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NASA NTRSDate not supplied

Summary of NASA Progress on the Development and Qualification of a 12-kW Hall-Effect, Solar Electric Propulsion Thruster

Beginning in 2014, the National Aeronautics and Space Administration (NASA) Space Technology Mission Directorate (STMD) began a project to increase the state of the art for the Hall-Effect Solar Electric Propulsion (SEP) technology. The Technology Demonstration Missions (TDM) Program Office provides programmatic oversight of SEP with the project being led by Glenn Research Center, supported by the Jet Propulsion Laboratory and development, qualification & flight hardware all provided by Aerojet Rocketdyne (AR). This technology was pursued as the propulsion system for the Asteroid Redirect and Robotic Mission (ARRM). While the concept was originally slated for ARRM, it was realigned to Gateway to support future Moon to Mars objectives. The Gateway lunar station was established and will play a key role in NASA’s Artemis Program which utilizes collaboration with the Canadian Space Agency (CSA), the European Space Agency (ESA) and the Japanese Space Agency (JAXA). The 12-kW hardware will be the primary propulsion for the Gateway element, Power & Propulsion Element (PPE), from Low Earth Orbit to a Near Rectilinear Halo Orbit around the Moon. Initial efforts began with utilizing Technology Development Units (TDU) built by NASA as the predecessor to the contract activity with AR. Over the past few years, AR has built Engineering Test Units (ETU), Engineering Development Units (EDU) and qualification & flight models (QM and FM, respectively). With requirement changes from the AARM mission to PPE, the joint team has modified the design and has started qualification activities for environment testing (shock, vibe) at multiple facilities in the US leading to eventual life testing. This paper will explore the various design changes, system modeling and the latest status for qualification testing.

Joel Robinson↗

NASA NTRSDate not supplied

Summary of NASA Progress on the Development and Qualification of a 12 kW Hall Effect, Solar Electric Propulsion Thruster

Joel W Robinson↗

DOE OSTI2024

Silicon Carbide Composite Cladding Qualification

This report examines the process to qualify a new fuel-cladding type focusing on the data requirements and types of irradiation testing necessary to meet the regulatory burden and related guidance applicable to fuel qualification of accident-tolerant fuel. The report considers the use of accelerated fuel qualification techniques and lead-test specimen programs that may shorten the timeline for qualifying fuel for use in a nuclear reactor at the desired burnup. The assessment framework particularly emphasizes the identification of key fuel manufacturing parameters, the specification of a fuel performance envelope to inform testing requirements, the use of evaluation models in the fuel qualification process, and the assessment of the experimental data used to develop and validate the empirical models and empirical safety criteria.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

NASA NTRS2011

Qualification of Bonding Process of Temperature Sensors to Extreme Temperature Deep Space Missions

A process has been explored based on the state-of-the-art technology to bond the platinum resistance thermometer (PRT) on to potential aerospace material such as a flat aluminum surface and a flexible copper tube to simulate coaxial cable for the flight applications. Primarily, PRTs were inserted into a metal plated copper braid to avoid stresses on the sensor while attaching the sensor with braid to the base material for long duration deep space missions. Appropriate pretreatment has been implemented in this study to enhance the adhesion of the PRTs to the base material. NuSil product has been chosen in this research to attach PRT to the base materials. The resistance (approx.1.1 k(Omega)) of PRTs has been electrically monitored continuously during the qualification thermal cycling testing from -150 C to +120 C and -100 C to -35 C. The test hardware has been thermal cycled three times the mission life per JPL design principles for JUNO project. No PRT failures were observed during and after the PRT thermal cycling qualification test for extreme temperature environments. However, there were some failures associated with staking of the PRT pig tails as a result of thermal cycling qualification test.

Extreme temperatures↗

NASA NTRS2013

A Motor Drive Electronics Assembly for Mars Curiosity Rover: An Example of Assembly Qualification for Extreme Environments

In this paper, the technology development and infusion of the motor drive electronics assembly, along with the technology qualification and space qualification, is described and detailed. The process is an example of the qualification methodology for extreme environmen

electronics↗

DOE OSTI2025

An Evaluation and Qualification of U.S.-Based Research Reactors for Irradiation Capabilities Supporting Advanced Nuclear Systems

