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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 37 records · Page 2
All sourcesNASA NTRSDOE OSTI
NASA NTRS2012

3D X-ray CT for BGA/CGA Workmanship Defect Detection

Commercial-off-the-shelf (COTS) advanced microelectronic technologies in high-reliability versions are now being considered for use in a number of National Aeronautics and Space Administration (NASA) electronic systems. One of the key drawbacks of advanced electronic packages with hidden solder joint interconnections, such as the column grid array (CGA), is that inspection can be challenging—whether visually or using X-rays. In general, inspection for solder joint integrity is poor, except for identifying shorts. The new, advanced X-ray systems, especially the 3D computer tomography version, may be able to provide the three-dimensional features that are extremely difficult to resolve under the 2D systems.This report presents both 2D and 3D X-ray images along with their representative optical photomicrographs for a number of advanced electronics package assemblies including 3D stack and CGA assemblies before and after thermal cycling.

Ghaffarian, Reza↗
NASA NTRS2008

Failure Analysis Study and Long-Term Reliability of Optical Assemblies with End-Face Damage

In June 2005, the NESC received a multi-faceted request to determine the long term reliability of fiber optic termini on the ISS that exhibited flaws not manufactured to best workmanship practices. There was a lack of data related to fiber optic workmanship as it affects the long term reliability of optical fiber assemblies in a harsh environment. A fiber optic defect analysis was requested which would find and/or create various types of chips, spalls, scratches, etc., that were identified by the ISS personnel. Once the defects and causes were identified the next step would be to perform long term reliability testing of similar assemblies with similar defects. The goal of the defect analysis would be for the defects to be observed and documented for deterioration of fiber optic performance. Though this report mostly discusses what has been determined as evidence of poor manufacturing processes, it also concludes the majority of the damage could have been avoided with a rigorous process in place.

Kichak, Robert A.↗
NASA NTRS2011

Advanced Stirling Convertor (ASC-E2) Performance Testing at NASA Glenn Research Center

The National Aeronautics and Space Administration (NASA) Glenn Research Center (GRC) has been supporting development of the Advanced Stirling Radioisotope Generator (ASRG) since 2006. A key element of the ASRG Project is providing life, reliability, and performance testing of the Advanced Stirling Convertor (ASC). For this purpose, four pairs of ASCs capable of operating to 850 C and designated with the model number ASC-E2, were delivered by Sunpower of Athens, OH, to GRC in 2010. The ASC-E2s underwent a series of tests that included workmanship vibration testing, performance mapping, and extended operation. Workmanship vibration testing was performed following fabrication of each convertor to verify proper hardware build. Performance mapping consisted of operating each convertor at various conditions representing the range expected during a mission. Included were conditions representing beginning-of-mission (BOM), end-of-mission (EOM), and fueling. This same series of tests was performed by Sunpower prior to ASC-E2 delivery. The data generated during the GRC test were compared to performance before delivery. Extended operation consisted of a 500-hour period of operation with conditions maintained at the BOM point. This was performed to demonstrate steady convertor performance following performance mapping. Following this initial 500-hour period, the ASC-E2s will continue extended operation, controller development and special durability testing, during which the goal is to accumulate tens of thousands of hours of operation. Data collected during extended operation will support reliability analysis. Performance data from these tests is summarized in this paper.

Oriti, Salvatore↗
NASA NTRS2011

Advanced Stirling Convertor (ASC-E2) Performance Testing at NASA Glenn Research Center

The National Aeronautics and Space Administration (NASA) Glenn Research Center (GRC) has been supporting development of the Advanced Stirling Radioisotope Generator (ASRG) since 2006. A key element of the ASRG Project is providing life, reliability, and performance testing of the Advanced Stirling Convertor (ASC). For this purpose, four pairs of ASCs capable of operating to 850 C and designated with the model number ASC-E2, were delivered by Sunpower of Athens, Ohio, to GRC in 2010. The ASC-E2s underwent a series of tests that included workmanship vibration testing, performance mapping, and extended operation. Workmanship vibration testing was performed following fabrication of each convertor to verify proper hardware build. Performance mapping consisted of operating each convertor at various conditions representing the range expected during a mission. Included were conditions representing beginning-of-mission (BOM), end-of-mission (EOM), and fueling. This same series of tests was performed by Sunpower prior to ASC-E2 delivery. The data generated during the GRC test were compared to performance before delivery. Extended operation consisted of a 500-hr period of operation with conditions maintained at the BOM point. This was performed to demonstrate steady convertor performance following performance mapping. Following this initial 500-hr period, the ASC-E2s will continue extended operation, controller development and special durability testing, during which the goal is to accumulate tens of thousands of hours of operation. Data collected during extended operation will support reliability analysis. Performance data from these tests is summarized in this paper.

