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NASA NTRS2020

PCB Quality Metrics that Drive Reliability (PD 18)

Risk based technology infusion is a deliberate and systematic process which defines the analysis and communication methodology by which new technology is applied and integrated into existing and new designs, identifies technology development needs based on trends analysis and facilitates the identification of shortfalls against performance objectives. This presentation at IPC Works Asia Aerospace 2019 Events provides the audience a snapshot of quality variations in printed wiring board quality, as assessed, using experiences in processing and risk analysis of PWB structural integrity coupons. The presentation will focus on printed wiring board quality metrics used, the relative type and number of non-conformances observed and trend analysis using statistical methods. Trend analysis shows the top five non-conformances observed across PWB suppliers, the root cause(s) behind these non-conformance and suggestions of mitigation plans. The trends will then be matched with the current state of the PWB supplier base and its challenges and opportunities. The presentation further discusses the risk based SMA approaches and methods being applied at GSFC for evaluating candidate printed wiring board technologies which promote the adoption of higher throughput and faster processing technology for GSFC missions.

Sood, Bhanu↗

NASA NTRS2017

EVA Human Health and Performance Benchmarking Study Overview and Development of a Microgravity Protocol

The primary objective of this study is to develop a protocol to reliably characterize human health and performance metrics for individuals working inside various EVA suits under realistic spaceflight conditions. Expected results and methodologies developed during this study will provide the baseline benchmarking data and protocols with which future EVA suits and suit configurations (e.g., varied pressure, mass, center of gravity [CG]) and different test subject populations (e.g., deconditioned crewmembers) may be reliably assessed and compared. Results may also be used, in conjunction with subsequent testing, to inform fitness-for-duty standards, as well as design requirements and operations concepts for future EVA suits and other exploration systems.

Norcross, Jason↗

NASA NTRS1992

Proof test methodology for composites

The special requirements for proof test of composites are identified based on the underlying failure process of composites. Two proof test methods are developed to eliminate the inevitable weak fiber sites without also causing flaw clustering which weakens the post-proof-test composite. Significant reliability enhancement by these proof test methods has been experimentally demonstrated for composite strength and composite life in tension. This basic proof test methodology is relevant to the certification and acceptance of critical composite structures. It can also be applied to the manufacturing process development to achieve zero-reject for very large composite structures.

Wu, Edward M.↗

NASA NTRS2001

Space Shuttle RTOS Bayesian Network

With shrinking budgets and the requirements to increase reliability and operational life of the existing orbiter fleet, NASA has proposed various upgrades for the Space Shuttle that are consistent with national space policy. The cockpit avionics upgrade (CAU), a high priority item, has been selected as the next major upgrade. The primary functions of cockpit avionics include flight control, guidance and navigation, communication, and orbiter landing support. Secondary functions include the provision of operational services for non-avionics systems such as data handling for the payloads and caution and warning alerts to the crew. Recently, a process to selection the optimal commercial-off-the-shelf (COTS) real-time operating system (RTOS) for the CAU was conducted by United Space Alliance (USA) Corporation, which is a joint venture between Boeing and Lockheed Martin, the prime contractor for space shuttle operations. In order to independently assess the RTOS selection, NASA has used the Bayesian network-based scoring methodology described in this paper. Our two-stage methodology addresses the issue of RTOS acceptability by incorporating functional, performance and non-functional software measures related to reliability, interoperability, certifiability, efficiency, correctness, business, legal, product history, cost and life cycle. The first stage of the methodology involves obtaining scores for the various measures using a Bayesian network. The Bayesian network incorporates the causal relationships between the various and often competing measures of interest while also assisting the inherently complex decision analysis process with its ability to reason under uncertainty. The structure and selection of prior probabilities for the network is extracted from experts in the field of real-time operating systems. Scores for the various measures are computed using Bayesian probability. In the second stage, multi-criteria trade-off analyses are performed between the scores. Using a prioritization of measures from the decision-maker, trade-offs between the scores are used to rank order the available set of RTOS candidates.

