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NASA NTRS2024

Lessons Learned from Particulate Characterization Laboratory Anomalies

The White Sands Test Facility chemistry laboratory provides quality control for cleanroom operations including cleanliness verification of aerospace hardware by particulate counts and non-volatile residue determinations, particulate counts for liquid hypergolic propellants, gaseous helium and nitrogen propellant pressurizing agents used for ground support equipment and flight test article valve actuation, gaseous oxygen primarily used for component testing, and deionized water for refurbished propellant hardware flushing. Cleanliness verification includes particulate counts and non-volatile residue determinations to industry standard, NASA, and program specifications and levels. Particulate counts are typically to customer-specified specifications and levels including JPR 5322.1H (2016) Levels 50 and 100, Orion (MPCV 70156. Revision H (2018)) Level 100, RPTSTD-8070-0001 Revision 3 (2022), and IEST-STD-CC1246E (2013) Levels 50 and 100. The laboratory issues high pressure filter holders containing membrane filters to test operations personnel, who collect samples by flowing the required volumes of fluid through the filter holder, and the filter holder is returned to the lab for counting. A passing particulate count is required before testing may proceed. Rapid data reduction and issuing of reports indicating a pass or fail of the particulate specification are required. Corrective action and resampling invariably occurs if a sample fails. Consequently, the laboratory must maintain the highest degree of reliability to facilitate quality data used to decide if testing may proceed. Experience and continual improvements have enabled reliability. However, anomalies attributed to lab processes and hardware including filter holders, membranes, and Petri dishes have been encountered. This paper presents a summary of problems, solutions, successes, and lessons learned from particle counting experience for over 35 years.

Lessons Learned↗
NASA NTRS2011

Land and Atmosphere Near-Real-Time Capability for Earth Observing System

The past decade has seen a rapid increase in availability and usage of near-real-time data from satellite sensors. The EOSDIS (Earth Observing System Data and Information System) was not originally designed to provide data with sufficiently low latency to satisfy the requirements for near-real-time users. The EOS (Earth Observing System) instruments aboard the Terra, Aqua and Aura satellites make global measurements daily, which are processed into higher-level 'standard' products within 8-40 hours of observation and then made available to users, primarily earth science researchers. However, applications users, operational agencies, and even researchers desire EOS products in near-real-time to support research and applications, including numerical weather and climate prediction and forecasting, monitoring of natural hazards, ecological/invasive species, agriculture, air quality, disaster relief and homeland security. These users often need data much sooner than routine science processing allows, usually within 3 hours, and are willing to trade science product quality for timely access. While Direct Broadcast provides more timely access to data, it does not provide global coverage. In 2002, a joint initiative between NASA (National Aeronautics and Space Administration), NOAA (National Oceanic and Atmospheric Administration), and the DOD (Department of Defense) was undertaken to provide data from EOS instruments in near-real-time. The NRTPE (Near Real Time Processing Effort) provided products within 3 hours of observation on a best-effort basis. As the popularity of these near-real-time products and applications grew, multiple near-real-time systems began to spring up such as the Rapid Response System. In recognizing the dependence of customers on this data and the need for highly reliable and timely data access, NASA's Earth Science Division sponsored the Earth Science Data and Information System Project (ESDIS)-led development of a new near-real-time system called LANCE (Land, Atmosphere Near-Real-Time Capability for EOS) in 2009. LANCE consists of special processing elements, co-located with selected EOSDIS data centers and processing facilities. A primary goal of LANCE is to bring multiple near-real-time systems under one umbrella, offering commonality in data access, quality control, and latency. LANCE now processes and distributes data from the Moderate Resolution Imaging Spectroradiometer (MODIS), Atmospheric Infrared Sounder (AIRS), Advanced Microwave Scanning Radiometer Earth Observing System (AMSR-E), Microwave Limb Sounder (MLS) and Ozone Monitoring Instrument (OMI) instruments within 3 hours of satellite observation. The Rapid Response System and the Fire Information for Resource Management System (FIRMS) capabilities will be incorporated into LANCE in 2011. LANCE maintains a central website to facilitate easy access to data and user services. LANCE products are extensively tested and compared with science products before being made available to users. Each element also plans to implement redundant network, power and server infrastructure to ensure high availability of data and services. Through the user registration system, users are informed of any data outages and when new products or services will be available for access. Building on a significant investment by NASA in developing science algorithms and products, LANCE creates products that have a demonstrated utility for applications requiring near-real-time data. From lower level data products such as calibrated geolocated radiances to higher-level products such as sea ice extent, snow cover, and cloud cover, users have integrated LANCE data into forecast models and decision support systems. The table above shows the current near-real-time product categories by instrument. The ESDIS Project continues to improve the LANCE system and use the experience gained through practice to seek adjustments to improve the quality and performance of the system. For example, anGC-compliant Web Map Service (WMS) will be added shortly that will allow users to download geo-referenced MODIS images for arbitrary bounding boxes. Further, an OGC-compliant Web Coverage Service (WCS) will be added later this year that will expedite user access to arbitrary data subsets or re-formatted products. AIRS images are now served through WMS and available in multiple formats (PNG, GeoTIFF, KMZ). NASA has established a LANCE User Working Group to steer the development of the system and create a forum for sharing ideas and experiences that are expected to further improve the LANCE capabilities. The LANCE system has proved a success by satisfying the growing needs of the applications and operational communities for land and atmosphere data in near-real-time. NASA's Earth Sciences Division was able to leverage existing science research capabilities to provide the near-real-time community with products and imagery that support monitoring of disasters in a timely manner.

