Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “component degradation”

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.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 397 records · Page 22

Few-Mode Fiber Coupled Superconducting Nanowire Single-Photon Detectors for Photon Efficient Optical Communications

The NASA Glenn Research Center's development of a high-photon efficiency real-time optical communications ground receiver has added superconducting nanowire single-photon detectors (SNSPDs) coupled with few-mode fibers (FMF). High data rate space-to-ground optical communication links require enhanced ground receiver sensitivity to reduce spacecraft transmitter constraints, and therefore require highly efficient coupling from fiber to detector. In the presence of atmospheric turbulence the received optical wave front can be severely distorted introducing higher-order spatial mode components to the received signal. To reduce mode filtering and mismatch loss and the resulting degradations to detector coupling efficiency, we explore the use of few-mode fiber coupling to commercial single-pixel SNSPDs. Graded index 20-µm few-mode fibers allow the commercial single pixel SNSPD's active area to couple with equal efficiency as single mode fibers. Here we determine detector characteristics such as count rate, detection efficiency, dark counts, and jitter, as well as detection efficiencies for higher-order fiber spatial modes. Additionally, we assess the laboratory performance of the detectors in an optical system which emulates future deep space optical communications links.

Vyhnalek, Brian E.↗

Modeling Pore Closure in the Hot Isostatic Pressing of Additively Manufactured Inconel 718 Samples

Additive manufacturing provides opportunity for a new world of possibilities for metallic component design and fabrication; however, as-built part quality is notoriously variable, anisotropic, and degraded by porous defects. To improve quality, parts are commonly post processed using a variety of techniques including hot isostatic pressing (HIP). During HIP, high temperature and pressure is employed to improve microstructure and reduce pore volume by inducing visco-plastic deformation in the metallic substrate. Validated computational capabilities can provide predictions to guide the selection of processing condition, expected pore reduction, and the effects of varying entrapped gas in the pores. This discussion describes a micro-scale finite element structural model developed to predict pore closure due to HIP in as-built additively manufactured Inconel 718 samples produced by the laser powder bed fusion process. The model accounts for plastic deformation, creep, and internal pressure for a single pore. Pores are characterized in physical samples before and after HIP, and model predictions are compared to this measured data.

defect model prediction↗

Reliability and Maintainability Analysis for the Amine Swingbed Carbon Dioxide Removal System

I have performed a reliability & maintainability analysis for the Amine Swingbed payload system. The Amine Swingbed is a carbon dioxide removal technology that has gone through 2,400 hours of International Space Station on-orbit use between 2013 and 2016. While the Amine Swingbed is currently an experimental payload system, the Amine Swingbed may be converted to system hardware. If the Amine Swingbed becomes system hardware, it will supplement the Carbon Dioxide Removal Assembly (CDRA) as the primary CO2 removal technology on the International Space Station. NASA is also considering using the Amine Swingbed as the primary carbon dioxide removal technology for future extravehicular mobility units and for the Orion, which will be used for the Asteroid Redirect and Journey to Mars missions. The qualitative component of the reliability and maintainability analysis is a Failure Modes and Effects Analysis (FMEA). In the FMEA, I have investigated how individual components in the Amine Swingbed may fail, and what the worst case scenario is should a failure occur. The significant failure effects are the loss of ability to remove carbon dioxide, the formation of ammonia due to chemical degradation of the amine, and loss of atmosphere because the Amine Swingbed uses the vacuum of space to regenerate the Amine Swingbed. In the quantitative component of the reliability and maintainability analysis, I have assumed a constant failure rate for both electronic and nonelectronic parts. Using this data, I have created a Poisson distribution to predict the failure rate of the Amine Swingbed as a whole. I have determined a mean time to failure for the Amine Swingbed to be approximately 1,400 hours. The observed mean time to failure for the system is between 600 and 1,200 hours. This range includes initial testing of the Amine Swingbed, as well as software faults that are understood to be non-critical. If many of the commercial parts were switched to military-grade parts, the expected mean time to failure would be 2,300 hours. Both calculated mean times to failure for the Amine Swingbed use conservative failure rate models. The observed mean time to failure for CDRA is 2,500 hours. Working on this project and for NASA in general has helped me gain insight into current aeronautics missions, reliability engineering, circuit analysis, and different cultures. Prior my internship, I did not have a lot knowledge about the work being performed at NASA. As a chemical engineer, I had not really considered working for NASA as a career path. By engaging in interactions with civil servants, contractors, and other interns, I have learned a great deal about modern challenges that NASA is addressing. My work has helped me develop a knowledge base in safety and reliability that would be difficult to find elsewhere. Prior to this internship, I had not thought about reliability engineering. Now, I have gained a skillset in performing reliability analyses, and understanding the inner workings of a large mechanical system. I have also gained experience in understanding how electrical systems work while I was analyzing the electrical components of the Amine Swingbed. I did not expect to be exposed to as many different cultures as I have while working at NASA. I am referring to both within NASA and the Houston area. NASA employs individuals with a broad range of backgrounds. It has been great to learn from individuals who have highly diverse experiences and outlooks on the world. In the Houston area, I have come across individuals from different parts of the world. Interacting with such a high number of individuals with significantly different backgrounds has helped me to grow as a person in ways that I did not expect. My time at NASA has opened a window into the field of aeronautics. After earning a bachelor's degree in chemical engineering, I plan to go to graduate school for a PhD in engineering. Prior to coming to NASA, I was not aware of the graduate Pathways program. I intend to apply for the graduate Pathways program as positions are opened up. I would like to pursue future opportunities with NASA, especially as my engineering career progresses.

