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Results for “accelerated lifetime testing”

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 NTRS2014

Development Status of Adjustable Grazing Incidence Optics for 0.5 Arcsecond X-Ray Imaging

We describe progress in the development of adjustable grazing incidence X-ray optics for 0.5 arcsec resolution cosmic X-ray imaging. To date, no optics technology is available to blend high resolution imaging like the Chandra X-ray Observatory, with square meter collecting area. Our approach to achieve these goals simultaneously is to directly deposit thin film piezoelectric actuators on the back surface of thin, lightweight Wolter-I or Wolter- Schwarschild mirror segments. The actuators are used to correct mirror figure errors due to fabrication, mounting and alignment, using calibration and a one-time figure adjustment on the ground. If necessary, it will also be possible to correct for residual gravity release and thermal effects on-orbit. In this paper we discuss our most recent results measuring influence functions of the piezoelectric actuators using a Shack-Hartmann wavefront sensor. We describe accelerated and real-time lifetime testing of the piezoelectric material, and we also discuss changes to, and recent results of, our simulations of mirror correction.

Reid, Paul B.↗
DOE OSTI2026

Relief Zones Enhance the Durability of Ultrathin Membranes in Electrochemical Conversion Devices

Premature failures in electrochemical conversion systems often result when membrane electrode assemblies (MEAs) use ultrathin (≤15 μm-thick) polymer electrolyte membranes, susceptible to mechanical degradation from stress concentrations arising from device-level integration. Herein, relief zones were developed to mitigate mechanical degradation by alleviating excess and nonuniform compression across active areas. Relief zones, created through ablation of carbonaceous diffusion media, enable seamless adaptation across MEA dimensions without need for hardware modifications. Demonstrated using fuel cells as a case study, accelerated stress tests revealed a 6-fold lifetime improvement (∼1500 h) compared to conventional edge-protected MEAs, decoupling device-level engineering effects from material limitations.

accelerated stress test↗
NASA NTRS2018

Space-and Ground-Based Non-Accelerated Long Lifetime Data for Ruggedized Commercial Non-Planar Ring Oscillator (NPRO) Lasers

Lifetime data is presented for ruggedized commercial NPRO lasers used in the Tropospheric Emission Spectrometer (TES) Instrument on NASA’s Aura Earth-orbiting spacecraft, including 20 years of data from two life test units on the ground, 12 years of on-orbit data from TES Laser A, and 2 years of on-orbit data from TES Laser B. The TES lasers are diode-pumped Non-Planar Ring Oscillator (NPRO) lasers using Nd:YAG crystals. Since accelerated life testing was not possible on the complete laser, early prototype lasers that had gone through thermal cycling and vibration testing were placed on non-accelerated life tests with the hope of gathering at least a couple of years of data before launch. Long-term lifetime data for hybrid laser systems in space applications is not abundant, and out of necessity, accelerated reliability testing is usually done over a relatively short time with a large number of devices. The data presented in this paper is unique as it tracks the optical power output over time of a total of four lasers on the order of decades rather than months or years. Two of the lasers have each been on life test for over 20 years on the ground and are still operating, and the other two lasers have been on-orbit for 14 years. TES Laser A was still operating when the TES Instrument was decommissioned in January 2018. Therefore, the data presented covers over 450,000 non-accelerated device-hours, with 23% of those hours being in space.

Kane, T.J.↗
NASA NTRS1991

LLNL contributions to MPD thrusters for SEI

Some of the topics covered with respect to the Lawrence Livermore National Laboratory's (LLNL's) contributions to Magnetoplasmadynamic (MPD) Thrusters for the Space Exploration Initiative (SEI) include: an IR camera, plasma-induced erosion/redeposition, the Mirror Fusion Test Facility-B (MFTF-B), the Thruster Lifetime Test Facility, the RACE Compact Torus Accelerator Facility, and a RACE program summary. Some of the other topics addressed include: flux contours for HAM simulation, comparison of RACE data of plasma ring formation with the HAM 2-D magnetohydrodynamic code, and the 2-D Ring Acceleration Code (TRAC).