Murphy, Kevin J.↗
NASA NTRS2017

Filter Efficiency and Pressure Testing of Returned ISS Bacterial Filter Elements (BFEs)

The air quality control equipment aboard the International Space Station (ISS) and future deep space exploration vehicles provide the vital function of maintaining a clean cabin environment for the crew and the hardware. This becomes a serious challenge in pressurized space compartments since no outside air ventilation is possible, and a larger particulate load is imposed on the filtration system due to lack of sedimentation. The ISS Environmental Control and Life Support (ECLS) system architecture in the U.S. Segment uses a distributed particulate filtration approach consisting of traditional High-Efficiency Particulate Air (HEPA) filters deployed at multiple locations in each U.S. Seg-ment module; these filters are referred to as Bacterial Filter Elements, or BFEs. In our previous work, we presented results of efficiency and pressure drop measurements for a sample set of two returned BFEs with a service life of 2.5 years. In this follow-on work, we present similar efficiency, pressure drop, and leak tests results for a larger sample set of six returned BFEs. The results of this work can aid the ISS Program in managing BFE logistics inventory through the stations planned lifetime as well as provide insight for managing filter element logistics for future exploration missions. These results also can provide meaningful guidance for particulate filter designs under consideration for future deep space exploration missions.

ISS Air Quality↗
NASA NTRS2017

International Space Station (ISS) Bacterial Filter Elements (BFEs): Filter Efficiency and Pressure Drop Testing of Returned Units

The air quality control equipment aboard the International Space Station (ISS) and future deep space exploration vehicles provide the vital function of maintaining a clean cabin environment for the crew and the hardware. This becomes a serious challenge in pressurized space compartments since no outside air ventilation is possible, and a larger particulate load is imposed on the filtration system due to lack of sedimentation. The ISS Environmental Control and Life Support (ECLS) system architecture in the U.S. Segment uses a distributed particulate filtration approach consisting of traditional High-Efficiency Particulate Air (HEPA) filters deployed at multiple locations in each U.S. Seg-ment module; these filters are referred to as Bacterial Filter Elements, or BFEs. In our previous work, we presented results of efficiency and pressure drop measurements for a sample set of two returned BFEs with a service life of 2.5 years. In this follow-on work, we present similar efficiency, pressure drop, and leak tests results for a larger sample set of six returned BFEs. The results of this work can aid the ISS Program in managing BFE logistics inventory through the stations planned lifetime as well as provide insight for managing filter element logistics for future exploration missions. These results also can provide meaningful guidance for particulate filter designs under consideration for future deep space exploration missions.

