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NASA NTRS2011

Component-Level Electronic-Assembly Repair (CLEAR) System Architecture

This document captures the system architecture for a Component-Level Electronic-Assembly Repair (CLEAR) capability needed for electronics maintenance and repair of the Constellation Program (CxP). CLEAR is intended to improve flight system supportability and reduce the mass of spares required to maintain the electronics of human rated spacecraft on long duration missions. By necessity it allows the crew to make repairs that would otherwise be performed by Earth based repair depots. Because of practical knowledge and skill limitations of small spaceflight crews they must be augmented by Earth based support crews and automated repair equipment. This system architecture covers the complete system from ground-user to flight hardware and flight crew and defines an Earth segment and a Space segment. The Earth Segment involves database management, operational planning, and remote equipment programming and validation processes. The Space Segment involves the automated diagnostic, test and repair equipment required for a complete repair process. This document defines three major subsystems including, tele-operations that links the flight hardware to ground support, highly reconfigurable diagnostics and test instruments, and a CLEAR Repair Apparatus that automates the physical repair process.

Oeftering, Richard C.↗

NASA NTRS2013

Integrated Electrical Wire Insulation Repair System

An integrated system tool will allow a technician to easily and quickly repair damaged high-performance electrical wire insulation in the field. Low-melt polyimides have been developed that can be processed into thin films that work well in the repair of damaged polyimide or fluoropolymer insulated electrical wiring. Such thin films can be used in wire insulation repairs by affixing a film of this low-melt polyimide to the damaged wire, and heating the film to effect melting, flow, and cure of the film. The resulting repair is robust, lightweight, and small in volume. The heating of this repair film is accomplished with the use of a common electrical soldering tool that has been modified with a special head or tip that can accommodate the size of wire being repaired. This repair method can furthermore be simplified for the repair technician by providing replaceable or disposable soldering tool heads that have repair film already "loaded" and ready for use. The soldering tool heating device can also be equipped with a battery power supply that will allow its use in areas where plug-in current is not available

Williams, Martha↗

DOE OSTI2024

Using Additive Manufacturing to Repair Gas Turbine Hot Section Components

Ni-based superalloys are used in the hot sections of gas turbine engines due to their excellent high temperature performance. During service the material degrades due to exposure at high temperature and mechanical loads. Hence, utility provides often inspect, service, and repair components in gas turbine engines to ensure safe operation. A major challenge, however, is that the most heat-resistant alloys are generally considered ‘non-weldable’ rendering them difficult to repair via welding operations. In these cases components are often scrapped and then replaced by parts which must be re-manufactured. This burdens utilities with additional cost and supply chain issues can result in long term outages or reduced operating limtis. In this work EPRI and ORNL investigated a proposed repair strategy for gas turbine hot section components. Hot section superalloy GTD-111 was selected as a candidate repair material system and AM material ABD-900 the repair material. Sandwich structures were fabricated via electron beam melting additive manufacturing (EBM-AM) producing tensile bars with gage sections consisting of dissimilar ABD-900 / GTD-111 / ABD-900 material. Metallography revealed that the interface exhibited no deleterious phases or processing defeats. Creep rupture experiments on heat treated material demonstrates that the emulated repair coupons exhibit creep resistance between GTD-111 and ABD-900. This study demonstrates that the proposed EBM-AM repair strategy presents a viable opportunity towards enabling AM repair of gas turbine engine components.

99 GENERAL AND MISCELLANEOUS↗

DOE OSTI2024

Using Additive Manufacturing to Repair Gas Turbine Hot Section Components

Ni-based superalloys are used in the hot sections of gas turbine engines due to their excellent high temperature performance. During service the material degrades due to exposure at high temperature and mechanical loads. Hence, utility provides often inspect, service, and repair components in gas turbine engines to ensure safe operation. A major challenge, however, is that the most heat-resistant alloys are generally considered ‘non-weldable’ rendering them difficult to repair via welding operations. In these cases components are often scrapped and then replaced by parts which must be re-manufactured. This burdens utilities with additional cost and supply chain issues can result in long term outages or reduced operating limits. In this work EPRI and ORNL investigated a proposed repair strategy for gas turbine hot section components. Hot section superalloy GTD-111 was selected as a candidate repair material system and AM material ABD-900 the repair material. Sandwich structures were fabricated via electron beam melting additive manufacturing (EBM-AM) producing tensile bars with gage sections consisting of dissimilar ABD-900 / GTD-111 / ABD-900 material. Metallography revealed that the interface exhibited no deleterious phases or processing defeats. Creep rupture experiments on heat treated material demonstrates that the emulated repair coupons exhibit creep resistance between GTD-111 and ABD-900. This study demonstrates that the proposed EBM-AM repair strategy presents a viable opportunity towards enabling AM repair of gas turbine engine components.

36 MATERIALS SCIENCE↗

NASA NTRS1974

Design, manufacture, development, test, and evaluation of boron/aluminum structural components for space shuttle. Volume 4: Repairability

The repairability of boron/aluminum structural components was investigated. It was demonstrated that metal matrix composite material, damaged in service, can be repaired by techniques that are not very different from those currently in use for conventional materials. A list of repair guidelines was prepared to aid in determining the proper repair techniques for a given structure. The guidelines include specifying types of repair material and their applicability, corrosion prevention procedures, design criteria, and inspection criteria. Boron/aluminum structural components were repaired and tested to compare as-fabricated and repaired performance. All but one set of specimens, when repaired, exceeded the strength of the original specimens.

