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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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The technology base of solar thermal energy is investigated. The materials, components, subsystems, and processes capable of meeting specific energy cost targets are emphasized, as are system efficiency and reliability.
The approach taken by NASA and JPL (Jet Propulsion Laboratory) in the development of a MIL-STD-975 section which contains advanced technology such as Large Scale Integration and Very Large Scale Integration (LSI/VLSI) microelectronic devices is described. The parts listed in this section are recommended as satisfactory for NASA flight applications, in the absence of alternate qualified devices, based on satisfactory results of a vendor capability audit, the availability of sufficient characterization and reliability data from the manufacturers and users and negotiated detail procurement specifications. The criteria used in the selection and evaluation of the vendors and candidate parts, the preparation of procurement specifications, and the status of this activity are discussed.
The first year of research to provide NASA support in predicting operational and support parameters and costs of proposed space systems is reported. Some of the specific research objectives were (1) to develop a methodology for deriving reliability and maintainability parameters and, based upon their estimates, determine the operational capability and support costs, and (2) to identify data sources and establish an initial data base to implement the methodology. Implementation of the methodology is accomplished through the development of a comprehensive computer model. While the model appears to work reasonably well when applied to aircraft systems, it was not accurate when used for space systems. The model is dynamic and should be updated as new data become available. It is particularly important to integrate the current aircraft data base with data obtained from the Space Shuttle and other space systems since subsystems unique to a space vehicle require data not available from aircraft. This research only addressed the major subsystems on the vehicle.
Petri nets augmented with timing specifications gained a wide acceptance in the area of performance and reliability evaluation of complex systems exhibiting concurrency, synchronization, and conflicts. The state space of time-extended Petri nets is mapped onto its basic underlying stochastic process, which can be shown to be Markovian under the assumption of exponentially distributed firing times. The integration of exponentially and non-exponentially distributed timing is still one of the major problems for the analysis and was first attacked for continuous time Petri nets at the cost of structural or analytical restrictions. We propose a discrete deterministic and stochastic Petri net (DDSPN) formalism with no imposed structural or analytical restrictions where transitions can fire either in zero time or according to arbitrary firing times that can be represented as the time to absorption in a finite absorbing discrete time Markov chain (DTMC). Exponentially distributed firing times are then approximated arbitrarily well by geometric distributions. Deterministic firing times are a special case of the geometric distribution. The underlying stochastic process of a DDSPN is then also a DTMC, from which the transient and stationary solution can be obtained by standard techniques. A comprehensive algorithm and some state space reduction techniques for the analysis of DDSPNs are presented comprising the automatic detection of conflicts and confusions, which removes a major obstacle for the analysis of discrete time models.
Microelectromechanical systems in MEMS is one of the fastest growing technologies in microelectronics, and is of great interest for military and aerospace applications. Accelerometers are the earliest and most developed representatives of MEMS. First demonstrated in 1979, micromachined accelerometers were used in automobile industry for air bag crash- sensing applications since 1990. In 1999, N4EMS accelerometers were used in NASA-JPL Mars Microprobe. The most developed accelerometers for airbag crash- sensing are rated for a full range of +/- 50 G. The range of sensitivity for accelerometers required for military or aerospace applications is much larger, varying from 20,000 G (to measure acceleration during gun and ballistic munition launches), and to 10(exp -6) G, when used as guidance sensors (to measure attitude and position of a spacecraft). The presence of moving parts on the surface of chip is specific to MEMS, and particularly, to accelerometers. This characteristic brings new reliability issues to micromachined accelerometers, including cyclic fatigue cracking of polysilicon cantilevers and springs, mechanical stresses that are caused by packaging and contamination in the internal cavity of the package. Studies of fatigue cracks initiation and growth in polysilicon showed that the fatigue damage may influence MEMS device performance, and the presence of water vapor significantly enhances crack initiation and growth. Environmentally induced failures, particularly, failures due to thermal cycling and mechanical shock are considered as one of major reliability concerns in MEMS. These environmental conditions are also critical for space applications of the parts. For example, the Mars pathfinder mission had experienced 80 mechanical shock events during the pyrotechnic separation processes.
The National Aeronautics and Space Administration (NASA) recently began development of a new reusable launch vehicle. The program office is located at Marshall Space Flight Center (MSFC) and is called the Second Generation Reusable Launch Vehicle (2GRLV). The purpose of the program is to improve upon the safety and reliability of the first generation reusable launch vehicle, the Space Shuttle. Specifically, the goals are to reduce the risk of crew loss to less than 1-in-10,000 missions and decreased costs by a factor of 10 to approximately $1,000 per pound of payload launched to low Earth orbit. The program is currently in the very early stages of development and many two-stage vehicle concepts will be evaluated. Risk reduction activities are also taking place. These activities include developing new technologies and advancing current technologies to be used by the vehicle. The Environments Group at MSFC is tasked by the 2GRLV Program to develop and maintain an extensive series of analytical tools and environmental databases which enable it to provide detailed atmospheric studies in support of structural, guidance, navigation and control, and operation of the 2GRLV.