ISS Air Quality↗
NASA NTRS2014

Development of Test Protocols for International Space Station Particulate Filters

Air quality control on the International Space Station (ISS) is a vital requirement for maintaining a clean environment for the crew and the hardware. This becomes a serious challenge in pressurized space compartments since no outside air ventilation is possible, and a larger particulate load is imposed on the filtration system due to lack of gravitational settling. The ISS Environmental Control and Life Support System (ECLSS) uses a filtration system that has been in use for over 14 years and has proven to meet this challenge. The heart of this system is a traditional High- Efficiency Particulate Air (HEPA) filter configured to interface with the rest of the life support elements and provide effective cabin filtration. Over the years, the service life of these filters has been re-evaluated based on limited post-flight tests of returned filters and risk factors. On earth, a well designed and installed HEPA filter will last for several years, e.g. in industrial and research clean room applications. Test methods for evaluating these filters are being developed on the basis of established test protocols used by the industry and the military. This paper will discuss the test methods adopted and test results on prototypes of the ISS filters. The results will assist in establishing whether the service life can be extended for these filters. Results from unused filters that have been in storage will also be presented to ascertain the shelf life and performance deterioration, if any and determine if the shelf life may be extended.

Aerosol↗
NASA NTRS2019

Cracking Problems in Low-Voltage Chip Ceramic Capacitors

Cracking remains the major reason of failures in multilayer ceramic capacitors (MLCCs) used in in space electronics. Due to a tight quality control of space-grade components, the probability that as manufactured capacitors have cracks is relatively low, and cracking is often occurs during assembly, handling and the following testing of the systems. Majority of capacitors with cracks are revealed during the integration and testing period, but although extremely rarely, defective parts remain undetected and result in failures during the mission. This situation is aggravated by manual soldering and rework that are often used during low volume production of circuit boards for space. Although failures of MLCCs are often attributed to the post-manufacturing stresses, in many cases they are due to a combination of certain deviations in the manufacturing processes that result in hidden defects in the parts and excessive stresses during assembly and use. This report gives an overview of design, manufacturing and testing processes of MLCCs focusing on elements related to cracking problems. The existing and new screening and qualification procedures and techniques are briefly described and assessed by their effectiveness in revealing cracks. The capability of different test methods to simulate stresses resulting in cracking, mechanisms of failures in capacitors with cracks, and possible methods of selecting the most robust to manual soldering stresses capacitors are discussed.

testing↗
NASA NTRSDate not supplied

NSCOR for Evaluating Risk Factors and Biomarkers for Adaptation and Resilience to Spaceflight: Emotional Valence and Social Processes in ICC/ICE Environments

