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NASA NTRS1993

Design and specification of a centralized manufacturing data management and scheduling system

As was revealed in a previous study, the Materials and Processes Laboratory's Productivity Enhancement Complex (PEC) has a number of automated production areas/cells that are not effectively integrated, limiting the ability of users to readily share data. The recent decision to utilize the PEC for the fabrication of flight hardware has focused new attention on the problem and brought to light the need for an integrated data management and scheduling system. This report addresses this need by developing preliminary designs specifications for a centralized manufacturing data management and scheduling system for managing flight hardware fabrication in the PEC. This prototype system will be developed under the auspices of the Integrated Engineering Environment (IEE) Oversight team and the IEE Committee. At their recommendation the system specifications were based on the fabrication requirements of the AXAF-S Optical Bench.

Farrington, Phillip A.↗

NASA NTRS1987

Thermal design, analysis and testing of the Halogen Occultation Experiment

This paper briefly introduces the Halogen Occultation Experiment (HALOE) and describes the thermal requirements in some detail. The thermal design of the HALOE is described, together with the design process and the analytical techniques used to arrive at this design. The flight hardware has undergone environmental testing in a thermal vacuum chamber to validate the thermal design. The HALOE is a unique problem in thermal control due to its variable solar loading, its extremely sensitive optical components and the high degree of pointing accuracy required. This paper describes the flight hardware, the design process and its verification.

Foss, Richard A.↗

NASA NTRSDate not supplied

Assembly and Integration Status of a High Fidelity Ground Test Bed for the Water Processor Assembly

The Water Recovery System (WRS) is a critical component of life support aboard the International Space Station (ISS) and will play an essential role in future missions beyond Low Earth Orbit (LEO). Its primary functional units – the Urine Processor Assembly (UPA), Brine Processor Assembly (BPA), and Water Processor Assembly (WPA) – must be evaluated for extended operation, dormancy resilience, material obsolescence, and reliability under exploration-driven constraints. Ground testing is vital for developing these technologies and generating statistically relevant reliability assessments, which requires extended runtime under integrated, Flight-like conditions. Currently, no high-fidelity, fully integrated WPA ground test bed exists to support these objectives. To address this gap, NASA is developing a WPA test bed at Marshall Space Flight Center (MSFC) that combines downgraded ISS flight hardware with functionally flight-like components in a cost-effective configuration while maintaining priority hardware investigations. This paper describes the current status of hardware assembly and integration, outlines key challenges such as simulating microgravity effects and mitigating obsolescence, and presents future test objectives including software development, reliability assessments, dormancy studies, and exploration-oriented upgrades.

Mary-Elizabeth Davis↗

NASA NTRSDate not supplied

Thermal Protection Materials and Systems at NASA Ames Research Center

Thermal Protection Systems (TPS) are critical for enabling NASA missions involving high-speed atmospheric flight where the entries usually include descending into the atmosphere followed by a trajectory that aims to burn off energy and result in a controlled landing. NASA Ames focuses on qualifying and certifying TPS for current missions, sustaining TPS for future missions, and developing new TPS for upcoming missions where a heritage solution is not viable. More recently there is also a focus on advancing and transferring technologies that can benefit both commercial and government space needs. Developing mature thermal protection systems is a lengthy process involving advanced tools, extensive research, and testing. Design and analysis tools are used to predict aerothermal environments, aid the design of test and flight hardware, and support the testing for the thermal/mechanical response of thermal protection systems. More recently, advances in computational methods help reduce the time and cost of technological advances, aid in optimized material architecture design, and improve material properties and performance. While high-enthalpy testing that simulates the conditions of space flight remains essential for the evaluation and development of TPS materials, computational tools are already showing promise in reducing the need for widespread testing and can help fast-track the design cycle. With the exploration of new destinations EDL instrumentation remains an important element of the heatshield and NASA Ames and partners have developed and delivered instrumentation flight hardware in support of recent Mars missions (MSL and M2020) as well as Artemis Orion. Sensors installed on the heatshield and backshell of spacecraft provide coveted information about the aerodynamic and aerothermal environment during entry. Over the years NASA Ames has brought several reusable and ablative TPS materials to a level of readiness to hand off to missions and the branch continues to serve as a TPS steward for the agency. This presentation will cover current developments in the above areas that have enabled recent missions, and look to future TPS needs for missions such as Ice Giants.