Morris, A. Terry↗

NASA NTRS2004

COTS Ceramic Chip Capacitors: An Evaluation of the Parts and Assurance Methodologies

Commercial-Off-The-Shelf (COTS) multilayer ceramic chip capacitors (MLCCs) are continually evolving to reduce physical size and increase volumetric efficiency. Designers of high reliability aerospace and military systems are attracted to these attributes of COTS MLCCs and would like to take advantage of them while maintaining the high standards for long-term reliable operation they are accustomed io when selecting military qualified established reliability (MIL-ER) MLCCs. However, MIL-ER MLCCs are not available in the full range of small chip sizes with high capacitance as found in today's COTS MLCCs. The objectives for this evaluation were to assess the long-term performance of small case size COTS MLCCs and to identify effective, lower-cost product assurance methodologies. Fifteen (15) lots of COTS X7R dielectric MLCCs from four (4) different manufacturers and two (2) MIL-ER BX dielectric MLCCs from two (2) of the same manufacturers were evaluated. Both 0805 and 0402 chip sizes were included. Several voltage ratings were tested ranging from a high of 50 volts to a low of 6.3 volts. The evaluation consisted of a comprehensive screening and qualification test program based upon MIL-PRF-55681 (i.e., voltage conditioning, thermal shock, moisture resistance, 2000-hour life test, etc.). In addition, several lot characterization tests were performed including Destructive Physical Analysis (DPA), Highly Accelerated Life Test (HALT) and Dielectric Voltage Breakdown Strength. The data analysis included a comparison of the 2000-hour life test results (used as a metric for long-term performance) relative to the screening and characterization test results. Results of this analysis indicate that the long-term life performance of COTS MLCCs is variable -- some lots perform well, some lots perform poorly. DPA and HALT were found to be promising lot characterization tests to identify substandard COTS MLCC lots prior to conducting more expensive screening and qualification tests. The results indicate that lot- specific screening and qualification are still recommended for high reliability applications. One significant and concerning observation is that MIL- type voltage conditioning (100 hours at twice rated voltage, 125 C) was not an effective screen in removing infant mortality parts for the particular lots of COTS MLCCs evaluated.

Brusse, Jay A.↗

NASA NTRS1975

Systems cost performance analysis (study 2.3). Volume 1: Executive summary

A methodology for developing balanced designs of spacecraft subsystems which interrelates cost, performance, safety, and schedule considerations was developed. The methodology consists of a two-step process: selection of all hardware designs which satisfy the given performance and safety requirements; and estimating the cost and schedule required to design, build, and operate each spacecraft design. Aggregate equations were written to describe the performance, safety (reliability), cost, and schedule required for one type of stabilization and control subsystem in terms of the equipment used. The methodology was applied to unmanned, automated spacecraft subsystems, and the resulting model was implemented as a digital computer program.

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NASA NTRS1991

Software life cycle methodologies and environments

Products of this project will significantly improve the quality and productivity of Space Station Freedom Program software processes by: improving software reliability and safety; and broadening the range of problems that can be solved with computational solutions. Projects brings in Computer Aided Software Engineering (CASE) technology for: Environments such as Engineering Script Language/Parts Composition System (ESL/PCS) application generator, Intelligent User Interface for cost avoidance in setting up operational computer runs, Framework programmable platform for defining process and software development work flow control, Process for bringing CASE technology into an organization's culture, and CLIPS/CLIPS Ada language for developing expert systems; and methodologies such as Method for developing fault tolerant, distributed systems and a method for developing systems for common sense reasoning and for solving expert systems problems when only approximate truths are known.

Fridge, Ernest↗

NASA NTRS1992

Probabilistic design of advanced composite structure

Advanced composite technology offers potentials for sizable improvements in many areas: weight savings, maintainability, durability, and reliability. However, there are a number of inhibitors to these improvements. One of the biggest inhibitors is the imposition of traditional metallic approaches to design of composite structure. This is especially detrimental in composites because new materials technology demands new design approaches. Of particular importance are the decisions made regarding structural criteria. Significant changes cannot be implemented without careful consideration and exploration. This new approach is to implement changes on a controlled, verifiable basis. Probabilistic design is the methodology and the process to accomplish this. Its foundation is to base design criteria and objectives on reliability targets instead of arbitrary factors carried over from metallic structural history. The background is discussed of probabilistic design and the results are presented of a side-by-side comparison to generic aircraft structure designed the 'old' way and the 'new'. Activities are also defined that need to be undertaken to evolve available approaches to probabilistic design followed by summary and recommendations.

