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At least 235 records · Page 13

NASA Physics of Failure (PoF) for Reliability

An item’s reliability or longevity is dependent not only on its design but also on how it is used, manufactured, tested, and the stresses it has or will experience. Stresses include operational and environmental exposures to thermal, voltage, current, age/exposure, mechanical, and radiation mechanisms. Therefore, in reliability analysis, it is important to consider the contributions of all these factors when predicting the failure rates of components. Historically, there has been a reliance on handbook data (e.g., MIL-HDBK-217), but experience has shown that these values and distributions are not representative of actual performance. Therefore, to make more credible reliability and risk assessments for its missions, NASA must transition to estimating likelihoods of failure based on an item’s reliability or longevity factors (or the physical susceptibilities and strengths impacting the design’s performance) has or will experience, whenever possible. To facilitate this transition, a Handbook on Methodology for Physics of Failure Based Reliability Assessments has been developed by NASA to assist in applying physics experiences or experimental physics for empirical analysis and conceptualized physics exposures or theoretical physics for deterministic analysis, to develop and aggregate realistic likelihoods of failure leading to more credible forecasts of item performance and longevity. In addition, since it is NASA’s intention that this document continues to evolve based on community lessons learned and the introduction of new assessment methodologies, NASA is encouraging and appreciates the contributions of current and future authors to maintain and enhance this handbook and its supporting case studies.

PoF↗

In-situ Testing to Acquire HR-EBSD and DIC Strain Data Within a Coincident Domain

For this project, an inked rubber stamp was applied to a small Inconel 625 specimen. The stamp transferred a thin pattern with microscale features for digital image correlation (DIC). The pattern is easily visible at lower voltages and thin enough to not obstruct backscattered electrons. The unique characteristics of the pattern enabled the concurrent acquisition of DIC and high-resolution electron backscatter diffraction (HR-EBSD) data while the specimen was loaded in-situ. The challenges of in-situ testing and combining EBSD with DIC measurements are discussed. By combining the elastic strains (from HR-EBSD) and total strains (from DIC) the result of this approach is an estimate of stress- strain behavior at points across the specimen surface. This combined dataset can then be used as higher-fidelity data in the calibration of crystal plasticity models.

Will Gilliland↗

NASA Physics of Failure (PoF) for Reliability

An item’s reliability or longevity is dependent not only on its design but also on how it is used, manufactured, tested, and the stresses it has or will experience. Stresses include operational and environmental exposures to thermal, voltage, current, age/exposure, mechanical, and radiation mechanisms. Therefore, in reliability analysis, it is important to consider the contributions of all of these factors when predicting the failure rates of components. Historically, there has been a reliance on handbook data (e.g., MIL-HDBK-217), but experience has shown that these values and distributions are not representative of actual performance (1,2). Therefore, to make more credible reliability and risk assessments for its missions, NASA must transition to estimating likelihoods of failure based on an item’s reliability/longevity factors (or the physical susceptibilities and strengths impacting the design’s performance) has or will experience, whenever possible. To facilitate this transition a “Handbook on Methodology for Physics of Failure Based Reliability Assessments” has been developed by NASA to assist in applying physics experiences or experiment physics for empirical analysis and conceptualized physics exposures or theoretical physics for deterministic analysis, to develop and aggregate realistic likelihoods of failure leading to more credible forecasts of item performance and longevity. In addition, since it is NASA’s intention that this document continues to evolve based on community lessons learned and the introduction of new assessment methodologies, NASA is encouraging and appreciates the contributions of current and future authors to maintain and enhance this handbook and its supporting case studies.

Physics of Failure↗

Mercury ion thruster research, 1977

The measured ion beam divergence characteristics of two and three-grid, multiaperture accelerator systems are presented. The effects of perveance, geometry, net-to-total accelerating voltage, discharge voltage and propellant are examined. The applicability of a model describing doubly-charged ion densities in mercury thrusters is demonstrated for an 8-cm diameter thruster. The results of detailed Langmuir probing of the interior of an operating cathode are given and used to determine the ionization fraction as a function of position upstream of the cathode orifice. A mathematical model of discharge chamber electron diffusion and collection processes is presented along with scaling laws useful in estimating performance of large diameter and/or high specific impluse thrusters. A model describing the production of ionized molecular nitrogen in ion thrusters is included.