Dunbar, Tyler↗

Reliability and life prediction of ceramic composite structures at elevated temperatures

Methods are highlighted that ascertain the structural reliability of components fabricated of composites with ceramic matrices reinforced with ceramic fibers or whiskers and subject to quasi-static load conditions at elevated temperatures. Each method focuses on a particular composite microstructure: whisker-toughened ceramics, laminated ceramic matrix composites, and fabric reinforced ceramic matrix composites. In addition, since elevated service temperatures usually involve time-dependent effects, a section dealing with reliability degradation as a function of load history has been included. A recurring theme throughout this chapter is that even though component failure is controlled by a sequence of many microfailure events, failure of ceramic composites will be modeled using macrovariables.

Duffy, Stephen F.↗

Investigation of Desiccants and CO2 Sorbents for Advanced Exploration Systems 2015-2016

Advanced Environmental Control and Life Support System (ECLSS) design is critical for human space flight beyond Earth. Current systems enable extended missions in low-Earth orbit, but for deep-space missions, not only will astronauts be outside the reach of resupply operations from Earth but they will also need to handle malfunctions and compensate for the degradation of materials. These two daunting challenges must be overcome for long-term independent space flight. In order to solve the first, separation and reuse of onboard atmosphere components is required. Current systems utilize space vacuum to fully regenerate adsorbent beds, but this is not sustainable thus necessitating a closed-loop system. The second challenge stems from material and performance degradation due to operational cycling and on-board contaminants. This report will review the recent work by the ECLSS team at Marshall Space Flight Center towards overcoming these challenges by characterizing materials via novel methods for use in future systems.

Cmarik, Gregory E.↗

Development of Laser Powder Bed Fusion NASA HR-2 for Hydrogen Sensitive Liquid Rocket Engine Applications

The National Aeronautics and Space Administration (NASA) has been involved in the development and maturation of metal additive manufacturing (AM) for space applications since the late 2000s. AM has provided new design and manufacturing opportunities to reduce cost and schedule, consolidate parts, and optimize performance. Laser Powder Bed Fusion (L-PBF) is one of the most commonly used AM processes to fabricate components of complex shape requiring fine feature resolution. Due to exposure to high-pressure gaseous hydrogen, mechanical property degradation caused by hydrogen environment embrittlement (HEE) is a critical concern for many materials in liquid hydrogen propulsion systems. NASA has identified the need to develop and advance new materials in unique engine applications using liquid hydrogen as a propellant. One such material being developed at NASA Marshall Space Flight Center is L-PBF NASA HR-2 (Hydrogen Resistant-2), a high-strength Fe-Ni-based superalloy resistant to HEE. The chemistry of NASA HR-2 was formulated to meet requirements for key liquid rocket engine (LRE) components that operate in high-pressure hydrogen environments. Initial development and material characterization found that NASA HR-2 has excellent L-PBF printability, and its microstructure evolves well after heat treatment. This new alloy has undergone fundamental metallurgical evaluations, heat treatment studies, detailed microstructure characterization, and mechanical testing across a range of temperatures. Tensile testing was performed in a pressurized gaseous hydrogen (GH2) environment to assess its resistance to HEE. L-PBF NASA HR-2 has an average yield stress of 95 ksi, an ultimate tensile stress of 165 ksi, and a very high fracture elongation of 34 - 36% when tested in a high-pressure (5 ksi) hydrogen environment. The tensile property data confirms hydrogen has little influence on HR-2’s ductility, strength, and fracture behavior. L-PBF NASA HR-2 is a promising option for many hydrogen-sensitive LRE components that require exceptional resistance to HEE. This paper will provide an overview of the L-PBF process development, material characterization, mechanical and thermophysical properties, and LRE hardware development for NASA HR-2.