Gray, P. M.↗

NASA NTRS1974

Space shuttle program: Shuttle Avionics Integration Laboratory. Volume 7: Logistics management plan

The logistics management plan for the shuttle avionics integration laboratory defines the organization, disciplines, and methodology for managing and controlling logistics support. Those elements requiring management include maintainability and reliability, maintenance planning, support and test equipment, supply support, transportation and handling, technical data, facilities, personnel and training, funding, and management data.

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NASA NTRS1976

Standardized development of computer software. Part 1: Methods

This work is a two-volume set on standards for modern software engineering methodology. This volume presents a tutorial and practical guide to the efficient development of reliable computer software, a unified and coordinated discipline for design, coding, testing, documentation, and project organization and management. The aim of the monograph is to provide formal disciplines for increasing the probability of securing software that is characterized by high degrees of initial correctness, readability, and maintainability, and to promote practices which aid in the consistent and orderly development of a total software system within schedule and budgetary constraints. These disciplines are set forth as a set of rules to be applied during software development to drastically reduce the time traditionally spent in debugging, to increase documentation quality, to foster understandability among those who must come in contact with it, and to facilitate operations and alterations of the program as requirements on the program environment change.

Tausworthe, R. C.↗

NASA NTRS1984

Evaluation methodologies for an advanced information processing system

The system concept and requirements for an Advanced Information Processing System (AIPS) are briefly described, but the emphasis of this paper is on the evaluation methodologies being developed and utilized in the AIPS program. The evaluation tasks include hardware reliability, maintainability and availability, software reliability, performance, and performability. Hardware RMA and software reliability are addressed with Markov modeling techniques. The performance analysis for AIPS is based on queueing theory. Performability is a measure of merit which combines system reliability and performance measures. The probability laws of the performance measures are obtained from the Markov reliability models. Scalar functions of this law such as the mean and variance provide measures of merit in the AIPS performability evaluations.

Schabowsky, R. S., Jr.↗

NASA NTRS1988

Preliminary analysis of an integrated logistics system for OSSA payloads. Volume 4: Supportability analysis of the 1.8m centrifuge

Supportability issues for the 1.8 meter centrifuge in the Life Science Research Facility are addressed. The analysis focuses on reliability and maintainability and the potential impact on supportability and affordability. Standard logistics engineering methodologies that will be applied to all Office of Space Science and Applications' (OSSA) payload programs are outlined. These methodologies are applied to the 1.8 meter centrifuge.

Palguta, T.↗

NASA NTRS1991

Probabilistic load simulation: Code development status

The objective of the Composite Load Spectra (CLS) project is to develop generic load models to simulate the composite load spectra that are included in space propulsion system components. The probabilistic loads thus generated are part of the probabilistic design analysis (PDA) of a space propulsion system that also includes probabilistic structural analyses, reliability, and risk evaluations. Probabilistic load simulation for space propulsion systems demands sophisticated probabilistic methodology and requires large amounts of load information and engineering data. The CLS approach is to implement a knowledge based system coupled with a probabilistic load simulation module. The knowledge base manages and furnishes load information and expertise and sets up the simulation runs. The load simulation module performs the numerical computation to generate the probabilistic loads with load information supplied from the CLS knowledge base.