thermal protection materials↗

NASA NTRSDate not supplied

Thermal Protection Materials and Systems at NASA Ames Research Center

Thermal Protection Systems (TPS) are critical for enabling NASA missions involving high-speed atmospheric flight where the entries usually include descending into the atmosphere followed by a trajectory that aims to burn off energy and result in a controlled landing. NASA Ames focuses on qualifying and certifying TPS for current missions, sustaining TPS for future missions, and developing new TPS for upcoming missions where a heritage solution is not viable. More recently there is also a focus on advancing and transferring technologies that can benefit both commercial and government space needs.Developing mature thermal protection systems is a lengthy process involving advanced tools, extensive research, and testing. Design and analysis tools are used to predict aerothermal environments, aid the design of test and flight hardware, and support the testing for the thermal/mechanical response of thermal protection systems. More recently, advances in computational methods help reduce the time and cost of technological advances, aid in optimized material architecture design, and improve material properties and performance. While high-enthalpy testing that simulates the conditions of space flight remains essential for the evaluation and development of TPS materials, computational tools are already showing promise in reducing the need for widespread testing and can help fast-trackthe design cycle.With the exploration of new destinations EDL instrumentation remains an important element of the heatshield and NASA Ames and partners have developed and delivered instrumentation flight hardware in support of recent Mars missions,including Mars Science Lab (MSL) and Mars 2020 (M2020),as well as Artemis Orion. Sensors installed on the heatshield and backshell of spacecraft provide coveted information about the aerodynamic and aerothermal environment during entry.Overthe years NASA Ames has brought several reusable and ablative TPS materials to a level of readiness to hand off to missions and the Thermal Protection Materials branch continues to serve as a TPS steward for the agency.

Thermal protection materials↗

NASA NTRS1985

Solid rocket booster retrieval operations

Solid Rocket Booster Retrieval operations are discussed in detail. The recovery of expended boosters and associated hardware without damage attributable to retrieval procedures is the main goal. The retrieval force consists tof ship's personnel and retrieval team members, each of whom has been trained and is highly skilled in multi-faceted operations. The retrieval force is equipped with two specially-built, highly maneuverable ships outfitted with parachute reels, retrieval cranes, towing winches, large volume-low pressure air compressors, SCUBA diving gear, inflatable boats with outboard motors and diver-operated SRB dewatering devices. The two ships are deployed in sufficient time to conduct an electronic and visual search of the impact area prior to launch. Upon search completeion, each ship takes station a safe distance from the predetermined impact point initiating both visual and electronic search in the direction of flight path, ensuring SRB acquisition at splashdown. When safe, the ships enter the impact area and commence recovery of all floating flight hardware which is subsequently returned to the Disassembly Facility for refurbishment and reuse. Retrieval techniques have evolved in parallel with equipment and flight hardware configuration changes. Additional changes have been initiated to improve personnel safety.

Rasmussen, A. M.↗

NASA NTRS1999

Nondestructive Detection of Cracks in Ceramics Using Vicinal Illumination

Cracks and other defects in ceramic materials can be difficult or impossible to examine and photograph due to the extreme lack of contrast. A method for inspecting translucent ceramics using scattered light, also known as vicinal illumination, will be described. This method has been known in the ceramics industry for quite some time, but is not well known in the testing and failure analysis community. Electronics applications include substrates, packages, multilayer capacitors, and thin film resistors. Ceramic materials are used in electronic applications as microcircuit packages and substrates which carry signals and power between microcircuits. Fine cracks in ceramic materials can result in mechanical failures, electrical failures, and loss of hermeticity. Often, fine cracks are difficult or impossible to detect using standard nondestructive inspection techniques such as visual inspection, ultrasonic inspection, or vapor crack detection. Dye penetrant inspection is usually effective, but contaminates the part, which is unacceptable for space flight hardware. One effective nondestructive inspection method of detecting cracks involves examining the way in which light scatters through the ceramic material when viewed with a standard bright field reflected light microscope. This method, termed vicinal illumination, has been used for detecting cracks during failure analyses of several part types, and screening of space flight hardware. The technique has proven effective on several different types of ceramic materials as well. A related method for use with dark field equipment has also been used to successfully locate otherwise invisible cracks.