Hooper, Edwin Bickford↗
NASA NTRS2017

Applications of Fracture Mechanics to Quantitative Accelerated Life Testing of Plastic Encapsulated Microelectronics

Accelerated testing must address the failure mechanisms active within the devices undergoing tests in order to assess lifetimes in a meaningful way. The assumption of constant temperature, thermally activated lifetime, based upon the Arrhenius assumptions, does not always provide the necessary understanding to interpret accelerated tests in microelectronics. Plastic encapsulants, dielectric polymers, and underfill materials are subject to delamination and cracking with thermal cycling. Crack propagation during use environment exposure, drives the potential for failure of microelectronic devices and is therefore a necessary focal point in qualification and life testing. This paper reviews the available research in the application of fracture mechanics to this class of problems in microelectronics including relevant test data. In addition, useful acceleration factor models are derived for polymer crack propagation based on principles of linear elastic fracture mechanics. Further, a simple approach to estimating the minimum temperature cycling ranges, necessary to propagate a crack, is also presented. Finally, a methodology of applying acceleration factors to develop testing plans is shown, with an example in spaceflight for a cubesat in low Earth orbit. Overall, this is a paper that shows a useful and appropriate process for creating physics of failure based life testing for delamination and cracking failures in microelectronic polymers in a temperature cycling environment.

Accelerated testing↗
NASA NTRS2015

Accelerated Test Method for Corrosion Protective Coatings Project

This project seeks to develop a new accelerated corrosion test method that predicts the long-term corrosion protection performance of spaceport structure coatings as accurately and reliably as current long-term atmospheric exposure tests. This new accelerated test method will shorten the time needed to evaluate the corrosion protection performance of coatings for NASA's critical ground support structures. Lifetime prediction for spaceport structure coatings has a 5-year qualification cycle using atmospheric exposure. Current accelerated corrosion tests often provide false positives and negatives for coating performance, do not correlate to atmospheric corrosion exposure results, and do not correlate with atmospheric exposure timescales for lifetime prediction.

Technology Portfolio System↗
NASA NTRS2005

The Effect of 17-4 PH Stainless Steel on the Lifetime of a Pennzane(Trademark) Lubricated Microwave Limb Sounder Antenna Actuator Assembly Ball Screw for the AURA Spacecraft

During ground based life testing of a Microwave Limb Sounder (MLS) Antenna Actuator Assembly (AAA) ball-screw assembly, lubricant darkening and loss were noted when approximately 10 percent of required lifetime was completed. The MLS-AAA ball screw and nut are made from 17-4 PH steel, the nut has 440C stainless steel balls, and the assembly is lubricated with a Pennzane formulation containing a three weight percent lead naphthenate additive. Life tests were done in dry nitrogen at 50 C. To investigate the MLS-AAA life test anomaly, Spiral Orbit Tribometer (SOT) accelerated tests were performed. SOT results indicated greatly reduced relative lifetimes of Pennzane formulations in contact with 17-4 PH steel compared to 440C stainless steel. Also, dry nitrogen tests yielded longer relative lifetimes than comparable ultrahigh vacuum tests. Generally, oxidized Pennzane formulations yielded shorter lifetimes than non-oxidized lubricant. This study emphasizes surface chemistry effects on the lubricated lifetime of moving mechanical assemblies.

Jones, William R., Jr.↗
NASA NTRS1977

Lifetimes of fiber composites under sustained tensile loading

Results are presented for a study intended to summarize lifetime data on several fiber/epoxy composite materials subjected to sustained uniaxial tensile loading, to report preliminary results of an accelerated test method for predicting the life of simple composites, and to describe related work in progress on pressure vessels and other filament-wound structures. The lifetime performance of the tested composites was compared by plotting the percent of ultimate strength (applied fiber stress normalized with respect to fiber failure stress in a composite) versus lifetime. In terms of performance in long-term tensile applications, the tested composites are ranked in the following order: graphite/epoxy, Be wire/epoxy, Aramid/epoxy, and S-glass/epoxy. The accelerated test using temperature and stress to simulate the passage of time proves to be encouraging, at least in the case of the Aramid/epoxy composite. The potential of a statistical analysis based on Weibull distribution analyses or a power law relationship is demonstrated.