Irradiation experiments are a prerequisite for evaluating nuclear reactor system designs, analyzing the performance of these systems, and obtaining licenses. Likewise, irradiation facilities are necessary for producing the radioisotopes used in industrial and medical applications. Recent developments in modeling and simulation capabilities and advancements in computational resources have further enabled the design of irradiation experiments for evaluating radiation-induced phenomena and determining nuclear fuel, material, and system design and safety criteria pertaining to both normal and accident scenarios. These computational tools and models require comprehensive experimental datasets acquired under prototypic radiation conditions—for exploring material and system performance under the uniquely harsh environments found in nuclear reactors—to enable verification and validation for qualification and licensing purposes. However, qualification of irradiation experimental facilities, primarily research and test reactors (RTRs), necessitates that their performance be evaluated based on the irradiation environment (e.g. flux, power, testing capabilities) using an appropriate scoring matrix. Although many university campus RTRs are available for research and development (R&D) activities and initiatives, this study focuses on evaluating and qualifying the irradiation facilities (mostly RTRs) within the United States that are suitable for advanced nuclear fuel, material, and system irradiation experiments aimed at establishing operational-performance limits and informing component and fuel designs so as to improve operational efficiencies and mitigate proliferation vulnerabilities, as well as for radioisotope production aimed at multipurpose applications. As a result, the findings of the present study support the acceleration of nuclear fuel and material qualifications, thus hastening new and advanced nuclear energy system demonstrations and radioisotope production efforts by using extended R&D.

irradiation experiment↗

DOE OSTI2024

Accelerated Irradiation and Qualification of Ceramic Nuclear Fuels

Accelerated irradiation efforts are an important topic in accelerated qualification of new nuclear fuel concepts for light water reactor (LWRs), microreactors, and other special purpose reactors. Accelerated fuel qualification combines both experimental and modeling work to expedite the total qualification time from approximately 20-25 years to 5-10 years timeframe. The scope covered under the current work package focuses on the experimental contributions for the neutron irradiations. Accelerated irradiation aims to reduce the total time needed for neutron irradiation to achieve targeted burnup, which is timely using conventional irradiation profiles. The purpose of this report is to detail the samples preparation for such irradiations, which contain standard, medium, and large grain undoped UO 2 , as well as large grain, Cr 2 O 3 -doped UO 2 . The data that will be generated from the irradiation of these samples will yield important information regarding fission gas retention as a function of grain size and the effect that Cr dopants have on diffusivity of fission gases.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2024

Updated ASME design correlations and qualification plan for powder bed fusion 316H stainless steel

This report provides an update on the Advanced Materials and Manufacturing Technologies (AMMT) program effort to qualify Laser-Powder Bed Fusion (L-PBF) 316H stainless steel for use with the ASME Boiler & Pressure Vessel Code Section III, Division 5 rules. The report summarizes progress in testing and characterizing L-PBF material at elevated temperatures by providing preliminary design data for L-PBF 316H and by comparing the elevated temperature performance of the L-PBF material to wrought and conventional fusion welded 316H. The report then updates the initial AMMT qualification plan for L-PBF 316H, originally developed in 2023, to update the accelerated qualification strategy adopted in that plan to account for the new high temperature test data. The report also explores a few methods for further accelerating the qualification process using machine learning techniques to supplement the more conventional, empirical analysis methods typically used by ASME to correlate and extrapolate time-dependent material test data.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Automated qualification data tool for high temperature metallic materials

This report describes a framework for storing, processing, and displaying qualification data for high temperature mechanical properties. The framework automates the process of generating design data from mechanical test results, for example for a data qualification report for the ASME Boiler \& Pressure Vessel Code. The framework has three parts: a data storage model with common formats for several types of typical mechanical property tests, a backend based on the \pycreep Python library for correlating and extrapolating the data to generate design material properties and allowable stresses, and a demonstration user interface for displaying, sorting, and filtering the data and exploring different options for modeling the design mechanical properties. The report discusses the options available for data processing, with illustrations from real test data on Alloy 617, Alloy 709, Alloy 740H, and Laser-Powder Bed Fusion 316H. The framework is complete for ASME type data analysis and will be used to store test data generated by the Department of Energy, Office of Nuclear Energy, Advanced Materials and Manufacturing Technologies sponsored qualification programs. Future work could extend the tool to other types of material properties and/or expand the demo user interface to make it accessible across the AMMT program.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Feature Based Qualification of 17-4PH Stainless Steel to Evaluate Location-Specific Variability in Wire Arc Additive Manufacturing