Hull, Scott M.↗

NASA NTRS2019

The Analysis of Adhesive Residue Failure

Adhesives have always been, and will continue to be, a crucial component of assembling flight hardware. Unfortunately, adhesives have a long standing history of being a source of costly contaminations. There are currently no existing documents that can aid a technician in discerning the proper adhesive/substrate combinations, nor the optimal solvent to use when removing adhesive residue. This project seeks to evaluate the performance of adhesive tapes on various flight hardware substrates in order to create an easy-to-use guide for spacecraft ground processing. The analyses performed were the adhesive/solvent solubility, SEM examinations, and peel adhesion tests. The solubility tests showed that amyl acetate, acetone, and MEK were the most successful in dissolving the adhesives. The SEM data gives preliminary insight into the morphology of the residues. Lastly, the peel adhesion testing proved that there is no relationship between the length of time the adhesive was applied and its adhesive strength.

Smiley, Adrienne↗

NASA NTRS2016

Advances in Rodent Research Missions on the International Space Station

A research platform for rodent experiment on the ISS is a valuable tool for advancing biomedical research in space. Capabilities offered by the Rodent Research project developed at NASA Ames Research Center can support experiments of much longer duration on the ISS than previous experiments performed on the Space Shuttle. NASAs Rodent Research (RR)-1 mission was completed successfully and achieved a number of objectives, including validation of flight hardware, on-orbit operations, and science capabilities as well as support of a CASIS-sponsored experiment (Novartis) on muscle atrophy. Twenty C57BL6J adult female mice were launched on the Space-X (SpX) 4 Dragon vehicle, and thrived for up to 37 days in microgravity. Daily health checks of the mice were performed during the mission via downlinked video; all flight animals were healthy and displayed normal behavior, and higher levels of physical activity compared to ground controls. Behavioral analysis demonstrated that Flight and Ground Control mice exhibited the same range of behaviors, including eating, drinking, exploratory behavior, self- and allo-grooming, and social interactions indicative of healthy animals. The animals were euthanized on-orbit and select tissues were collected from some of the mice on orbit to assess the long-term sample storage capabilities of the ISS. In general, the data obtained from the flight mice were comparable to those from the three groups of control mice (baseline, vivarium and ground controls, which were housed in flight hardware), showing that the ISS has adequate capability to support long-duration rodent experiments. The team recovered 35 tissues from 40 RR-1 frozen carcasses, yielding 3300 aliquots of tissues to distribute to the scientific community in the U.S., including NASAs GeneLab project and scientists via Space Biology's Biospecimen Sharing Program Ames Life Science Data Archive. Tissues also were distributed to Russian research colleagues at the Institute for Biomedical Problems. The expression levels of select genes including albumin, catalase, GAPDH, HMGCoA Reductase, and IGF1 were determined using RNA isolated from the livers by qPCR and no significant differences by one factor ANOVA were found between flight and ground control groups. In addition, some of the liver samples were analyzed for transcriptomic, epigenomic and proteomic profiles; some of the data sets are now available to the scientific community through GeneLabs open science data website. A second long duration mission, Rodent Research-2 (RR-2) was completed on the ISS in 2015; 20 female C57BL6J mice were successfully maintained on the ISS for various durations, with the last group of 5 animals living on-orbit for 54 days. Furthermore, we continue to expand the ISSs capabilities by introducing new on-orbit technologies including blood collection and separation, bone densitometry scanning, muscle grip strength and anesthesia with recovery. In addition, series of ground-based verification testing to fly male mice and increase the total number of mice on-orbit from 20 to 40. Subsequent missions will provide the capability to return live mice from the ISS animals to evaluate recovery on Earth, further expanding operational and science capabilities of the RR project on the ISS.