Po S Chen↗

Prognostics Approach for Power MOSFET Under Thermal-Stress

The prognostic technique for a power MOSFET presented in this paper is based on accelerated aging of MOSFET IRF520Npbf in a TO-220 package. The methodology utilizes thermal and power cycling to accelerate the life of the devices. The major failure mechanism for the stress conditions is dieattachment degradation, typical for discrete devices with leadfree solder die attachment. It has been determined that dieattach degradation results in an increase in ON-state resistance due to its dependence on junction temperature. Increasing resistance, thus, can be used as a precursor of failure for the die-attach failure mechanism under thermal stress. A feature based on normalized ON-resistance is computed from in-situ measurements of the electro-thermal response. An Extended Kalman filter is used as a model-based prognostics techniques based on the Bayesian tracking framework. The proposed prognostics technique reports on preliminary work that serves as a case study on the prediction of remaining life of power MOSFETs and builds upon the work presented in [1]. The algorithm considered in this study had been used as prognostics algorithm in different applications and is regarded as suitable candidate for component level prognostics. This work attempts to further the validation of such algorithm by presenting it with real degradation data including measurements from real sensors, which include all the complications (noise, bias, etc.) that are regularly not captured on simulated degradation data. The algorithm is developed and tested on the accelerated aging test timescale. In real world operation, the timescale of the degradation process and therefore the RUL predictions will be considerable larger. It is hypothesized that even though the timescale will be larger, it remains constant through the degradation process and the algorithm and model would still apply under the slower degradation process. By using accelerated aging data with actual device measurements and real sensors (no simulated behavior), we are attempting to assess how such algorithm behaves under realistic conditions.

Power MOSFET PHM↗

The 6670-Newton attitude-control thruster using hydrogen-oxygen propellant

The development of a reusable, attitude-control propulsion system for the space transportation system is discussed. A flight weight, gaseous oxygen attitude control thruster assembly was tested to obtain data on cyclic life, thermal and hydraulic characteristics, pulse response, and performance. The basic thruster components were tested in excess of 51,000 pulses and 660 seconds, steady state, with no degradation of the 93 percent characteristic exhaust velocity efficiency level. Nominal operating conditions were a chamber pressure of 207 N sq cm (300 psia), a mixture ratio of 4.0, a pulse width of 100 ms, and a pulse frequency of 2 Hz.

Gordon, L. H.↗

Damage and Repair of Composite Structures

NASA technical memorandum reports on research in damage and repair of composite-material structures of types used in airplane. Research includes: Identifying defect areas, determining whether particular kind of damage weakens structure in manner that degrades performance in intended application, developing repair procedures, and testing to demonstrate given repair procedure enables component to serve during remainder of its design life.

Deaton, J. W.↗

Space vehicle thermal testing: Principles, practices and effectiveness

Component qualification and acceptance temperatures are derived from worst case thermal analyses and analytic uncertainty margin subject to certain specified temperature extremes. Temperature requirements are shown for equipment operation within specification and for survival and turn-on (need not operate within specification, but must not experience any degradation when returned to operational range). Temperature excursions for most equipment are seen to be 20 to 50 C above and below room temperature. Components without active electronics which are mounted outboard, such as solar arrays and antennas, are usually designed to withstand wider temperature excursions, particularly at the cold end. Batteries are tightly controlled at cold temperatures to increase life. Payload components such as extremely accurate clocks for precise navigation are controlled over a relatively narrow temperature range.