Newell, J. F.↗

NASA NTRS2011

Spacecraft Conceptual Design Compared to the Apollo Lunar Lander

Future human exploration of the Moon will require an optimized spacecraft design with each sub-system achieving the required minimum capability and maintaining high reliability. The objective of this study was to trade capability with reliability and minimize mass for the lunar lander spacecraft. The NASA parametric concept for a 3-person vehicle to the lunar surface with a 30% mass margin totaled was considerably heavier than the Apollo 15 Lunar Module "as flown" mass of 16.4 metric tons. The additional mass was attributed to mission requirements and system design choices that were made to meet the realities of modern spaceflight. The parametric tool used to size the current concept, Envision, accounts for primary and secondary mass requirements. For example, adding an astronaut increases the mass requirements for suits, water, food, oxygen, as well as, the increase in volume. The environmental control sub-systems becomes heavier with the increased requirements and more structure was needed to support the additional mass. There was also an increase in propellant usage. For comparison, an "Apollo-like" vehicle was created by removing these additional requirements. Utilizing the Envision parametric mass calculation tool and a quantitative reliability estimation tool designed by Valador Inc., it was determined that with today?s current technology a Lunar Module (LM) with Apollo capability could be built with less mass and similar reliability. The reliability of this new lander was compared to Apollo Lunar Module utilizing the same methodology, adjusting for mission timeline changes as well as component differences. Interestingly, the parametric concept's overall estimated risk for loss of mission (LOM) and loss of crew (LOC) did not significantly improve when compared to Apollo.

Young, C.↗

NASA NTRS1994

System engineering toolbox for design-oriented engineers

This system engineering toolbox is designed to provide tools and methodologies to the design-oriented systems engineer. A tool is defined as a set of procedures to accomplish a specific function. A methodology is defined as a collection of tools, rules, and postulates to accomplish a purpose. For each concept addressed in the toolbox, the following information is provided: (1) description, (2) application, (3) procedures, (4) examples, if practical, (5) advantages, (6) limitations, and (7) bibliography and/or references. The scope of the document includes concept development tools, system safety and reliability tools, design-related analytical tools, graphical data interpretation tools, a brief description of common statistical tools and methodologies, so-called total quality management tools, and trend analysis tools. Both relationship to project phase and primary functional usage of the tools are also delineated. The toolbox also includes a case study for illustrative purposes. Fifty-five tools are delineated in the text.

Goldberg, B. E.↗

NASA NTRS2021

Model-Based SMA Initiative Phase 1 Report: Reliability Tips Excerpt

The emergence of model-based engineering, with Model- Based Systems Engineering (MBSE) leading the way, is transforming design and analysis methodologies. [7] The recognized benefits to systems development include moving from document-centric information systems and document-centric project communication to a model-centric environment in which control of design changes in the life cycles is facilitated. In addition, a “single source of truth” about the system, that is up-to-date in all respects of the design, becomes the authoritative source of data and information about the system. This promotes consistency and efficiency in regard to integration of the system elements as the design emerges and thereby may further optimize the designs. Therefore Reliability Engineers (REs) supporting NASA missions must be integrated into model-based engineering, using these recommended modeling techniques, to ensure the outputs of their analyses are relevant and value-needed to the design, development, and operational processes for failure risk assessment and communication.

Nancy J. Lindsey↗

NASA NTRS1983

Computational aerodynamic design methodology

The transonic wing design process has been vastly improved at Lockheed-Georgia. The revised design procedure enhances useability and reliability by combining numerical optimization and inverse design into a single wing design code with transonic analysis provided by a modified version of FLO22. A more versatile set of geometric decision variables has been integrated into the optimization portion for geometry perturbations. An automatic restart feature permits the interchangeability of solutions between optimization and inverse design as the design progresses. In combination, these improvements enable practical utilization of a VAX 11/780 computer and significantly reduce the elapsed time required to complete a transonic wing design.

Burris, C. B.↗

NASA NTRS1991

Materials and light thermal structures research for advanced space exploration

The Light Thermal Structures Center at the University of Virginia sponsors educational and research programs focused on the development of reliable, lightweight structures to function in hostile thermal environments. Technology advances in materials and design methodology for light thermal structures will contribute to improved space vehicle design concepts with attendant weight savings. This paper highlights current research activities in three areas relevant to space exploration: low density, high temperature aluminum alloys, composite materials, and structures with thermal gradients. Advances in the development of new aluminum-lithium alloys and mechanically alloyed aluminum alloys are described. Material properties and design features of advanced composites are highlighted. Research studies in thermal structures with temperature gradients include inelastic panel buckling and thermally induced unstable oscillations. Current and future research is focused on the integration of new materials with applications to structural components with thermal gradients.

Thornton, Earl A.↗