Space exploration class missions, such as a mission to Mars, will require optimization of human performance, adaptability, and resilience. This NASA Specialized Center of Research (NSCOR) utilizes the NIMH Research Domain Criteria (RDoC) framework to identify biological and behavioral markers of individual social adaptation and emotional resilience (as well as vulnerability) to spaceflight-relevant stressors such as living in extended isolation. The overarching goal of this NSCOR is to obtain novel information to help identify biomarkers of individuals who are resilient and/or adaptable to the stressors of isolated, confined, and controlled (ICC) and isolated, confined, and extreme (ICE) environments.A total of N=90 healthy adult astronaut surrogates are being studied in three spaceflight-analog environments: (1) n=40 healthy adults in the Isolation and Confinement Analog Research Unit (ICARUS), an ICC at the University of Pennsylvania, during 7-day missions, for a target total of 280 subject days; (2) n=32 healthy adult astronaut surrogates studied in NASA’s Human Exploration Research Analog (HERA), an ICC at Johnson Space Center during 45-day missions, for a target total of 2,112 subject days; and (3) n=18 healthy adults in the Alfred-Wegener-Institute’s Neumayer Station III, an ICE in Antarctica, during 14-month missions, for a target total of 7,560 subject days. Dr. Nindl’s Laboratory at the University of Pittsburgh is analyzing a priori selected protein biomarkers in blood, saliva, and urine. Complementary rodent models of exposure to early life stressors, confinement, and isolation are being evaluated at Dr. Hensch’s Laboratory to further validate the neurobehavioral and biological findings from the human studies.Given the inconsistency and varied definition of resilience/adaptation in the scientific literature, the NSCOR team developed a composite resilience/adaptation measure that reflects the most relevant outcomes to resilience/adaptation across psychosocial and neurobehavioral functions, as well as neurocognitive and spaceflight-relevant operational performance. To achieve this, group consensus was attained from subject matter experts to produce a rank-order of importance for each input variable. The final resilience/adaptation score included 36 variables that were collected across spaceflight analogs. As of 10/1/2021, the NSCOR project acquired data on n=27 subjects at ICARUS, n=16 at HERA, and n=18 at Neumayer. The COVID-19 pandemic delayed data acquisition at ICARUS and HERA.Among subjects studied to date, 99% of neural and neurobehavioral data (e.g., neuroimaging for structure and function, behavioral measures) as well as blood, saliva, and urine for biochemical assays have been acquired. For rodent models, Dr. Hensch’s laboratory has established biochemical and behavioral parameters reflecting confinement stress in social networks of mice for comparison to stress responses in the human spaceflight analog environments.Group social behaviors were measured with a Social Network Analysis (SNA) approach to define objective parameters associated with sociability and its plasticity by sex. This analytic approach may help identify a network of individuals who are more effective teammates or more likely to generate new social relationships. Data acquisition, biomarker assessment, and data quality control will continue through September 2022.

D F Dinges↗
NASA NTRS2015

Evaluation of Volatile Species in Green Monopropellant Project

NASA is interested in green monopropellants to replace hydrazine in reaction control systems (RCSs). Some current NASA programs require reduced vapor pressure and low toxicity monopropellant (green) and superior performance (specific impulse and density) formulations. Earlier vapor phase studies of a candidate green monopropellant at the NASA White Sands Test Facility (WSTF) showed the presence of a volatile species that warranted further investigation. The purpose of this study was to further characterize the volatile species and to evaluate it. The evaluation was with respect to whether the volatile species was an impurity or how it is formed, and to use that information to examine whether its presence as an impurity can be eliminated during formulation. The evaluation also considered whether formation of the volatile impurity could be prevented while not compromising the propellant. To reduce variables associated with evaluation of the propellant formulation as a whole, a precursor to one of the individual components in the propellant formulation was subjected to a NASA Standard 6001B Flammability, Off-gassing, and Compatibility Requirements and Test Procedures "Determination of Off-gassed Products (Test 7)". Testing took place in the NASA WSTF Molecular Desorption and Analysis Laboratory. One gram of the precursor was placed in a flask within a specimen container. After thermal conditioning for 72 +/- 1 h at 50 +/- 3 deg C (122 +/- 5 deg F), the atmosphere inside the specimen container was analyzed for off-gassed compounds by cryotrap gas chromatography-mass spectrometry (GC-MS) and fixed sample loop GC-flame ionization detection (GC-FID). The specimen container used was glass to minimize potential catalytic surfaces. The identification of compounds was difficult due to the complexity of the vapor phase concentrations and overlapping chromatographic peaks and mass spectra. However, eleven compounds were specifically identified and five compounds or classes of compounds were reported as unidentified. Quantitation of most of the compounds, including unidentified compounds, was as methane. Quantitating compounds or classes of compounds that were detected but for which specific calibration is not established as methane is in accordance with the Test 7 standard protocol. The thermal decomposition temperature of the precursor was significantly higher than the test temperature. Based on thermal decomposition temperature and on an examination of the structure and chemistry of the identified volatile species, the presence of the volatile species appears to be chemically reasonable with respect to the propellant formulation and is at this time attributed to impurities. Further examination of the overall propellant formulation process (including the individual components' synthesis processes) and process quality control (including purity of reagents and possible decomposition reactions) is indicated.

Greene, Benjamin↗