Wilbur, P. J.↗

Planar doped barrier subharmonic mixers

The Planar Doped Barrier (PDB) diode is a device consisting of a p(+) doping spike between two intrinsic layers and n(+) ohmic contacts. This device has the advantages of controllable barrier height, diode capacitance and forward to reverse current ratio. A symmetrically designed PDB has an anti-symmetric current vs. voltage characteristic and is ideal for use as millimeter wave subharmonic mixers. We have fabricated such devices with barrier heights of 0.3, 0.5 and 0.7 volts from GaAs and InGaAs using a multijunction honeycomb structure with junction diameters between one and ten microns. Initial RF measurements are encouraging. The 0.7 volt barrier height 4 micron GaAs devices were tested as subharmonic mixers at 202 GHz with an IF frequency of 1 GHz and had 18 dB of conversion loss. The estimated mismatch loss was 7 dB and was due to higher diode capacitance. The LO frequency was 100.5 GHz and the pump power was 8 mW.

Lee, T. H.↗

Four quadrant control of induction motors

Induction motors are the nation's workhorse, being the motor of choice in most applications due to their simple rugged construction. It has been estimated that 14 to 27 percent of the country's total electricity use could be saved with adjustable speed drives. Until now, induction motors have not been suited well for variable speed or servo-drives, due to the inherent complexity, size, and inefficiency of their variable speed controls. Work at NASA Lewis Research Center on field oriented control of induction motors using pulse population modulation method holds the promise for the desired drive electronics. The system allows for a variable voltage to frequency ratio which enables the user to operate the motor at maximum efficiency, while having independent control of both the speed and torque of an induction motor in all four quadrants of the speed torque map. Multiple horsepower machine drives were demonstrated, and work is on-going to develop a 20 hp average, 40 hp peak class of machine. The pulse population technique, results to date, and projections for implementation of this existing new motor control technology are discussed.

Hansen, Irving G.↗

Test results of modified electrical charged particle generator for application to fog dispersal

Modifications to a charged particle generator for use in fog dispersal applications were made and additional testing carried out. The modified nozzle, however, did not work as planned, and reported results are the unmodified nozzle. The addition of a positive displacement pump to supply the liquid water was highly successful. Measurements of the generator output current were made with a cylindrical collector system as well as with the needle probe used in previous studies. Measurements with the cylindrical collector and the needle probe showed identical agreement within the variability of the experiment. A high-voltage prove was purchased, and measurements of the corona voltage as well as the voltage variation in the charged particle jet were made. Electric fields in the vertical direction on the order of 1,000,000 v/m were measured. The voltage distribution along the centerline of the jet was compared with the numerical solutions of the Poisson equation and showed very good agreement. Velocity measurements using a pitot tube were made. The resulting measurements were compared with theoretical and other reported experimental results. The measured data showed the appropriate trends and agreed well with reported results. Based on the measured current-to-mass ratio from the charged particle generator, a calculation of the average droplet size was made. Droplet sizes were estimated to range between 0.8 and 0.4 microns. Using measured data, an analysis of the height to which the droplet can be dispersed by the charged particle generator was made. Although the mathematical model is highly simplified, the results indicated that particles would achieve heights on the order of 80 m.

Frost, W.↗

Electrical Characteristics of the Mars Electrostatic Precipitator

NASA's next generation Mars missions will include chemical processing plants to convert the Martian atmosphere into consumable products needed to support astronaut activities. The thin, mostly carbon dioxide atmosphere of Mars is estimated to have 5-10 particles/cu. cm which have a radius of 1.6-2.27 microns on average. These dust particles could potentially foul the chemical process or reduce the purity of the products. Electrostatic precipitation is one possible solution to remove dust particles from the ingested Mars atmosphere. The Electrostatics and Surface Physics Laboratory at NASA's Kennedy Space Center has developed an electrostatic precipitator testbed to understand the intricacies of corona discharges in dusty flows simulating Mars atmospheric conditions. Current-voltage trends have been established for a number of precipitator flow conditions. Corona onset voltage and streamer onset voltage trends versus pressure are also established.