Choi, S. Y.↗

NASA NTRSDate not supplied

NASA Extreme Environment Mission Operations (NEEMO)

Introduction: NASA is preparing to land the first woman and first person of color on the Moon within the next decade, and ensuring the success of these missions will depend on our preparation on the ground in multiple ground-based lunar environment analogs. To achieve this, NASA has used full mission class analogs, of which NASA Extreme Environment Mission Operations (NEEMO) is the longest continuously running example. Discussion: NEEMO is NASA’s long-standing undersea high-fidelity spaceflight mission analog. It focuses on exploration science, EVA techniques and tools, and maturing ISS IVA flight hardware and operations concepts. NEEMO crews are composed of groups of US and International Partner (IP) astronauts, engineers and scientists who live, work and explore in a challenging environment analogous to the environment experienced currently on ISS and what is expected for future deep space exploration destinations. NEEMO missions are conducted at Aquarius Reef Base (ARB), which includes a shore base in Tavernier, FL, and the world's only undersea research station, the Aquarius habitat, which is located 5.4 miles (9 kilometers) off Key Largo in the Florida Keys National Marine Sanctuary. ARB is owned and operated by Florida International University (FIU). Aquarius was selected due to its remote and extreme location and its ability to provide the unique isolation and risk factors that spaceflight presents. NEEMO missions allow for evaluations of end-to-end EVA and Science exploration concepts of operations with a crew that is in situ in a true extreme environment. They also allow for evaluations of flight hardware and ops tools that are either pondered or destined for ISS or Gateway in the near future. NEEMO missions feature flight-like interactions between the crew and a Mission Control Center (MCC )and Science Team, which in turn allows evaluation of mission and science operations decision making and communications techniques. One reason NEEMO missions are of such high fidelity is that so many of the participants are experienced human space flight end operators. The majority of crewmembers are trained astronauts, and many of the MCC operators have credentials as current or former certified ISS MCC operators (e.g., CapCom, EVA Officer, etc.). Mission products are generated daily by the ground team and are modeled on ISS products (but modified as needed). A planning team manages the constantly evolving mission timelines in response to the ever-changing constraints and opportunities. During NEEMO missions, suited EVA crewmembers (using diving helmets) have clear voice communications with each other, the habitat, and the MCC and Science Team back on shore. Each EVA crewmember also sends helmet cam video to the habitat and MCC and Science Teams. Appropriate communications latencies are inserted for the destination being simulated as well. NEEMO missions are made possible by a broad collaboration of participants. Astronauts from all of the ISS partner agencies are eligible for crew assignment. Often the crew includes a NASA scientist, doctor or engineer with a particular skill to contribute. Sometimes crewmembers come from external entities–generally institutes or universities. Objectives come from a wide variety of sources as well, from within NASA, IPs, government agencies, academia, commercial companies and research institutes. A typical NEEMO mission is a collaboration between at least 5 NASA centers. To date, 23 NEEMO missions have been conducted since 2001, and NEEMO 24 is planned for 2022. Conclusion: NEEMO is a high-fidelity mission analog conducted in an extreme subsea environment. It features experienced end-operators in human spaceflight, from the astronaut crewmembers to key personnel staffing Mission Control. Acknowledgments: The authors wish to thank FIU and NASA’s HEO SEI/Strategic Analysis and Exploration Integration and Science Directorate organizations for the continued support that makes the NEEMO Project possible.

M L Reagan↗

NASA NTRS2000

Effects of AEA Cell-Bypass-Switch Closure on Charged EOS-Aqua NiH2 Cell

A viewgraph presentation outlines the effects of AEA cell bypass-switch closure on a charged EOS-Aqua NiH2 cell. The objectives of the presentation are to: (1) Verify the Performance of AEA Cell Bypass Protection Device (CBPD) under simulated EOS-Aqua/Aura flight hardware configuration; (2) Assess the safety of the hardware under an inadvertent firing of CBPD switch, as well as the closing of CBPD switch under simulated high cell impedance; and (3) Confirm that the mode of operation of CBPD switch is the formation of a continuous low impedance path-homogeneous low melting point eutectic (Indium alloy). Details are given on the EOS-Aqua flight hardware, AEA hardware tested, AEA bypass switch schematic, and the tests performed, which include images of equipment and results.