Gluck, Donald F.↗

Adaptation of NASA technology for the optimization of orthopedic knee implants

The NASA technology originally developed for the optimization of composite structures (engine blades) is adapted and applied to the optimization of orthopedic knee implants. A method is developed enabling the tailoring of the implant for optimal interaction with the environment of the tibia. The shape of the implant components are optimized, such that the stresses in the bone are favorably controlled to minimize bone degradation and prevent failures. A pilot tailoring system is developed and the feasibility of the concept is elevated. The optimization system is expected to provide the means for improving knee prosthesis and individual implant tailoring for each patient.

Saravanos, D. A.↗

Shortcomings in ground testing, environment simulations, and performance predictions for space applications

This paper addresses the issues involved in radiation testing of devices and subsystems to obtain the data that are required to predict the performance and survivability of satellite systems for extended missions in space. The problems associated with space environmental simulations, or the lack thereof, in experiments intended to produce information to describe the degradation and behavior of parts and systems are discussed. Several types of radiation effects in semiconductor components are presented, as for example: ionization dose effects, heavy ion and proton induced Single Event Upsets (SEUs), and Single Event Transient Upsets (SETUs). Examples and illustrations of data relating to these ground testing issues are provided. The primary objective of this presentation is to alert the reader to the shortcomings, pitfalls, variabilities, and uncertainties in acquiring information to logically design electronic subsystems for use in satellites or space stations with long mission lifetimes, and to point out the weaknesses and deficiencies in the methods and procedures by which that information is obtained.

Stassinopoulos, E. G.↗

NASA's flight-technological development program - A 650 Mbps laser communications testbed

A 650 Mbps laser communications testbed under construction for the development of flight qualifiable hardware suitable for near-term operation on geosynchronous-to-geosynchronous crosslink missions is presented. The program's primary purpose is to develop and optimize laser communications unique subsystems. Requirements for the testbed experiments are to optimize the acquisition processes, to fully simulate the long range (up to 21,000 km) and the fine tracking characteristics of two narrow-beam laser communications terminals, and to fully test communications performance which will include average and burst bit error rates, effects of laser diode coalignment, degradation due to internal and external stray light, and the impact of drifts in the optical components.

Hayden, W. L.↗

Viscoelastic properties of pressure overload hypertrophied myocardium: effect of serine protease treatment

To determine whether and to what extent one component of the extracellular matrix, fibrillar collagen, contributes causally to abnormalities in viscoelasticity, collagen was acutely degraded by activation of endogenous matrix metalloproteinases (MMPs) with the serine protease plasmin. Papillary muscles were isolated from normal cats and cats with right ventricular pressure overload hypertrophy (POH) induced by pulmonary artery banding. Plasmin treatment caused MMP activation, collagen degradation, decreased the elastic stiffness constant, and decreased the viscosity constant in both normal and POH muscles. Thus, whereas many mechanisms may contribute to the abnormalities in myocardial viscoelasticity in the POH myocardium, changes in fibrillar collagen appear to play a predominant role.

NASA Discipline Cardiopulmonary↗

Corrosion Issues for Ceramics in Gas Turbines

The requirements for hot-gas-path materials in gas turbine engines are demanding. These materials must maintain high strength and creep resistance in a particularly aggressive environment. A typical gas turbine environment involves high temperatures, rapid gas flow rates, high pressures, and a complex mixture of aggressive gases. Over the past forty years, a wealth of information on the behavior of ceramic materials in heat engine environments has been obtained. In the first part of the talk we summarize the behavior of monolithic SiC and Si3N4. These materials show excellent baseline behavior in clean, oxygen environments. However the aggressive components in a heat engine environment such as water vapor and salt deposits can be quite degrading. In the second part of the talk we discuss SiC-based composites. The critical issue with these materials is oxidation of the fiber coating. We conclude with a brief discussion of future directions in ceramic corrosion research.

Jacobson, Nathan↗

Processing-Related Issues for the Design and Lifing of SiC/SiC Hot-Section Components

For successful SiC/SiC engine components, numerous process steps related to the fiber, fiber architecture, interphase coating, and matrix need to be optimized. Under recent NASA-sponsored programs, it was determined that many of these steps in their initial approach were inadequate, resulting in less than optimum thermostructural and life properties for the as-fabricated components. This presentation will briefly review many of these process issues, the key composite properties they degrade, their underlying mechanisms, and current process remedies developed by NASA and others.