Johansen, Michael R.↗

Effect of Preconditioning on Post-Soldering Failures in Tantalum Capacitors

Soldering have a strong effect on performance and reliability of most surface mount technology components, including tantalum capacitors. High quality tantalum capacitors are likely the only type of components where soldering simulation is the first step during screening. Nevertheless, post-soldering failures of tantalum capacitors do happen and require additional analysis. Popcorning is a well-known effect in plastic encapsulated microcircuits (PEM) and it occurs also in chip tantalum capacitors. The sensitivity of parts to the presence of moisture during soldering is characterized by the moisture sensitivity level (MSL); however, contrary to PEMs, there is no standard procedure for establishing MSL for tantalum capacitors, and standard J-STD-020 is applicable partially only. In this work, the effect of absorbed moisture on soldering related degradation and failures in tantalum capacitors have been studied using 22 types of polymer and 11 types of MnO2 cathodes tantalum capacitors including single and multianode parts. The amount of moisture released during soldering has been estimated by measurements of mass and capacitance variations. Results show that moisture uptake in similar parts is approximately two times greater in polymer than in MnO2 capacitors. Cracking of the case and degradation of parameters can occur in both types of parts, but MnO2 capacitors are much more susceptible to catastrophic short circuit failures and their ignition is possible during the first power-on cycle. This type of failure in MnO2 capacitors is lot-related, can occur even at derated voltages and relatively low levels of moisture sorption corresponding to room conditions. Baking before soldering is an effective measure to prevent failures even in lots susceptible to popcorning damage. Recommendations for testing to establish MSL and for baking to reduce the probability of failures are suggested.

tantalum polymer capacitors↗

Real time charge efficiency monitoring for nickel electrodes in NICD and NIH2 cells

The charge efficiency of nickel-cadmium and nickel-hydrogen battery cells is critical in spacecraft applications for determining the amount of time required for a battery to reach a full state of charge. As the nickel-cadmium or nickel-hydrogen batteries approach about 90 percent state of charge, the charge efficiency begins to drop towards zero, making estimation of the total amount of stored charge uncertain. Charge efficiency estimates are typically based on prior history of available capacity following standardized conditions for charge and discharge. These methods work well as long as performance does not change significantly. A relatively simple method for determining charge efficiencies during real time operation for these battery cells would be a tremendous advantage. Such a method was explored and appears to be quite well suited for application to nickel-cadmium and nickel-hydrogen battery cells. The charge efficiency is monitored in real time, using only voltage measurements as inputs. With further evaluation such a method may provide a means to better manage charge control of batteries, particularly in systems where a high degree of autonomy or system intelligence is required.

Zimmerman, A. H.↗

Flexible Electrostatic Technologies for Capture and Handling, Phase 1

Fundamental to many of NASA's in-space transportation missions is the capture and handling of various objects and vehicles in various orbits for servicing, debris disposal, sample retrieval, and assembly without the benefit of sufficient grapple fixtures and docking ports. To perform similar material handling tasks on Earth, pincher grippers, suction grippers, or magnetic chucks are used, but are unable to reliably grip aluminum and composite spacecraft, insulation, radiators, solar arrays, or extra-terrestrial objects in the vacuum of outer space without dedicated handles in the right places. The electronic Flexible Electrostatic Technologies for space Capture and Handling (FETCH) will enable reliable and compliant gripping (soft dock) of practically any object in various orbits or surfaces without dedicated mechanical features, very low impact capture, and built-in proximity sensing without any conventional actuators. Originally developed to handle semiconductor and glass wafers during vacuum chamber processing without contamination, the normal rigid wafer handling chucks are replaced with thin metal foil segments laminated in flexible insulation driven by commercial off-the-shelf solid state, high-voltage power supplies. Preliminary testing in NASA Marshall Space Flight Center's (MSFC's) Flat Floor Robotics Lab demonstrated compliant alignment and gripping with a full-sized, 150-lb microsat mockup and translation before a clean release with a flip of a switch. The flexible electrostatic gripper pads can be adapted to various space applications with different sizes, shapes, and foil electrode layouts even with openings through the gripper pads for addition of guidance sensors or injection of permanent adhesives. With gripping forces estimated between 0.5 and 2.5 lb/in2 or 70-300 lb/ft2 of surface contact, the FETCH can turn on and off rapidly and repeatedly to enable sample handling, soft docking, in-space assembly, precision relocation, and surface translation for accurate anchoring.