Nickel-cadmium (Ni/Cd) and nickel-hydrogen (Ni/H2) secondary alkaline batteries are vital to aerospace applications. Battery performance and cycle life are significantly affected by the type of separators used in those batteries. A team from NASA Lewis Research Center's Electrochemical Technology Branch developed standardized testing procedures to characterize and evaluate new and existing separator materials to improve performance and cycle life of secondary alkaline batteries. Battery separators must function as good electronic insulators and as efficient electrolyte reservoirs. At present, new types of organic and inorganic separator materials are being developed for Ni/Cd and Ni/H2 batteries. The separator material previously used in the NASA standard Ni/Cd was Pellon 2505, a 100-percent nylon-6 polymer that must be treated with zinc chloride (ZnCl2) to bond the fibers. Because of stricter Environmental Protection Agency regulation of ZnCl2 emissions, the battery community has been searching for new separators to replace Pellon 2505. As of today, two candidate separator materials have been identified; however, neither of the two materials have performed as well as Pellon 2505. The separator test procedures that were devised at Lewis are being implemented to expedite the search for new battery separators. The new test procedures, which are being carried out in the Separator Laboratory at Lewis, have been designed to guarantee accurate evaluations of the properties that are critical for sustaining proper battery operation. These properties include physical and chemical stability, chemical purity, gas permeability, electrolyte retention and distribution, uniformity, porosity, and area resistivity. A manual containing a detailed description of 12 separator test procedures has been drafted and will be used by the battery community to evaluate candidate separator materials for specific applications. These standardized procedures will allow for consistent, uniform, and reliable results that will ensure that separator materials have the desired properties for long life and good performance in secondary alkaline cells.
The United States National Aeronautics and Space Administration (NASA) is in the midst of a space exploration program called Constellation to send crew and cargo to the international Space Station, to the moon, and beyond. As part of the Constellation program, a new launch vehicle, Ares I, is being developed by NASA Marshall Space Flight Center. Designing a launch vehicle with high reliability and increased safety requires a significant effort in understanding design variability and design uncertainty at the various levels of the design (system, element, subsystem, component, etc.) and throughout the various design phases (conceptual, preliminary design, etc.). In a previous paper [1] we discussed a probabilistic functional failure analysis approach intended mainly to support system requirements definition, system design, and element design during the early design phases. This paper provides an overview of the application of probabilistic engineering methods to support the detailed subsystem/component design and development as part of the "Design for Reliability and Safety" approach for the new Ares I Launch Vehicle. Specifically, the paper discusses probabilistic engineering design analysis cases that had major impact on the design and manufacturing of the Space Shuttle hardware. The cases represent important lessons learned from the Space Shuttle Program and clearly demonstrate the significance of probabilistic engineering analysis in better understanding design deficiencies and identifying potential design improvement for Ares I. The paper also discusses the probabilistic functional failure analysis approach applied during the early design phases of Ares I and the forward plans for probabilistic design analysis in the detailed design and development phases.
Implementation of integrated system health management (ISHM) capability is fundamentally linked to the management of data, information, and knowledge (DIaK) with the purposeful objective of determining the health of a system. It is akin to having a team of experts who are all individually and collectively observing and analyzing a complex system, and communicating effectively with each other in order to arrive to an accurate and reliable assessment of its health. We present concepts, procedures, and a specific approach as a foundation for implementing a credible ISHM capability. The capability stresses integration of DIaK from all elements of a system. The intent is also to make possible implementation of on-board ISHM capability, in contrast to a remote capability. The information presented is the result of many years of research, development, and maturation of technologies, and of prototype implementations in operational systems (rocket engine test facilities). The paper will address the following topics: 1. ISHM Model of a system 2. Detection of anomaly indicators. 3. Determination and confirmation of anomalies. 4. Diagnostic of causes and determination of effects. 5. Consistency checking cycle. 6. Management of health information 7. User Interfaces 8. Example implementation ISHM has been defined from many perspectives. We define it as a capability that might be achieved by various approaches. We describe a specific approach that has been matured throughout many years of development, and pilot implementations. ISHM is a capability that is achieved by integrating data, information, and knowledge (DIaK) that might be distributed throughout the system elements (which inherently implies capability to manage DIaK associated with distributed sub-systems). DIaK must be available to any element of a system at the right time and in accordance with a meaningful context. ISHM Functional Capability Level (FCL) is measured by how well a system performs the following functions: (1) detect anomalies, (2) diagnose causes, (3) predict future anomalies/failures, and (4) provide the user with an integrated awareness about the condition of every element in the system and guide user decisions.
