) missions on the exterior of the International Space Station (ISS). In continuing these studies, three new Glenn experiments have accepted for flight on the new ISS MISSE-Flight Facility (MISSE-FF). The Polymers and Composites Experiment (PCE) is being flown as part of the MISSE-9 inaugural mission of MISSE-FF. The Polymers and Composites Experiment-2 (PCE-2) and Polymers and Composites-3 Experiment (PCE-3) are being flown as part of the MISSE-10 and MISSE-12 missions, respectively. This presentation provides an overview of the Glenn's three MISSE-FF flight experiments including the objectives and initial spaceflight results.

spaceflight↗

Space Launch Vehicle Transient Particle Redistribution Modeling and Implications for Optically Sensitive Payloads

The performance of contamination sensitive components—such as optical components—can be degraded by particulate matter depositing on the surfaces. Particles can accumulate during manufacturing, handling and operation. For a space-based system, particles can shed from the fairing and redistribute onto sensitive surfaces during launch. An engineering modeling approach has been developed for modeling particle migration during launch. The approach involves particle detachment from the fairing, particle transport through the venting atmosphere inside the fairing, and attachment to the receiving surface. Particle size and amounts on the fairing surface can be modeled using distributions from standards, such as IEST-STD-CC1246E, as well as from empirical data obtained from tape lifts. Surface interactions are modeled using theoretical as well as empirical data. Commercial computational fluid dynamics codes are used to calculate the gas flow in the fairing during depressurization during launch. This approach not only provides insight into particle redistribution during launch but also can be used to establish fairing cleanliness requirements.

Brieda, Lubos↗

Engineering the Interface: Advanced Surface Technologies for Lunar Dust Management and Equipment Longevity

Through the Artemis program, NASA intends to develop a sustainable human foothold on the Moon, ultimately paving the way for crewed exploration of Mars. The Moon's hostile environment poses numerous obstacles, including exposure to radiation, temperature extremes, micrometeoroid threats, and particularly the persistent problem of lunar dust. Lunar dust impacts nearly every aspect of surface operations through adhesion and abrasion mechanisms, with contamination from anthropogenic activities (landing, rovers) far outweighing natural phenomena. Multiple adhesion pathways contribute to surface contamination in the lunar environment, including van der Waals forces, electrostatic forces, chemical reaction, and magnetic forces from elemental iron deposits. Sharp asperities from micrometeoroid bombardment and atmospheric absence increase interaction potential and enable mechanical interlocking. Low cohesion between dust particles exacerbates these challenges, as minimal interaction potential between dust and nearby surfaces overcomes particle cohesion, causing contamination. Lunar dust adhesion mitigation technologies can be categorized as either active, requiring external energy, or passive, relying on intrinsic material properties. Ultrasonic and electrodynamic technologies have been developed to the highest technology readiness level for active approaches. Passive strategies primarily focus on surface chemistry and topography modifications. At NASA Langley Research Center, approaches include surface migration agents to reduce surface energy, topographical modification using laser ablation patterning, and tailored surface conductivity to reduce intrinsic adhesion force. Performance has been evaluated using custom-built ultrasonic and centrifuge instruments. Plume-surface interactions from lunar landers can propel micrometer-sized particles at velocities up to 1000 m s-1.8 These particles pose risks to landers, habitats and infrastructure, leading to erosion, degradation, and reduced component lifespan. A panel recovered from Surveyor III was determined to have been severely abraded because of lunar dust displaced from the Apollo 12 lunar module that landed 160 m away. The performance of metallic surfaces has been evaluated via high velocity single particle impact using the laser-induced project impact test (LIPIT) facility at the University of Utah. Peridynamics modeling, a form of continuum mechanics that uses a nonlocal approach enabling greater simulation capabilities of crack initiation and fracture, has also been utilized to gain greater insight into material response during impact events. Lunar dust contamination challenges extend to power generation systems and moving equipment. Cables, rotation stages, and other mechanisms may experience limited range of motion and reduced lifetime due to dust infiltration. NASA Langley Research Center has evaluated traditional aerospace alloys, softgoods, wear resistant ceramics, and several polymer and polymer composite materials. Test methods have included traditional techniques like Taber abrasion testing, as well as designed test configurations developed in the DUSTE (dust, ultraviolet radiation, and space thermal environmental) chamber that reproduce mechanism functions in operational environment. Beyond laboratory experiments, several flight experiments have been conducted. Materials were exposed to the low Earth orbit environment on the Materials International Space Station Experiment (MISSE) and to the lunar surface environment through the Aegis Aerospace Regolith Adherence Characterization (RAC) payload and the Honeybee Robotics PlanetVac payload. Determining lunar dust's impact on surface exploration and habitation requires comprehensive experimental and computational capabilities combined with lessons learned from initial lunar activities. Identifying the greatest environmental challenges and developing mitigation technologies provides the clearest path toward successfully, expeditiously, and efficaciously completing NASA's mission. This presentation will discuss ongoing efforts at NASA Langley Research Center and collaborator contributions to these critical objectives.