Bryan, Thomas↗

Electrical Characteristics of the Mars Electrostatic Precipitator

NASA's next generation Mars missions will include chemical processing plants to convert the Martian atmosphere into consumable products needed to support astronaut activities. The thin, mostly carbon dioxide atmosphere of Mars is estimated to have 5-10 particles/cu. cm which have a radius of 1.6-2.27 microns on average. These dust particles could potentially foul the chemical process or reduce the purity of the products. Electrostatic precipitation is one possible solution to remove dust particles from the ingested Mars atmosphere. The Electro-statics and Surface Physics Laboratory at NASA's Kennedy Space Center has developed an electrostatic precipitator testbed to understand the intricacies of corona discharges in dusty flows simulating Mars atmospheric conditions. Current-voltage trends have been estab-lished for a number of precipitator flow conditions. Corona onset voltage and streamer onset voltage trends versus pressure are also established.

Johansen, Michael R.↗

Effect of anode ring arrangement on the spectroscopic characteristics of the NASA Lewis Bumpy Torus plasma

The modified Penning discharge in the NASA Lewis Bumpy Torus is normally produced by an anode ring at high voltage in each of the 12 magnetic mirror midplanes. For this investigation, the plasma was run with 12, 6, 3, and 1 anode rings. When 3 anode rings were used, the spectroscopically determined relative electron density and mean ion residence time increased by factors of 10 and 5, respectively, in one mode of operation. The discharge is observed to uniformly fill all bumps around the torus regardless of the anode arrangement and number. A plasma density on axis of 100 billion per cu cm is estimated for the 3-anode case in one mode of operation based on an observed discharge current to ion loss rate correlation and a measured mean ion residence time of .5 msec.

Richardson, R. W.↗

Effect of anode ring arrangement on the spectroscopic characteristics of the NASA Lewis bumpy torus plasma

The modified Penning discharge in the NASA Lewis Bumpy Torus is normally produced by an anode ring at high voltage in each of the 12 magnetic mirror midplanes. For this investigation, the plasma was run with 12, 6, 3, and 1 anode rings. When 3 anode rings were used, the spectroscopically determined relative electron density and mean ion residence time increase by factors of 10 and 5, respectively, in one mode of operation. The discharge is observed to uniformly fill all bumps around the torus regardless of the anode arrangement and number. A plasma density on axis of 10 to the 11th power cm/3 is estimated for the 3 anode case in one mode of operation based on an observed discharge current to ion loss rate correlation and a measured mean ion residence time of .5 msec.

Richardson, R. W.↗

Estimation of minority carrier diffusion lengths in InP/GaAs solar cells

Minority carrier diffusion length is one of the most important parameters affecting the solar cell performance. An attempt is made to estimate the minority carrier diffusion lengths is the emitter and base of InP/GaAs heteroepitaxial solar cells. The PC-1D computer model was used to simulate the experimental cell results measured at NASA Lewis under AMO (air mass zero) spectrum at 25 C. A 16 nm hole diffusion length in the emitter and a 0.42 micron electron diffusion length in the base gave very good agreement with the I-V curve. The effect of varying minority carrier diffusion lengths on cell short current, open circuit voltage, and efficiency was studied. It is also observed that the front surface recombination velocity has very little influence on the cell performance. The poor output of heteroepitaxial cells is caused primarily by the large number of dislocations generated at the interfaces that propagate through the bulk indium phosphide layers. Cell efficiency as a function of dislocation density was calculated and the effect of improved emitter bulk properties on cell efficiency is presented. It is found that cells with over 16 percent efficiencies should be possible, provided the dislocation density is below 10(exp 6)/sq cm.