The increasingly ambitious requirements levied on JPL's space science missions, and the development pace of such missions, challenge our current engineering practices. All the engineering disciplines face this growth in complexity to some degree, but the challenges are greatest in systems engineering where numerous competing interests must be reconciled and where complex system level interactions must be identified and managed. Undesired system-level interactions are increasingly a major risk factor that cannot be reliably exposed by testing, and natural-language single-viewpoint specifications areinadequate to capture and expose system level interactions and characteristics. Systems engineering practices must improve to meet these challenges, and the most promising approach today is the movement toward a more integrated and model-centric approach to mission conception, design, implementation and operations. This approach elevates engineering models to a principal role in systems engineering, gradually replacing traditional document centric engineering practices.
Current shortcomings in both the overall injector design process and its underlying combustion stability assessment methodology are rooted in the use of empirically based or low fidelity representations of complex physical phenomena and geometry details that have first order effects on performance, thermal environments and combustion stability. The result is a design and analysis capability that is often inadequate to reliably arrive at a suitable injector design in an efficient manner. Specifically, combustion instability has been particularly difficult to predict and mitigate. Large hydrocarbon-fueled booster engines have been especially problematic in this regard. Where combustion instability has been a problem, costly and time-consuming redesign efforts have often been an unfortunate consequence. This paper presents an overview of a recently completed effort at NASA Marshall Space Flight Center to advance the state-of-the-practice for liquid rocket engine injector design. Multiple perturbations of a gas-centered swirl coaxial (GCSC) element that burned gaseous oxygen and RP-1 were designed, assessed for combustion stability, and tested. Three designs, one stable, one marginally unstable and one unstable, were used to demonstrate both an enhanced overall injector design process and an improved combustion stability assessment process. High-fidelity results from state-of-the-art computational fluid dynamics CFD simulations were used to substantially augment and improve the injector design methodology. The CFD results were used to inform and guide the overall injector design process. They were also used to upgrade selected empirical or low-dimensional quantities in the ROCket Combustor Interactive Design (ROCCID) stability assessment tool. Hot fire single element injector testing was used to verify both the overall injector designs and the stability assessments. Testing was conducted at the Air Force Research Laboratory and at Purdue University. Companion papers provide details of the overall injector design process, full- and sub-scale testing, ROCCID-based stability assessments and the CFD simulations.
The Spaceflight Standard Measures is a NASA Johnson Space Center Human Research Project (HRP) project that proposes to collect a set of core measurements, representative of many of the human spaceflight risks, from astronauts before, during and after long-duration International Space Station (ISS) missions. The term "standard measures" is defined as a set of core measurements, including physiological, biochemical, psychosocial, cognitive, and functional, that are reliable, valid, and accepted in terrestrial science, are associated with a specific and measurable outcome known to occur as a consequence of spaceflight, that will be collected in a standardized fashion from all (or most) crewmembers. While such measures might be used to define standards of health and performance or readiness for flight, the prime intent in their collection is to allow longitudinal analysis of multiple parameters in order to answer a variety of operational, occupational, and research-based questions. These questions are generally at a high level, and the approach for this project is to populate the standard measures database with the smallest set of data necessary to indicate further detailed research is required. Also included as standard measures are parameters that are not outcome-based in and of-themselves, but provide ancillary information that supports interpretation of the outcome measures, e.g., nutritional assessment, vehicle environmental parameters, crew debriefs, etc. The project's main aim is to ensure that an optimized minimal set of measures is consistently captured from all ISS crewmembers until the end of Station in order to characterize the human in space. -This allows the HRP to identify, establish, and evaluate a common set of measures for use in spaceflight and analog research to: develop baselines, systematically characterize risk likelihood and consequences, and assess effectiveness of countermeasures that work for behavioral health and performance risk factors. -By standardizing the battery of measures on all crewmembers, it will allow the HRP to evaluate countermeasures that work for one physiological system and ensure another system is not negatively affected. -These measures, named "Standard Measures," will serve as a data repository and be available to other studies under data sharing agreements.