Keys, Denney↗

NASA NTRS2004

Examination of B. subtilis var. niger Spore Killing by Dry Heat Methods

Dry heat microbial reduction is the only NASA approved sterilization method to reduce the microbial bioburden on space-flight hardware prior to launch. Reduction of the microbial bioburden on spacecraft is necessary to meet planetary protection requirements specific for the mission. Microbial bioburden reduction also occurs if a spacecraft enters a planetary atmosphere (e.g., Mars) and is heated due to frictional forces. Temperatures reached during atmospheric entry events (>200 C) are sufficient to damage or destroy flight hardware and also kill microbial spores that reside on the in-bound spacecraft. The goal of this research is to determine the survival rates of bacterial spores when they are subjected to conditions similar to those the spacecraft would encounter (i.e., temperature, pressure, etc.). B. subtilis var. niger spore coupons were exposed to a range of temperatures from 125 C to 200 C in a vacuum oven (at <1 Torr). After the exposures, the spores were removed by sonication, dilutions were made, and the spores were plated using the pour plate method with tryptic soy agar. After 3 days incubation at 32 C, the number of colony-forming units was counted. Lethality rate constants and D-values were calculated at each temperature. The calculated D-values were: 27 minutes (at 125 C), 13 minutes (at 135 C), and <0.1 minutes (at 150 C). The 125 C and 135 C survivor curves appeared as concavedownward curves. The 150 C survivor curve appeared as a straight-line. Due to the prolonged ramp-up time to the exposure conditions, spore killing during the ramp-up resulted in insufficient data to draw curves for exposures at 160 C, 175 C, and 200 C. Exploratory experiments using novel techniques, with short ramp times, for performing high temperature exposures were also examined. Several of these techniques, such as vacuum furnaces, thermal spore exposure vessels, and laser heating of the coupons, will be discussed.

bacillus subtilis var niger↗

NASA NTRS2000

Mir Environmental Effects Payload and Returned Mir Solar Panel Cleanliness

The MIR Environmental Effects Payload (MEEP) was attached to the Docking Module of the MIR space station for 18 months during calendar years 1996 and 1997 (March 1996, STS 76 to October 1997, STS 86). A solar panel array with more than 10 years space exposure was removed from the MIR core module in November 1997, and returned to Earth in January, 1998, STS 89. MEEP and the returned solar array are part of the International Space Station (ISS) Risk Mitigation Program. This space flight hardware has been inspected and studied by teams of space environmental effects (SEE) investigators for micrometeoroid and space debris effects, space exposure effects on materials, and electrical performance. This paper reports changes in cleanliness of parts of MEEP and the solar array due to the space exposures. Special attention is given to the extensive water soluble residues deposited on some of the flight hardware surfaces. Directionality of deposition and chemistry of these residues are discussed.

Harvey, Gale A.↗

NASA NTRS2007

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↗

NASA NTRSDate not supplied

Nomenclature for the OSIRIS-REx Returned Sample Collection to be Curated at NASA Johnson Space Center

The Origins, Spectral Interpretation, Resource Identification, and Security–Regolith Explorer (OSIRIS-REx) space-craft collected material from the asteroid Bennu on October 20, 2020. The OSIRIS-REx Sample Return Capsule (SRC) is planned to return to Earth on September 24, 2023. The OSIRIS-REx returned sample collection to be curated at NASA Johnson Space Center (JSC) will include both the asteroid material and the flight hardware. We expect most of the asteroid material to be inside the head of the Touch-and-Go Sample Acquisition Mechanism (TAGSAM), and that this material will include a broad range of particles sizes from as large as a few centimeters to less than a micrometer across in their longest dimension. In addition, asteroid material may have been returned along with the flight hardware: intentionally by the contact pads or screens on the witness plates, or serendipitously wedged into or adhering to hardware items. The nomenclature for this new astromaterials collection must accommodate the different types of samples it comprises.