Surface Engineering↗

Development of a Digital Twin for Electrified Aircraft Powertrain Health Management

The augmentation of aircraft powertrains with electrical power systems is a promising path to reducing aircraft fuel consumption, emissions, and noise. Like conventional propulsion systems, electrified aircraft propulsion (EAP) systems will be subject to wear and tear throughout their lifecycles. System health management for EAP will enable efficient flight and maintenance scheduling, realizing economic, safety, and reliability benefits. A digital twin is, broadly, a dynamically updated virtual representation of an individual physical asset. This paper presents a Kalman filter-based approach for the development of a digital twin for an electrified powertrain and applies the approach to an EAP controls testbed. Measurements from nominal testbed operations are used to update a nonlinear model of the testbed. A Kalman filter is then created and used to identify and isolate anomalous testbed behavior based on measurements from off- nominal operations. Results show that the Kalman filter-based digital twin can monitor individual powertrain components’ health for degradation or other changes in performance. The applicability of the presented digital twin approach to any hybrid- or fully-electrified powertrain is emphasized.

Electrified Aircraft Propulsion↗

Graphite Degradation Modeling and Analysis

A graphite component in a nuclear reactor core is subjected to variety of stresses and can experience degradation during normal and off-normal operation. Understanding how a graphite component will behave in service is essential to ensuring core structural stability and safe reactor operation. This report summarizes a graphite modeling tool currently under development at Idaho National Laboratory. The model incorporates several of the anticipated stresses during service and includes the effects of oxidation and irradiation prior to turnaround. This tool is intended to be used to help assess the design of graphite components by utilizing design code rules found in Section III, Division 5 of the American Society of Mechanical Engineering Boiler and Pressure Vessel Code. Specifically, the tool uses the methodologies found within the Full and Simplified assessments from Article HHA-3000 to verify that a graphite component has an acceptably low probability of failure.

36 MATERIALS SCIENCE↗

FENIX: Towards a Fully Integrated Multiphysics Framework for Plasma Facing Component Modeling

Computational tools have a crucial role to play in accelerating the deployment of fusion as a clean, reliable, abundant, and sustainable energy source. Multiphysics, high-fidelity simulation capabilities can help model, study, and predict intricate interactions between materials performance, plasma exposure, neutron irradiation, and engineering processes. As such, they can assist in the resolution of scientific and engineering challenges underpinning design, construction, and commission of fusion power plants. To address these needs, ongoing efforts are leveraging the Multiphysics Object-Oriented Simulation Environment (MOOSE) framework and delivering new computational tools for the fusion community. These tools inherit crucial attributes from MOOSE. They are open-source, modular, integrated with nuclear industry-standard software quality assurance processes, and enable multiphysics, multi-fidelity, fully integrated, zero- to three-dimensional, and massively parallel simulations. After a short overview of these capabilities, we will present the development of Fusion ENergy Integrated multiphys-X (FENIX), a MOOSE-based application designed to enable plasma facing component design and performance evaluation. Throughout their lifetime, plasma facing components are exposed to extreme thermal loads, repeated thermal shocks, and irradiation by plasma ions, neutral particles, and high-energy neutrons. Consequently, designing a plasma facing component with acceptable lifetime degradation is extremely challenging. FENIX aims to model the multiphysics environment in which plasma facing components evolve to accelerate their design studies. To that end, FENIX couples existing MOOSE capabilities such as heat transfer, thermomechanics, and thermal hydraulics, with tritium transport via the MOOSE-based Tritium Migration Analysis Program, Version 8 (TMAP8), with neutronics via the MOOSE-based high-fidelity neutron-photon transport and fluid dynamics code Cardinal, and finally with Particle-in-Cell plasma simulation capabilities being developed in this project. In this study, we present the current FENIX capabilities and preliminary results of its application to model the Tritium Plasma Experiment set up at Idaho National Laboratory.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

Fundamental Ice Crystal Accretion Physics Studies

Due to numerous engine power-loss events associated with high-altitude convective weather, ice accretion within an engine due to ice-crystal ingestion is being investigated. The National Aeronautics and Space Administration (NASA) and the National Research Council (NRC) of Canada are starting to examine the physical mechanisms of ice accretion on surfaces exposed to ice-crystal and mixed-phase conditions. In November 2010, two weeks of testing occurred at the NRC Research Altitude Facility utilizing a single wedge-type airfoil designed to facilitate fundamental studies while retaining critical features of a compressor stator blade or guide vane. The airfoil was placed in the NRC cascade wind tunnel for both aerodynamic and icing tests. Aerodynamic testing showed excellent agreement compared with CFD data on the icing pressure surface and allowed calculation of heat transfer coefficients at various airfoil locations. Icing tests were performed at Mach numbers of 0.2 to 0.3, total pressures from 93 to 45 kPa, and total temperatures from 5 to 15 C. Ice and liquid water contents ranged up to 20 and 3 grams per cubic meter, respectively. The ice appeared well adhered to the surface in the lowest pressure tests (45 kPa) and, in a particular case, showed continuous leading-edge ice growth to a thickness greater than 15 millimeters in 3 minutes. Such widespread deposits were not observed in the highest pressure tests, where the accretions were limited to a small area around the leading edge. The suction surface was typically ice-free in the tests at high pressure, but not at low pressure. The icing behavior at high and low pressure appeared to be correlated with the wet-bulb temperature, which was estimated to be above 0 C in tests at 93 kPa and below 0 C in tests at lower pressure, the latter enhanced by more evaporative cooling of water. The authors believe that the large ice accretions observed in the low pressure tests would undoubtedly cause the aerodynamic performance of a compressor component such as a stator blade to degrade significantly, and could damage downstream components if shed.