DiCarlo, J.↗

A Study of the Degradation of Electronic Speed Controllers for Brushless DC Motors

Brushless DC motors are frequently used in electric aircraft and other direct drive applications. As these motors are notactually direct current machines but synchronous alternating current machines; they are electronically commutated by a power inverter. The power inverter for brushless DC motors typically used in small scale UAVs is a semiconductor base delectronic commutator that is external to the motor and is referred to as an electronic speed control (ESC). This paper examines the performance changes of a UAV electric propulsion system resulting from ESC degradation. ESC performance is evaluated in simulation and on a new developed test bed featuring propulsion components from a reference UAV. An increase in the rise fall times of the switched voltages is expected to cause timing issues at high motor speeds. This study paves the way for further development of diagnostic and prognostic methods for inverter circuits which are part of the overall electric UAV system.

Gorospe, George E., Jr.↗

Dust Mitigation Technology to Enable Survive the Night Capabilities

Introduction: As we return to the Moon, the lunar regolith (i.e. lunar dust) covering the surface will be an obstacle to nominal operations. Accounts from Apollo astronauts and analysis of hardware returned from the surface illustrate just how deleterious the dust can be [1]. During Apollo missions, the lunar dust adhered to hardware mechanically and electrostatically [2]. Surviving the Night: Mitigating the lunar dust will be critical to surviving the night. Going hand-in-hand with other extreme environment considerations, dust mitigation is critical to mission success. Dust Impacts on Other Systems: The lunar dust can have negative implications for power, thermal, mechanisms, and several other systems or sub-systems. For example, Apollo encountered marked degradation of performance in heat rejection systems for the lunar roving vehicle, science packages, and other components because of the lunar dust [1]. For power alone, dust can cause internal clogging for power connectors, heat rejection issues, excessive dust on reflective surfaces, reduced power output for solar arrays, and so on. Dust Mitigation Strategy: In addition to considering technology solutions, it is important for hardware, systems, and or components to have a dust mitigation strategy. At a high level, hardware that will encounter the lunar dust should consider these things when defining a dust mitigation strategy: • Understand Natural Environment • Understand Induced Environment • Understand Tolerance to Dust • Write Dust Requirements • Select Dust Mitigation Solutions • Test Hardware in Dusty Environment More information on each of these can be provided to hardware owners. Dust Mitigation Technology Development: NASA has a series of technologies that may be available for hardware that needs to survive the lunar night. Many of these solutions are leveraging dust mitigation technology development efforts from NASA’s Space Technology Mission Directorate (STMD), as well as efforts from ESDMD programs, industry, and academia. Through a series of STMD programs (both internal to NASA and through partnerships), there are several technologies in development as considerations as dust mitigation solutions for hardware. Within STMD, the Game Changing Development Program (GCD) has funded several internal dust mitigation projects including low to mid TRL development, demonstrations on CLPS landers of high TRL solutions, and creating standards and best practices for dust mitigation. STMD dust mitigation efforts also include a series of partnerships for developing technologies and advancing the state of dust mitigation at NASA. This includes the Lunar Surface Innovation Consortium (LSIC), Small Business Innovation Research, Early Stage Innovations (ESI), Space Technology Research Grants (STRG), Announcement of Collaboration Opportunities (ACOs) and Tipping Points (TPs), and Challenges and Crowdsourcing, among others. There are also a series of dust mitigation solutions that have been widely used terrestrially, or during Apollo. In recent years, several studies have produced more data on the efficacy of these potential solutions in the lunar environment. Dust Mitigation Solutions: Dust mitigation solutions generally fall into four categories: • Dust Tolerant Mechanisms • Passive Dust Mitigation Capabilities • Active Dust Mitigation Capabilities • Dust Measurement Capabilities There are a series of solutions that may prove beneficial for hardware that needs to survive the lunar night, including new technology development as well as proven, terrestrial solutions. This presentation will discuss in more detail what some of these solutions are for payloads going to the surface. References: [1] J. R. Gaier, NASA/TM—2005-213610, The Effects of Lunar Dust on EVA Systems During the Apollo Missions [2] T. J. Stubbs, et al. Impact of Dust on Lunar Exploration, 2005

dust mitigation↗