Chiao, T. T.↗
NASA NTRS1991

Low cost space power generation

The success of this study has given a method of fabricating durable copolymer films without size limitations. Previously, only compression molded samples were durable enough to generate electrical energy. The strengthened specimens are very long lived materials. The lifetime was enhanced at least a factor of 1,300 in full pyroelectric conversion cycle experiments compared with extruded, non-strengthened film. The new techniques proved so successful that the lifetime of the resultant copolymer samples was not fully characterized. The lifetime of these new materials is so long that accelerated tests were devised to probe their durability. After a total of more than 67 million high voltage electrical cycles at 100 C, the electrical properties of a copolymer sample remained stable. The test was terminated without any detectable degradation to allow for other experiments. One must be cautious in extrapolating to power cycle performance, but 67 million electrical cycles correspond to 2 years of pyroelectric cycling at 1 Hz. In another series of experiments at reduced temperature and electrical stress, a specimen survived over one-third of a billion electrical cycles during nearly three months of continuous testing. The radiation-limited lifetimes of the copolymer were shown to range from several years to millions of years for most earth orbits. Thus, the pyroelectric copolymer has become a strong candidate for serious consideration for future spacecraft power supplies.

Olsen, Randall B.↗
NASA NTRS2010

LISA Technology Development and Risk Reduction at NASA

The Laser Interferometer Space Antenna (LISA) is a joint ESA-NASA project to design, build and operate a space-based gravitational wave detector based on a laser interferometer. LISA relies on several technologies that are either new to spaceflight or must perform at levels not previously demonstrated in a spaceflight environment. The ESA-led LISA Pathfinder mission is the main effort to demonstrate LISA technology. NASA also supports complementary ground-based technology development and risk reduction activities. This presentation will report the status of NASA work on micronewton thrusters, the telescope, the optical pointing subsystem and mission formulation. More details on some of these topics will be given in posters. Other talks and posters will describe NASA-supported work on the laser subsystem, the phasemeter, and aspects of the interferometry. Two flight-qualified clusters of four colloid micronewton thrusters, each capable of thrust Levels between 5 and 30 microNewton with a resolution less than 0.l microNewton and a thrust noise less than 0.1 microNewton/vHz (0.001 to 4 Hz), have been integrated onto the LISA Pathfinder spacecraft. The complementary ground-based development focuses on lifetime demonstration. Laboratory verification of failure models and accelerated life tests are just getting started. LISA needs a 40 cm diameter, afocal telescope for beam expansion/reduction that maintains an optical pathlength stability of approximately 1 pm/vHz in an extremely stable thermal environment. A mechanical prototype of a silicon carbide primary-secondary structure has been fabricated for stability testing. Two optical assemblies must point at different distant spacecraft with nanoradian accuracy over approximately 1 degree annual variation in the angle between the distant spacecraft. A candidate piezo-inchworm actuator is being tested in a suitable testbed. In addition to technology development, NASA has carried out several studies in support of the mission formulation. The results of systems engineering work on flight software, avionics and reliability will be summarized.

Stebbins, Robin T.↗
NASA NTRS1997

Development of an Ion Thruster and Power Processor for New Millennium's Deep Space 1 Mission

The NASA Solar Electric Propulsion Technology Applications Readiness Program (NSTAR) will provide a single-string primary propulsion system to NASA's New Millennium Deep Space 1 Mission which will perform comet and asteroid flybys in the years 1999 and 2000. The propulsion system includes a 30-cm diameter ion thruster, a xenon feed system, a power processing unit, and a digital control and interface unit. A total of four engineering model ion thrusters, three breadboard power processors, and a controller have been built, integrated, and tested. An extensive set of development tests has been completed along with thruster design verification tests of 2000 h and 1000 h. An 8000 h Life Demonstration Test is ongoing and has successfully demonstrated more than 6000 h of operation. In situ measurements of accelerator grid wear are consistent with grid lifetimes well in excess of the 12,000 h qualification test requirement. Flight hardware is now being assembled in preparation for integration, functional, and acceptance tests.