Oriti, Salvatore↗
NASA NTRS2016

Spacecraft Vibration Testing: Benefits and Potential Issues

JPL has traditionally performed system level vibration testing of flight spacecraft. The benefits and potential issues of fully assembled flight spacecraft vibration testing are discussed herein. The following specific topics, which may be complementary to the special session on “Virtual Vibration Testing,” are discussed: spacecraft workmanship, functional and structural integrity testing to uncover workmanship problems, force- and moment-limited vibration testing, potential issues with structural frequency identification using base shake test data, and several failures related to vibration shaker testing. The information provided in this paper is complementary to the special session on “Virtual Shaker Testing,’ and attention is given to issues that virtual shaker testing may face.

Kolaini, Ali R.↗
NASA NTRS2017

InSight System Acoustic Requirement Evolution

The InSight Mars lander is to be launched to Mars in 2018 on a rocket, contained within an aeroshell designed for Mars entry. The primary mission objective is to deliever an ultra-sensitive seismometer to the Martian surface for scientific investigations. The preliminary InSight PF acoustic requirement (the heritage Phoenix environment, 139.8 dB overall SPL maximum expected environment) was reduced significantly when the Launch vehicle was selected as the InSight launch vehicle (134.5 dB overall SPL maximum expected environment). This reduction would have resulted in a very low Lander Deck random vibration at SEIS, and other instruments inside the aeroshell, during the system Protoflight (PF) acoustic test with questionable workmanship value. To mitigate this concern JPL and Launch vehicle contractor agreed to increase the InSight PF acoustic test requirement to enhance workmanship testing for science instruments and assemblies inside the aeroshell. The actual InSight system acoustic test vibration responses at the SEIS instrument are compared to the predicted responses.

O'Connell, Michael↗
NASA NTRS1965

Systems integration

Qualifications testing of basic design and acceptance testing of workmanship for Relay I satellite - systems integration

RELAY I SATELLITE↗
NASA NTRS1973

Report to the administrator by the NASA Aerospace Safety Advisory Panel on the Skylab program. Volume 1: Summary report

Contractor and NASA technical management for the development and manufacture of the Skylab modules is reviewed with emphasis on the following management controls: configuration and interface management; vendor control; and quality control of workmanship. A review of the modified two-stage Saturn V launch vehicle which focused on modifications to accommodate the Skylab payload; resolution of prior flight anomalies; and changes in personnel and management systems is presented along with an evaluation of the possible age-life and storage problems for the Saturn 1-B launch vehicle. The NASA program management's visibility and control of contractor operations, systems engineering and integration, the review process for the evaluation of design and flight hardware, and the planning process for mission operations are investigated. It is concluded that the technical management system for development and fabrication of the modules, spacecraft, and launch vehicles, the process of design and hardware acceptance reviews, and the risk assessment activities are satisfactory. It is indicated that checkout activity, integrated testing, and preparations for and execution of mission operation require management attention.

Source record↗
NASA NTRS1976

Apollo experience report environmental acceptance testing

Environmental acceptance testing was used extensively to screen selected spacecraft hardware for workmanship defects and manufacturing flaws. The minimum acceptance levels and durations and methods for their establishment are described. Component selection and test monitoring, as well as test implementation requirements, are included. Apollo spacecraft environmental acceptance test results are summarized, and recommendations for future programs are presented.