Nuclear electric propulsion (NEP)-powered vehicles have been contemplated for human Mars missions. The nuclear power system contemplates using a high temperature light-weight nuclear reactor for the production of electrical power in the range of 2-5 MWe with a 3-10 year service life. A myriad of technology options exist for achieving these mission objectives. The analytic hierarchy process (AHP), a multi-attribute decision method, is being used to narrow down the candidate designs. The AHP is a structured decision process that fuses model-supplied quantitative data with subjective assessments to facilitate decisions that involve multiple competing criteria. Proven end-to-end nuclear design and systems analysis tools will be used to provide quantitative performance data such as end-to-end system reliability, system robustness to recover from off-normal conditions, system specific weight (α in kg/kWe), and the ability to meet the service life-time and power level requirements. Three high assay low enriched uranium (HALEU) reactor concepts, namely, gas-, heat pipe- and pumped liquid-cooled nuclear cores coupled to a He/Xe gas or supercritical CO2- Brayton power conversion system are being modeled using the AHP to understand the trade-offs associated with these design combinations. In addition to the reactor and power conversion options, there are a myriad of additional components and subsystems – e.g., radiators, heat exchangers, and recuperators – that also figure into the evaluation process. The choice of the right overall system is a multidimensional problem that has to include not only quantitative data, but also the so called “external factors”, examples of which include the component and subsystem Technology Readiness Levels (TRLs), the associated Advancement Degrees of Difficulty (AD2), the cost and schedule required to achieve a technical maturity consistent with mission infusion, alignment with the priorities of NASA’s Space Nuclear Propulsion program, and alignment with other ongoing government and commercial investments in micro reactors. Focused expert elicitations form the basis for qualitative data set. As a final step, decision-makers individually express their opinions regarding the relative importance of the criteria and preferences among the alternatives through pairwise comparisons. The paper will describe the AHP approach, progress to-date applying it to the NEP human Mars mission problem, and preliminary results. Use of AHP provides sufficient flexibility for incorporating industry input at different stages as the technologies evolve through additional research and development. It is expected that the decision process will be ongoing and expanded to examine additional options and technology choices, culminating in a defensible set of candidate reactor concepts that will form the basis for developing a multi-year NEP technology maturation strategy. .
The reliability of semiconductor devices as influenced by the reliability of wire bonds used in the assembly of the devices is investigated. The specific type of failure dealt with involves fracture of wire bonds as a result of repeated flexure of the wire at the heel of the bond when the devices are operated in an on-off mode. The mechanism of failure is one of induced fracture of the wire. To improve the reliability of a chosen transistor, one-mil diameter wires of aluminum with various alloy additions were studied using an accelerated fatigue testing machine. In addition, the electroprobe was used to study the metallurgy of the wires as to microstructure and kinetics of the growth of insoluble phases. Thermocompression and ultrasonic bonding techniques were also investigated.
There are clear parallels between the ground processing of spacecraft and the maintenance of airline aircraft. In both cases, reliable human performance is critical to safe outcomes. Examples of human factors in airline maintenance and spacecraft ground processing illustrate the similarities between these two domains. The worldwide aviation industry began to pay close attention to human factors in maintenance after several maintenance-related disasters in the 1970s and 80s. Rather than simply applying solutions that had been developed for flight crew and air traffic controllers, the aviation industry developed human factors interventions specifically tailored for maintenance personnel. These interventions have led to safety improvements, greater reliability, and significant cost savings. Six human factors approaches from airline maintenance that can be usefully applied to enhance the quality and safety of ground processing are outlined. These are 1) Design for assembly, test, and maintenance, 2) Non technical skills training, 3) Improved design of documentation, 4) Reduction of iatrogenic quality lapses, 5) Barrier and control analysis, and 6) Continuous improvement based on learning from quality lapses.
This paper reviews the current status of MEMS packaging technology from COTS to specific application provides lessons learned, and finally, identifies a need for systematic approach for this purpose.
A framework is proposed which addresses traditional reliability validation approaches consisting of life testing techniques which are inapplicable for digital flight control systems. A specific validation methodology is identified based on logical proofs, analytical modeling, and experimental testing. Research activities required to support continued development of validation technology are identified, and the validation procedure is driven by the reliability model obtained from the system description. The analytical reliability model is shown to be a proper abstraction of the system under consideration, and a proof of correctness of system design and system scheduler performance is proposed.
RELAV, a NASA-developed computer program, enables Systems Control Technology, Inc. (SCT) to predict performance of aircraft subsystems. RELAV provides a system level evaluation of a technology. Systems, the mechanism of a landing gear for example, are first described as a set of components performing a specific function. RELAV analyzes the total system and the individual subsystem probabilities to predict success probability, and reliability. This information is then translated into operational support and maintenance requirements. SCT provides research and development services in support of government contracts.