Sovey, James S.↗
NASA NTRS2009

Bayes Analysis and Reliability Implications of Stress-Rupture Testing a Kevlar/Epoxy COPV using Temperature and Pressure Acceleration

Composite Overwrapped Pressure Vessel (COPVs) that have survived a long service time under pressure generally must be recertified before service is extended. Sometimes lifetime testing is performed on an actual COPV in service in an effort to validate the reliability model that is the basis for certifying the continued flight worthiness of its sisters. Currently, testing of such a Kevlar49(registered TradeMark)/epoxy COPV is nearing completion. The present paper focuses on a Bayesian statistical approach to analyze the possible failure time results of this test and to assess the implications in choosing between possible model parameter values that in the past have had significant uncertainty. The key uncertain parameters in this case are the actual fiber stress ratio at operating pressure, and the Weibull shape parameter for lifetime; the former has been uncertain due to ambiguities in interpreting the original and a duplicate burst test. The latter has been uncertain due to major differences between COPVs in the data base and the actual COPVs in service. Any information obtained that clarifies and eliminates uncertainty in these parameters will have a major effect on the predicted reliability of the service COPVs going forward. The key result is that the longer the vessel survives, the more likely the more optimistic stress ratio is correct. At the time of writing, the resulting effect on predicted future reliability is dramatic, increasing it by about one nine , that is, reducing the probability of failure by an order of magnitude. However, testing one vessel does not change the uncertainty on the Weibull shape parameter for lifetime since testing several would be necessary.

Phoenix, S. Leigh↗
DOE OSTI2024

Photovoltaic Cable Jackets: A Comparison of Representative Products Using Combined-Accelerated Stress Testing [Slides]

Photovoltaic (PV) cables facilitate the distribution of electricity collected from modules to the energy grid. Durable cabling enables continuous operation of PV installations, whereas cables with a lifetime less than the modules must be replaced - reducing electricity generation and adding to the operating expense. This study primarily focusses on the aging of the key cable types using the combined-accelerated stress testing (C-AST) protocol. Representative cables for utility, building, and control/auxiliary applications were examined. Cable jacket materials examined include: polyolefin, polyethylene, polyamide, poly(vinyl chloride), chlorinated polyethylene, thermoplastic elastomer, and ethylene propylene diene monomer rubber. Specimen characterizations applied include: optical microscopy, mechanical profilometry, instrumented indentation, scanning electron microscopy (SEM), energy-dispersive X-ray spectroscopy (EDS), Fourier-transform infrared spectroscopy (FTIR), thermogravimetric analysis (TGA), and differential scanning calorimetry (DSC). A variety of performance and durability characteristics were observed, depending on the base material, polymer formulation, and jacket color. The results from C-AST are analyzed and discussed relative to a recent industry survey on electronic balance of system components in addition to a recent study where similar cables were aged using steady state ultraviolet weathering (International Electrotechnical Commission Technical Specification 62788-7-2). Recommendations are made for the screening, industry qualification, and service life prediction of PV cable jackets.

24 POWER TRANSMISSION AND DISTRIBUTION↗
NASA NTRS1997

The Effect of ODC-Free Cleaning Techniques on Bearing Lifetimes in the Parched Elastohydrodynamic Regime

A parched elastohydrodynamic rig was used to determine relative bearing lifetimes as a function of cleaning procedures in a series of accelerated tests. Two ODC-free cleaning procedures (super critical CO2 and ultraviolet-ozone) were compared to a CFC-113 control. Bearings (52100 steel) were run in the counter rotating mode (equivalent to 4600 rpm) with a full complement (i.e. no retainer) and a single charge of lubricant (Krytox 143 AC). Test conditions included: an air atmosphere, 445N load, approx. 1.0 GPa mean Hertz stress. There was approximately a 50% reduction in life with bearings cleaned with UV/ozone and a 70% reduction in life with SFE CO2 when compared to the Freon control. Possible reasons for these decreases in lifetimes are presented.