Jain, R. K.↗

Interfacial Structure and Capacitance of Li-doped Ionic Liquid Electrolytes from Molecular Simulations

Ionic liquids have been proposed as candidate electrolytes for high-energy density, rechargeable batteries, supercapacitors, and hybrid energy storage devices. Though Li-salt is often present in these systems, its influence on interfacial properties is largely uncharacterized. We, thereby, present an extensive computational analysis, supported by experimental comparisons, of the properties of a representative set of these electrolytesat an ideal carbon interface as a function of Li-salt doping and voltage. We have performed polarizable molecular (MD) dynamics simulations, using the APPLEP force field, to evaluate electric double layer (EDL) capacitance and distribution of Li+ in the EDL. Differential capacitance exhibits the characteristic camel profile and is insensitive to Li-doping. Li+ localizes in the second molecular layer of the EDL, which is a result of confinement from free energy barriers associated with ion layering. Joint MDelectronic structure computations show the electrochemical window of the electrolytes to be a weak function of Li-doping. Estimates of supercapacitor specific energy are made using the computed window and capacitance. The magnitude and trends in specific energy are in good agreement with experiment.

batteries↗

Electro-Thermal Simulation Studies of SiC Junction Diodes Containing Screw Dislocations Under High Reverse-Bias Operation

The objective of this work was to conduct a modeling study of SiC P-N junction diodes operating under high reverse biased conditions. Analytical models and numerical simulation capabilities were to be developed for self-consistent electro-thermal analysis of the diode current-voltage (I-V) characteristics. Data from GRC indicate that screw dislocations are unavoidable in large area SiC devices, and lead to changes in the SiC diode electrical response characteristics under high field conditions. For example, device instability and failures linked to internal current filamentation have been observed. The physical origin of these processes is not well understood, and quantitative projections of the electrical behavior under high field and temperature conditions are lacking. Thermal calculations for SiC devices have not been reported in the literature either. So estimates or projections of peak device temperatures and power limitations do not exist. This numerical study and simulation analysis was aimed at resolving some of the above issues. The following tasks were successfully accomplished: (1) Development of physically based models using one- and two-dimensional drift-diffusion theory for the transport behavior and I-V characteristics; (2) One- and two-dimensional heat flow to account for internal device heating. This led to calculations of the internal temperature profiles, which in turn, were used to update the electrical transport parameters for a self-consistent analysis. The temperature profiles and the peak values were thus obtainable for a given device operating condition; (3) Inclusion of traps assumed to model the presence of internal screw dislocations running along the longitudinal direction; (4) Predictions of the operating characteristics with and without heating as a function of applied bias with and without traps. Both one and two-dimensional cases were implemented; (5) Assessment of device stability based on the operating characteristics. The presence of internal non-uniformities, particularly filamentary structures, was probed and demonstrated; (6) Cause and physical origins of filamentary behavior and unstable I-V characteristics were made transparent; (7) It was demonstrated that diodes containing defects would be more prone to thermal breakdown associated with the temperature dependent decrease in the thermal conductivity; and (8) Finally, negative differential resistance (S-shaped NDR) which can potential lead to device instability and filamentary behavior was shown to occur for diodes containing a line of defects such as could be associated with a screw dislocation line.

Joshi, R. P.↗

Data and results of a laboratory investigation of microprocessor upset caused by simulated lightning-induced analog transients

Advanced composite aircraft designs include fault-tolerant computer-based digital control systems with thigh reliability requirements for adverse as well as optimum operating environments. Since aircraft penetrate intense electromagnetic fields during thunderstorms, onboard computer systems maya be subjected to field-induced transient voltages and currents resulting in functional error modes which are collectively referred to as digital system upset. A methodology was developed for assessing the upset susceptibility of a computer system onboard an aircraft flying through a lightning environment. Upset error modes in a general-purpose microprocessor were studied via tests which involved the random input of analog transients which model lightning-induced signals onto interface lines of an 8080-based microcomputer from which upset error data were recorded. The application of Markov modeling to upset susceptibility estimation is discussed and a stochastic model development.

Belcastro, C. M.↗