ATLO (Assembly Test and Launch Operations) Monitoring of OSIRIS-REx Spacecraft Facilities Using an Amplicon Sequencing Approach
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Four bearing assemblies, lubricated with Apiezon C oil with 5% lead naphthenate (PbNp), were life tested in support of the Advanced Microwave Sounding Unit-A (AMSU-A). These assemblies were tested continuously for five to six years using the scanning pattern of the flight instrument. A post-life-test analysis was performed on two of the assemblies to evaluate the lubricant behavior and wear in the bearings.
The purpose is to document the testing performed on both hardware and software developed under the Space Station Berthing Mechanisms Program. Testing of the mechanism occurred at three locations. Several system components, e.g., actuators and computer systems, were functionally tested before assembly. A series of post assembly tests were performed. The post assembly tests, as well as the dynamic testing of the mechanism, are presented.
Testing of electronic assemblies varies throughout industry, NASA, and the military. Differences include test levels, atmospheric versus vacuum testing of assemblies, dwell durations at temperature extremes (especially high temperature), and thermal cycling versus dwell testing. Of particular interest are the different philosophies of thermal cycling versus single-cycle thermal dwell. An examination of the various failure physics for electronic assemblies has been initiated at JPL. The intent is to determine which failure modes are best revealed by thermal cycling testing and which are susceptible to high-temperature dwell physics. Preliminary results of this study are presented, along with discussions of testing goals, flight environments, reliability models, and the differences between industry and JPL design/test approaches.
Fabrication, assembly, and quality control of solar simulator optical train nickel mirrors
The Communications Research Laboratory plans to test an antenna-assembling mechanism on the Engineering Test Satellite 7. The test is one of the application missions for the space robotics experiments that will be conducted mainly by the National Space Development Agency of Japan (NASDA). The purpose of the test is to verify the ability of the antenna assembling mechanism to function in space and to experiment on the teleoperation of a space robot to develop antenna-assembling technology. We present the test experiment plans and the outline of the onboard assembling mechanism.
Manufacture, assembly, and static tests of Saturn S-IB-1 stage
In order to better understand launch vehicle abort environments, Bangham Engineering Inc. (BEi) built a test assembly that fails sample materials (steel and aluminum plates of various alloys and thicknesses) under quasi-realistic vehicle failure conditions. Samples are exposed to pressures similar to those expected in vehicle failure scenarios and filmed at high speed to increase understanding of complex fracture mechanics. After failure, the fragments of each test sample are collected, catalogued and reconstructed for further study. Post-test analysis shows that aluminum samples consistently produce fewer fragments than steel samples of similar thickness and at similar failure pressures. Video analysis shows that there are several failure 'patterns' that can be observed for all test samples based on configuration. Fragment velocities are also measured from high speed video data. Sample thickness and material are analyzed for trends in failure pressure. Testing is also done with cryogenic and noncryogenic liquid loading on the samples. It is determined that liquid loading and cryogenic temperatures can decrease material fragmentation for sub-flight thicknesses. A method is developed for capture and collection of fragments that is greater than 97 percent effective in recovering sample mass, addressing the generation of tiny fragments. Currently, samples tested do not match actual launch vehicle propellant tank material thicknesses because of size constraints on test assembly, but test findings are used to inform the design and build of another, larger test assembly with the purpose of testing actual vehicle flight materials that include structural components such as iso-grid and friction stir welds.
This work discusses the ablative response of thermal protection system materials when exposed to aerothermal environments. It focuses on modeling instrumented test article assemblies tested in the Plasmatron X inductively coupled plasma wind tunnel. For this purpose, as the samples are mounted to a water-cooled arm using numerous assembly components and are embedded with thermocouples for in-depth temperature measurements, the variation in ablative response of the samples as a result of these components is studied. The aerothermal boundary conditions for Plasmatron X are obtained for hypersonic flight-relevant conditions using the multi-physics aerothermal framework built at the University of Illinois at Urbana-Champaign. For simulating the material response, a material response code, Porous Material Analysis Toolbox based on OpenFOAM (PATO) is used. In PATO, numerous configurations and materials of thermocouples were studied. The optimal configuration for obtaining temperature measurements with minimal error using embedded thermocouples was found to be the U-shaped Type S, 30 American wire gauge thermocouple configuration.