Jones, William R., Jr.↗
NASA NTRS1996

The Effect of ODC-Free Cleaning Techniques on Bearing Lifetimes in the Parched Elastohydrodynamic Regime

A parched elastohydrodynamic rig was used to determine relative bearing lifetimes as a function of cleaning procedures in a series of accelerated tests. Two ODC-free cleaning procedures (super critical CO2 and ultraviolet-ozone) were compared to a CFC-113 control. Bearings (52100 steel) were run in the counter rotating mode (equivalent to 4600 rpm) with a full complement (i.e. no retainer) and a single charge of lubricant (Krytox 143 AC). Test conditions included: an air atmosphere, 445 N load, approx. 1.0 GPa mean Hertz stress. There was approximately a 50% reduction in life with bearings cleaned with UV/ozone and a 70% reduction in life with SFE CO2 when compared to the Freon control. Possible reasons for these decreases in lifetimes are presented.

Jones, William R., Jr.↗
DOE OSTI2026

Feedback, physics, and forecasts: The emerging paradigm of machine learning-driven battery research

Machine learning (ML) is reshaping how we understand, predict, and optimize electrochemical systems. In batteries, ML accelerates discovery across chemistry, design, and operation by transforming massive experimental and simulated datasets into predictive, interpretable models. This review consolidates a decade of progress in ML-driven battery innovation, from early-cycle feature extraction to operando image analysis and physics-informed modeling. We categorize approaches by data domain and physical fidelity, emphasizing interpretable ML for diagnostics, reinforcement learning for control, and multi-objective optimization for lifetime extension strategies. Additionally, we demonstrate how integrated models accelerate discovery, reduce testing time, and guide sustainable design. Economic analyses furthermore illustrate how these advances can lower cost per cycle and improve circularity. Together, these developments chart a path toward self-optimizing, sustainable battery technologies.

artificial intelligence↗
NASA NTRS1994

An Acoustic Charge Transport Imager for High Definition Television Applications: Reliability Modeling and Parametric Yield Prediction of GaAs Multiple Quantum Well Avalanche Photodiodes

Reliability modeling and parametric yield prediction of GaAs/AlGaAs multiple quantum well (MQW) avalanche photodiodes (APDs), which are of interest as an ultra-low noise image capture mechanism for high definition systems, have been investigated. First, the effect of various doping methods on the reliability of GaAs/AlGaAs multiple quantum well (MQW) avalanche photodiode (APD) structures fabricated by molecular beam epitaxy is investigated. Reliability is examined by accelerated life tests by monitoring dark current and breakdown voltage. Median device lifetime and the activation energy of the degradation mechanism are computed for undoped, doped-barrier, and doped-well APD structures. Lifetimes for each device structure are examined via a statistically designed experiment. Analysis of variance shows that dark-current is affected primarily by device diameter, temperature and stressing time, and breakdown voltage depends on the diameter, stressing time and APD type. It is concluded that the undoped APD has the highest reliability, followed by the doped well and doped barrier devices, respectively. To determine the source of the degradation mechanism for each device structure, failure analysis using the electron-beam induced current method is performed. This analysis reveals some degree of device degradation caused by ionic impurities in the passivation layer, and energy-dispersive spectrometry subsequently verified the presence of ionic sodium as the primary contaminant. However, since all device structures are similarly passivated, sodium contamination alone does not account for the observed variation between the differently doped APDs. This effect is explained by the dopant migration during stressing, which is verified by free carrier concentration measurements using the capacitance-voltage technique.

Hunt, W. D.↗
NASA NTRS2003

Determination of Lubricants on Ball Bearings by FT-IR using an Integrating Sphere

The lifetime determination of space lubricants is done at our facility by accelerated testing. Several micrograms of lubricant are deposited on the surface of a ball by syringing tens of micro liters of dilute lubricant solution. The solvent evaporates and the mass of lubricant is determined by twenty weighings near the balance reliability limit. This process is timely but does not produce a good correlation between the mass of lubricant and the volume of solution applied, as would be expected. The amount of lubricant deposited on a ball can be determined directly by Fourier Transform - Infrared Spectroscopy using an integrating sphere. In this paper, we discuss reasons for choosing this methodology, optimization of quantification conditions and potential applications for the technique. The volume of lubricant solution applied to the ball gives better correlation to the IR intensity than does the weight.

Street, K. W.↗