Qualifying large-scale metal additive manufacturing (M-AM) technologies such as wire arc additive manufacturing (WAAM) can be challenging. This is especially significant in precipitation hardened martensitic stainless steels like SS 17-4PH, where thermal histories induce location-specific microstructural variability and property anisotropy. The Department of Defense (DOD) and the United States Army Combat Capabilities Development Command Ground Vehicle Systems Center (GVSC) Ground Vehicle Materials Engineering (GVME) aim to build robust and qualified large-scale M-AM workflows that could reduce the time and cost through quick and informed evaluation, testing, and development of feedstock, processes, and parts. The report presents the findings from the collaborative efforts between Oak Ridge National Laboratory (ORNL) and the U.S. Army GVSC GVME. The aim of this project was to develop a geometric feature-based qualification framework for WAAM of SS 17-4PH components. This report outlines selection methodology of representative build geometries, optimization of WAAM process parameters, in-situ monitoring, microstructure-property evaluation, thermal simulations, as well as data visualization techniques incorporated in this project. The results from this project demonstrate a clear understanding of thermal history dependent phase evolution and consequent location-specific property variations in WAAM of SS 17-4PH. These results in conjunction with the data-driven methodologies used in this project are expected to reduce qualification timelines, improve predictability, and accelerate the development of reliable feature-based qualification strategies for part production via large-scale M-AM technologies.

36 MATERIALS SCIENCE↗

NASA NTRS1983

Qualification of the flight-critical AFTI/F-16 digital flight control system

Qualification considerations for assuring the safety of a life-critical digital flight control system include four major areas: systems interactions, verification, validation, and configuration control. The AFTI/F-16 design, development, and qualification illustrate these considerations. In this paper, qualification concepts, procedures, and methodologies are discussed and illustrated through specific examples.

Mackall, D. A.↗

NASA NTRS1983

Qualification testing for a central station

Qualification testing for a Central Station Photovoltaic (PV) Facility depends to a great extent on the system design, (fixed versus tracking), and the level of data acquisition/control which is incorporated into the system. The basic elements which require qualification tests include: dc power production/collection; tracker conversion systems; ac utility interface; system level control; and data acquisition/reporting. The qualification tests from the Lungo (ARCO) 1 MW Facility which were completed in January 1983 are discussed. The philosophy and many of the procedures are applicable to any central station PV facility.

Forrester, D. L.↗

NASA NTRS1994

Role of Wind Tunnels and Computer Codes in the Certification and Qualification of Rotorcraft for Flight in Forecast Icing

The cost and time to certify or qualify a rotorcraft for flight in forecast icing has been a major impediment to the development of ice protection systems for helicopter rotors. Development and flight test programs for those aircraft that have achieved certification or qualification for flight in icing conditions have taken many years, and the costs have been very high. NASA, Sikorsky, and others have been conducting research into alternative means for providing information for the development of ice protection systems, and subsequent flight testing to substantiate the air-worthiness of a rotor ice protection system. Model rotor icing tests conducted in 1989 and 1993 have provided a data base for correlation of codes, and for the validation of wind tunnel icing test techniques. This paper summarizes this research, showing test and correlation trends as functions of cloud liquid water content, rotor lift, flight speed, and ambient temperature. Molds were made of several of the ice formations on the rotor blades. These molds were used to form simulated ice on the rotor blades, and the blades were then tested in a wind tunnel to determine flight performance characteristics. These simulated-ice rotor performance tests are discussed in the paper. The levels of correlation achieved and the role of these tools (codes and wind tunnel tests) in flight test planning, testing, and extension of flight data to the limits of the icing envelope are discussed. The potential application of simulated ice, the NASA LEWICE computer, the Sikorsky Generalized Rotor Performance aerodynamic computer code, and NASA Icing Research Tunnel rotor tests in a rotorcraft certification or qualification program are also discussed. The correlation of these computer codes with tunnel test data is presented, and a procedure or process to use these methods as part of a certification or qualification program is introduced.

Flemming, Robert J.↗

NASA NTRS1994

Development and qualification testing of a laser-ignited, all-secondary (DDT) detonator

The Indian Head Division, Naval Surface Warfare Center (IHDIV, NSWC) is conducting a qualification program for a laser-ignited, all-secondary (DDT) explosive detonator. This detonator was developed jointly by IHDIV, NSWC and the Department of Energy's EG&G Mound Applied Technologies facility in Miamisburg, Ohio to accept a laser initiation signal and produce a fully developed shock wave output. The detonator performance requirements were established by the on-going IHDIV, NSWC Laser Initiated Transfer Energy Subsystem (LITES) advanced development program. Qualification of the detonator as a component utilizing existing military specifications is the selected approach for this program. The detonator is a deflagration-to-detonator transfer (DDT) device using a secondary explosive, HMX, to generate the required shock wave output. The prototype development and initial system integration tests for the LITES and for the detonator were reported at the 1992 International Pyrotechnics Society Symposium and at the 1992 Survival and Flight Equipment National Symposium. Recent results are presented for the all-fire sensitivity and qualification tests conducted at two different laser initiation pulses.