This work discusses the ablative response of thermal protection system materials when exposed to aerothermal environments. It focuses on modeling instrumented test article assemblies tested in the Plasmatron X inductively coupled plasma wind tunnel. For this purpose, as the samples are mounted to a water-cooled arm using numerous assembly components and are embedded with thermocouples for in-depth temperature measurements, the variation in ablative response of the samples as a result of these components is studied. The aerothermal boundary conditions for Plasmatron X are obtained for hypersonic flight-relevant conditions using the multi-physics aerothermal framework built at the University of Illinois at Urbana-Champaign. For simulating the material response, a material response code, Porous Material Analysis Toolbox based on OpenFOAM (PATO) is used. In PATO, numerous configurations and materials of thermocouples were studied. The optimal configuration for obtaining temperature measurements with minimal error using embedded thermocouples was found to be the U-shaped Type S, 30 American wire gauge thermocouple configuration.
Simulated space environment life testing of step- servo assembly for radiation experiments on OSO D satellite
Reliability considerations in design, assembly, and testing of Mariner IV power system
Hydraulic-powered self propelled six degree of freedom loading vehicle moving tests assembly to test chamber with high accuracy positioning
Texts included: short circuit analysis, voltage reversal, high temperature exposure, parallel loading sharing, capacity tests, shock and vibration tests, and assembly tests. Both the AA and D cell configurations were tested. Certification of the cells is discussed and applications are highlighted.
NASA’s Europa Clipper mission – which is planned to launch in the mid-2020s – is designed to investigate the habitability of the jovian moon Europa with a state-of-the-art suite of over 10 sensors and instruments. Now past its project critical design review, Europa Clipper is starting the execution of its verification and validation (V&V) program. The payload V&V function in particular is responsible for designing and coordinating a thorough test and analysis program that will confirm the proper functioning and performance of our payload instruments. Given the large number of instruments to manage, we have developed a suite of standardized tests and analyses that are designed to cover all of the common interfaces across instruments, while allowing for flexibility to support the unique needs of individual instruments. This suite of activities, coordinated and/or performed by the payload team, forms the bulk of our payload verification and validation campaign. This paper provides a detailed summary of the full set of V&V activities in that suite, covering the four categories of activities: analysis of lower-level evidence, analysis via simulation, testing in the system testbeds, and testing in assembly, test, and launch operations (ATLO). We will describe the purpose of each activity type, how the activities are developed, and the review process for each type of activity. We then define the complete list of activities written for each instrument and how subtleties specific to certain instruments are managed. The discussion will provide a comprehensive understanding of the activities in the payload V&V purview and how various interfaces with different levels of the project are managed. This paper also describes key metrics the payload team uses to track V&V progress and some insights into the teaming design and division of labor we use to ensure consistency and completeness across the entire payload suite. Finally, the paper will offer a snapshot of the status of the Payload V&V program prior to instrument delivery and offer insights into the upcoming phase of instrument delivery and the start of ATLO.
Microbial contamination levels on Apollo 6 spacecraft, discussing intramural environments for assembly and testing
The Clouds and the Earth's Radiant Energy System (CERES) elevation scan bearings lubricated with Pennzane SHF X2000 and 2% lead naphthenate (PbNp) were life tested for a seven-year equivalent Low Earth Orbit (LEO) operation. The bearing life assembly was tested continuously at an accelerated and normal rate using the scanning patterns developed for the CERES Earth Observing System AM-1 mission. A post-life-test analysis was performed on the collected data, bearing wear, and lubricant behavior.
Recent experiments were performed in which return loss and insertion loss of waveguide test assemblies in the frequency range from 325 to 508 GHz were measured by use of a swept-frequency two-port vector network analyzer (VNA) test set. The experiments were part of a continuing effort to develop means of characterizing passive and active electronic components and systems operating at ever increasing frequencies. The waveguide test assemblies comprised WR-2.2 end sections collinear with WR-3.3 middle sections. The test set, assembled from commercially available components, included a 50-GHz VNA scattering- parameter test set and external signal synthesizers, augmented with recently developed frequency extenders, and further augmented with attenuators and amplifiers as needed to adjust radiofrequency and intermediate-frequency power levels between the aforementioned components. The tests included line-reflect-line calibration procedures, using WR-2.2 waveguide shims as the "line" standards and waveguide flange short circuits as the "reflect" standards. Calibrated dynamic ranges somewhat greater than about 20 dB for return loss and 35 dB for insertion loss were achieved. The measurement data of the test assemblies were found to substantially agree with results of computational simulations.