Laubach, C. H. M.↗
NASA NTRS1978

Considerations in STS payload environmental verification

The current philosophy of the GSFS regarding environmental verification of Shuttle payloads is reviewed. In the structures area, increased emphasis will be placed on the use of analysis for design verification, with selective testing performed as necessary. Furthermore, as a result of recent cost optimization analysis, the multitier test program will presumably give way to a comprehensive test program at the major payload subassembly level after adequate workmanship at the component level has been verified. In the thermal vacuum area, thought is being given to modifying the approaches used for conventional spacecraft.

Keegan, W. B.↗
NASA NTRS1979

Environmental requirements for flat plate photovoltaic modules for terrestrial applications

The environmental test requirements that have been developed for flat plate modules purchased through Department of Energy funding are described. Concurrent with the selection of the initial qualification tests from space program experience - temperature cycling and humidity - surveys of existing photovoltaic systems in the field revealed that arrays were experiencing the following failure modes: interconnect breakage, delamination, and electrical termination corrosion. These coupled with application-dependent considerations led to the development of additional qualification tests, such as cyclic pressure loading, warped mounting surface, and hail. Rationale for the selection of tests, their levels and durations is described. Comparisons between field-observed degradation and test-induced degradation show a positive correlation with some of the observed field effects. Also, the tests are proving useful for detecting design, process, and workmanship deficiencies. The status of study efforts for the development of environmental requirements for field-related problems is reviewed.

Hoffman, A. R.↗
NASA NTRS1979

Environmental testing of terrestrial flat plate photovoltaic modules

The Low-Cost Solar Array (LSA) Project at the Jet Propulsion Laboratory has as one objective: the development and implementation of environmental tests for flat plate photovoltaic modules as part of the Department of Energy's terrestrial photovoltaic program. Modules procured under this program have been subjected to a variety of laboratory tests intended to simulate service environments, and the results of these tests have been compared to available data from actual field service. This comparison indicates that certain tests (notably temperature cycling, humidity cycling, and cyclic pressure loading) are effective indicators of some forms of field failures. Other tests have yielded results useful in formulating module design guidelines. Not all effects noted in field service have been successfully reproduced in the laboratory, however, and work is continuing in order to improve the value of the test program as a tool for evaluating module design and workmanship. This paper contains a review of these ongoing efforts and an assessment of significant test results to date.

Hoffman, A.↗
NASA NTRS1975

The prevention of electronical breakdown and electrostatic voltage problems in the space shuttle and its payloads. Part 2: Design guides and operations considerations

The specific electrical discharge problems that can directly affect the shuttle vehicle and its payloads are addressed. General design guidelines are provided to assist flight hardware managers in minimizing these kinds of problems. Specific data are included on workmanship practices and system testing while in low pressure environments. Certain electrical discharge problems that may be unique to the design of the shuttle vehicle itself and to its various mission operational models are discussed.

Whitson, D. W.↗
NASA NTRS1981

An Investigation of Assembly and Performance of a Resistoflex Dynatube 1/4 Inch Fitting

Installation of titanium (6Al-4V) threaded fittings on 1/4 in. tubing is sensitive to workmanship and to the state of repair of the installation tooling. Tooling with very slight out-of-specification imperfections produces less than optimum swaged fittings. A significant quantity of samples were fabricated and X-rays were used to determine the depth of swage. Joint performance was assessed through static and dynamic testing.

Ehl, J. H.↗
NASA NTRS1980

Space Telescope performance and verification

The verification philosophy for the Space Telescope (ST) has evolved from years of experience with multispacecraft programs modified by the new factors introduced by the Space Transportation System. At the systems level of test, the ST will undergo joint qualification/acceptance tests with environment simulation using Lockheed's large spacecraft test facilities. These tests continue the process of detecting workmanship defects and module interface incompatibilities. The test program culminates in an 'all up' ST environmental test verification program resulting in a 'ready to launch' ST.

Wright, W. F.↗
NASA NTRS1981

The quality assurance role in the Deep Space Network

The quality assurance section provides skilled personnel who perform the following functions: quality hardware engineering, quality software engineering, inspection and testing, and an independent assessment to quality, engineering and project requirements. The quality assurance section provides specifications, workmanship standards, process specifications and quality assurance procedures in support of DSN equipment. In addition, the quality assurance section reviews DSN engineering documents to ensure that appropriate and adequate quality provisions are included.

Sirpilla, R. L.↗