Blachowski, Thomas J.↗

NASA NTRS1998

Integrated Advanced Microwave Sounding Unit-A (AMSU-A). Engineering Test Report: AMSU-A1 EOS Instrument, (S/N 202) Qualification Level Vibration Tests of August/September 1998, (S/O 565632, OC-417) Plus Addendum A

The purpose of this report is to present a qualification level vibration testing performed on the S/N 202, EOS AMSU-A1 Instrument was vibration tested to qualification levels per the Ref. 1 shop order. The instrument withstood the 8 g sine sweep test, the 7.5 Grms random vibration test, and the 18.75 g sine burst test in each of the three orthogonal axes. Some loss of transmissibility, however, is seen in the lower reflector after Z-axis random vibration. The test sequence was not without incidence. Failure of Channel 7 in the Limited Performance Test (LPT) performed after completion of the 1 st (X-axis) axis vibration sequence, required replacement of the DRO and subsequent re-testing of the instrument. The post-vibration comprehensive performance test (CPT) was successfully run after completion of the three axes of vibration with the replacement component installed in the instrument. Passing the CPT signified the successful completion of the S/N 202 A1 qualification vibration testing.

Heffer, R.↗

NASA NTRS2006

Sensor Data Qualification for Autonomous Operation of Space Systems

NASA's new Exploration initiative for both robotic and manned missions will require higher levels of reliability, autonomy and reconfiguration capability to make the missions safe, successful and affordable. Future systems will require diagnostic reasoning to assess the health of the system in order to maintain the system s functionality. The diagnostic reasoning and assessment will involve data qualification, fault detection, fault isolation and remediation control. A team of researchers at the NASA Glenn Research Center is currently working on a Sensor Data Qualification (SDQ) system that will support these critical evaluation processes, for both automated and human-in-the-loop applications. Data qualification is required as a first step so that critical safety and operational decisions are based on good data. The SDQ system would monitor a network of related sensors to determine the health of individual sensors within that network. Various diagnostic systems such as the Caution and Warning System would then use the sensor health information with confidence. The proposed SDQ technology will be demonstrated on a variety of subsystems that are relevant to NASA s Exploration systems, which currently include an electrical power system and a cryogenic fluid management system. The focus of this paper is the development and demonstration of a SDQ application for a prototype power distribution unit that is representative of a Crew Exploration Vehicle electrical power system; this provides a unique and relevant environment in which to demonstrate the feasibility of the SDQ technology.

Maul, William A.↗

NASA NTRS2004

Qualification and Reliability for MEMS and IC Packages

Advanced IC electronic packages are moving toward miniaturization from two key different approaches, front and back-end processes, each with their own challenges. Successful use of more of the back-end process front-end, e.g. microelectromechanical systems (MEMS) Wafer Level Package (WLP), enable reducing size and cost. Use of direct flip chip die is the most efficient approach if and when the issues of know good die and board/assembly are resolved. Wafer level package solve the issue of known good die by enabling package test, but it has its own limitation, e.g., the I/O limitation, additional cost, and reliability. From the back-end approach, system-in-a-package (SIAP/SIP) development is a response to an increasing demand for package and die integration of different functions into one unit to reduce size and cost and improve functionality. MEMS add another challenging dimension to electronic packaging since they include moving mechanical elements. Conventional qualification and reliability need to be modified and expanded in most cases in order to detect new unknown failures. This paper will review four standards that already released or being developed that specifically address the issues on qualification and reliability of assembled packages. Exposures to thermal cycles, monotonic bend test, mechanical shock and drop are covered in these specifications. Finally, mechanical and thermal cycle qualification data generated for MEMS accelerometer will be presented. The MEMS was an element of an inertial measurement unit (IMU) qualified for NASA Mars Exploration Rovers (MERs), Spirit and Opportunity that successfully is currently roaring the Martian surface

inertial measurement unit↗

NASA NTRS2005

Qualification Strategies of Field Programmable Gate Arrays (FPGAs) for Space Application

This viewgraph document reviews the issue of using Field Programmable Gate Arrays (FPGAs) in Space Application, and the some of the strategies for qualifying the FPGA. Qualification and risk management of such complex systems requires new approaches. The paper presents a matrix approach to qualification has been presented that: - Complements historical specifications - Highlights the importance of device physics as a cornerstone to qualification. - Provides levels of risk management that expressly document trade offs. - Stresses the role of the FPGA vendor as team member in the development of modern spacecraft.

Mil Standard 883↗