asteroid↗

NASA NTRS2019

Spacecraft Adhesive Residue On-Composite Analysis

Tapes are used on space vehicles for numerous reasons. They are used for taping close ports, labeling, and even temporarily attaching something to the spacecraft. This project stemmed from the need to determine which tapes are most effective for our customer's space vehicle during its ground processing stage. During ground processing, there are multiple stages of building where workers need to use tape to temporarily stabilize or close something for a matter of seconds, days, weeks, or even a few months. After peeling these tapes off the flight hardware, the residue left behind by the tape poses potential risks that can lead to incidents, which may not be easily noticeable to the engineers. It is important to identify these issues since nothing can be done once it is in space. The purpose of this project is to assist in research to create an accessible reference for which tapes are preferred on common flight hardware surfaces. Five different substrates and eight tapes were selected for evaluation. The selected substrates were chosen because they comprise the most surface area on the vehicle. The tapes selected were either heritage or new contenders. The adhesive studies were performed for multiple dwell times to study the tendency of different tapes to leave residue behind on various substrates and quantifying that residue. Many other tests were performed to supplement the main objective of the project. These tests included adhesive solubility, peel adhesion, and SEM analyses.

McFadden, Saleah J.↗

NASA NTRS2014

A Historical Analysis of Crane Mishaps at Kennedy Space Center

Cranes and hoists are widely used in many areas. Crane accidents and handling mishaps are responsible for injuries, costly equipment damage, and program delays. Most crane accidents are caused by preventable factors. Understanding these factors is critical when designing cranes and preparing lift plans. Analysis of previous accidents provides insight into current recommendations for crane safety. Cranes and hoists are used throughout Kennedy Space Center to lift everything from machine components to critical flight hardware. Unless they are trained crane operators, most NASA employees and contractors do not need to undergo specialized crane training and may not understand the safety issues surrounding the use of cranes and hoists. A single accident with a crane or hoist can injure or kill people, cause severe equipment damage, and delay or terminate a program. Handling mishaps can also have a significant impact on the program. Simple mistakes like bouncing or jarring a load, or moving the crane down when it should go up, can damage fragile flight hardware and cause major delays in processing. Hazardous commodities (high pressure gas, hypergolic propellants, and solid rocket motors) can cause life safety concerns for the workers performing the lifting operations. Most crane accidents are preventable with the correct training and understanding of potential hazards. Designing the crane with human factors taken into account can prevent many accidents. Engineers are also responsible for preparing lift plans where understanding the safety issues can prevent or mitigate potential accidents. Cranes are widely used across many areas of KSC. Failure of these cranes often leads to injury, high damage costs, and significant delays in program objectives. Following a basic set of principles and procedures during design, fabrication, testing, regular use, and maintenance can significantly minimize many of these failures. As the accident analysis shows, load drops are often caused or influenced by human factors. Therefore, proper training and understanding of crane safety throughout the workforce is critical. It is important that the engineers designing the cranes, lift planners preparing the lift plans, operators performing the lifts, and training officers conducting the operator training all understand the problems that can happen with cranes and how to ensure the safety of the workforce and equipment being lifted.

Materials Handling↗

NASA NTRS2019

The Effect of Hole Quality on the Bearing Strength of Carbon Fiber Laminates

On programs involving flight hardware for launch vehicles that the author has been involved in over the years, the question always arises as to how to best machine and inspect holes drilled for fasteners. While common sense dictates that ‘well-drilled’ holes are desired over ‘poorly drilled’ holes for bolt bearing applications, the effect of hole quality on the bearing strength of carbon fiber laminates has not been extensively studied in the open literature. If this effect is not quantitatively known, the question of what hole quality needs to be required for the flight hardware cannot be answered. In addition, the function of the part with respect to the holes needs to be taken into account. There is no such thing as a defect-free hole since some chip-out of fibers within the hole will occur regardless of drill bit and backing plate pressure. For most holes machined in a carbon fiber laminate, some extent of delamination and fiber breakout on the entrance and exit of the hole is going to occur. Much time and money can be spent on trying to perfect the drilling technique and subsequent inspection of holes in carbon fiber laminates, including adding extra plies of cloth to the surfaces to help prevent fiber breakout; but is this effort really justified if little-to-no increase in bearing strength is realized by good-quality holes over those of lesser quality?

Nettles, A. T.↗