Currie, Tom↗

Fundamental Ice Crystal Accretion Physics Studies

Due to numerous engine power-loss events associated with high-altitude convective weather, ice accretion within an engine due to ice crystal ingestion is being investigated. The National Aeronautics and Space Administration (NASA) and the National Research Council (NRC) of Canada are starting to examine the physical mechanisms of ice accretion on surfaces exposed to ice-crystal and mixed-phase conditions. In November 2010, two weeks of testing occurred at the NRC Research Altitude Facility utilizing a single wedge-type airfoil designed to facilitate fundamental studies while retaining critical features of a compressor stator blade or guide vane. The airfoil was placed in the NRC cascade wind tunnel for both aerodynamic and icing tests. Aerodynamic testing showed excellent agreement compared with CFD data on the icing pressure surface and allowed calculation of heat transfer coefficients at various airfoil locations. Icing tests were performed at Mach numbers of 0.2 to 0.3, total pressures from 93 to 45 kPa, and total temperatures from 5 to 15 C. Ice and liquid water contents ranged up to 20 and 3 g/m3, respectively. The ice appeared well adhered to the surface in the lowest pressure tests (45 kPa) and, in a particular case, showed continuous leading-edge ice growth to a thickness greater than 15 mm in 3 min. Such widespread deposits were not observed in the highest pressure tests, where the accretions were limited to a small area around the leading edge. The suction surface was typically ice-free in the tests at high pressure, but not at low pressure. The icing behavior at high and low pressure appeared to be correlated with the wet-bulb temperature, which was estimated to be above 0 C in tests at 93 kPa and below 0 C in tests at lower pressure, the latter enhanced by more evaporative cooling of water. The authors believe that the large ice accretions observed in the low pressure tests would undoubtedly cause the aerodynamic performance of a compressor component such as a stator blade to degrade significantly, and could damage downstream components if shed.

Struk, Peter M.↗

Evaluating the Durability of Balance of Systems Components Using Combined-Accelerated Stress Testing

The degradation of photovoltaic (PV) balance of systems (BoS) components is not well-studied, but the consequences include offline modules, strings, and inverters; system shutdown; arc faults; and fires. A utility provider experienced a ~30% failure rate in their power transfer chain, originally attributed to branch connectors. Field-failed specimen assemblies were therefore examined, consisting of cable connector, branch connector, and discrete fuse components. In this study, unused field-vintage specimens are examined using combined-accelerated stress testing (C-AST) to clarify the most influential environmental stressors as well as the effect of external mechanical perturbation. A benchtop prototype fixture was used to develop the perturbation capability for the C-AST chamber. The benchtop experiments were also used to develop the in-situ data acquisition of specimen current, voltage, and temperature. A significant increase in operating temperature (~100 degrees C from ~40 degrees C) and a different failure mode were observed promptly once periodic mechanical perturbation was applied. The current at failure was decreased from 35 A (with failure in the fuses) to 15 A (failure at the male/female metal pin connection). After initial examination using X-ray computed tomography, the external plastic was machined away from failed specimens to allow for failure analysis, including the extraction of the internal convolute springs for morphological examination (optical and electron microscopy).

balance of systems↗

Evaluating the Durability of Balance of Systems Components Using Combined-Accelerated Stress Testing

The degradation of photovoltaic (PV) balance of systems (BoS) components is not well-studied, but the consequences include: offline-modules, -strings, -inverters; system shutdown; arc-faults; and fires. A utility provider experienced a ~30% failure rate in their power transfer chain, attributed to branch connectors. Field-failed specimen assemblies were therefore examined, consisting of cable connector, branch connector and discrete fuse components. Unused field-vintage specimens are presently being examined using combined-accelerated stress testing (C-AST) to clarify the most influential environmental stressors as well as the effect of external mechanical perturbation. A benchtop prototype fixture was used to develop the perturbation capability for C-AST. The benchtop experiments were also used to develop the in-situ data acquisition of specimen: current, voltage, and temperature. A significant increase in operating temperature, ~100 deg C from ~40 deg C, and a different failure mode was observed immediately once periodic mechanical perturbation was applied. The current at failure was decreased from 35 A (with failure occurring in the fuses) to 15 A (failure at the male/female metal pin connection). After initial examination using X-ray computed tomography, the external plastic was machined away from failed specimens to allow failure analysis, including the extraction of the internal convolute springs for morphological examination (optical- and electron-microscopy). Chemical composition analysis included: energy-dispersive X-ray spectroscopy, differential scanning calorimetry, and Fourier transform infrared spectroscopy.

balance of systems↗