Miller, M. F.↗

NASA NTRS1974

Repair of major system elements on Skylab

In-flight maintenance, as conceived and preplanned for the Skylab mission was limited to simple scheduled and unscheduled replacement tasks and minor contingency repairs. Tools and spares were provided accordingly. However, failures during the mission dictated complicated and sophisticated repairs to major systems so that the mission could continue. These repairs included the release of a large structure that failed to deploy, the assembly and deployment of large mechanical devices, the installation and checkout of precision electronic equipment, troubleshooting and repair of precision electromechanical equipment, and tapping into and recharging a cooling system. The repairs were conducted both inside the spacecraft and during extravehicular activities. Some of the repair tasks required team effort on the part of the crewmen including close procedural coordination between internal and extravehicular crewmen. The Skylab experience indicates that crewmen can, with adequate training, make major system repairs in space using standard or special tools. Design of future spacecraft systems should acknowledge this capability and provide for more extensive in-flight repair and maintenance.

Pace, R. E., Jr.↗

NASA NTRS1997

Advanced Technology Composite Fuselage - Repair and Damage Assessment Supporting Maintenance

Under the NASA-sponsored contracts for Advanced Technology Composite Aircraft Structures (ATCAS) and Materials Development Omnibus Contract (MDOC), Boeing is studying the technologies associated with the application of composite materials to commercial transport fuselage structure. Included in the study is the incorporation of maintainability and repairability requirements of composite primary structure into the design. This contractor report describes activities performed to address maintenance issues in composite fuselage applications. A key aspect of the study was the development of a maintenance philosophy which included consideration of maintenance issues early in the design cycle, multiple repair options, and airline participation in design trades. Fuselage design evaluations considered trade-offs between structural weight, damage resistance/tolerance (repair frequency), and inspection burdens. Analysis methods were developed to assess structural residual strength in the presence of damage, and to evaluate repair design concepts. Repair designs were created with a focus on mechanically fastened concepts for skin/stringer structure and bonded concepts for sandwich structure. Both a large crown (skintstringer) and keel (sandwich) panel were repaired. A compression test of the keel panel indicated the demonstrated repairs recovered ultimate load capability. In conjunction with the design and manufacturing developments, inspection methods were investigated for their potential to evaluate damaged structure and verify the integrity of completed repairs.

Flynn, B. W.↗

NASA NTRS2005

In-Space Repair of Reinforced Carbon-Carbon (RCC) Thermal Protection System Structures

Advanced repair and refurbishment technologies are critically needed for the RCC-based thermal protection system of current space transportation system as well as for future Crew Exploration Vehicles (CEV). The damage to these components could be caused by impact during ground handling or due to falling of ice or other objects during launch. In addition, in-orbit damage includes micrometeoroid and orbital debris impact as well as different factors (weather, launch acoustics, shearing, etc.) during launch and re-entry. The GRC developed GRABER (Glenn Refractory Adhesive for Bonding and Exterior Repair) material has shown multiuse capability for repair of small cracks and damage in reinforced carbon-carbon (RCC) material. The concept consists of preparing an adhesive paste of desired ceramic with appropriate adhesives and then applying the paste to the damaged/cracked area of the RCC composites with adhesive delivery system. The adhesive paste cures at 100-120 C and transforms into a high temperature ceramic during simulated entry conditions. A number of plasma torch and ArcJet tests were carried out to evaluate the crack repair capability of GRABER materials for Reinforced Carbon-Carbon (RCC) composites. For the large area repair applications, PLASTER (Patch Laminates and Sealant Technology for Exterior Repair) based systems have been developed. In this presentation, critical in-space repair needs and technical challenges as well as various issues and complexities will be discussed along with the plasma performance and post test characterization of repaired RCC materials.

Singh, Mrityunjay↗

NASA NTRS2006

In-Space Repair of Reinforced Carbon-Carbon Thermal Protection System Structures

Advanced repair and refurbishment technologies are critically needed for the thermal protection system of current space transportation system as well as for future Crew Exploration Vehicles (CEV). The damage to these components could be caused by impact during ground handling or due to falling of ice or other objects during launch. In addition, in-orbit damage includes micrometeoroid and orbital debris impact as well as different factors (weather, launch acoustics, shearing, etc.) during launch and re-entry. The GRC developed GRABER (Glenn Refractory Adhesive for Bonding and Exterior Repair) material has shown multiuse capability for repair of small cracks and damage in reinforced carbon-carbon (RCC) material. The concept consists of preparing an adhesive paste of desired ceramic with appropriate additives and then applying the paste to the damaged/cracked area of the RCC composites with adhesive delivery system. The adhesive paste cures at 100-120 C and transforms into a high temperature ceramic during simulated entry conditions. A number of plasma torch and ArcJet tests were carried out to evaluate the crack repair capability of GRABER materials for Reinforced Carbon-Carbon (RCC) composites. For the large area repair applications, integrated system for tile and leading edge repair (InSTALER) have been developed. In this presentation, critical in-space repair needs and technical challenges as well as various issues and complexities will be discussed along with the plasma performance and post test characterization of repaired RCC materials.

Singh, Mrityunjay↗

NASA NTRS2007

In-Space Repair and Refurbishment of Thermal Protection System Structures for Reusable Launch Vehicles

Advanced repair and refurbishment technologies are critically needed for the thermal protection system of current space transportation systems as well as for future launch and crew return vehicles. There is a history of damage to these systems from impact during ground handling or ice during launch. In addition, there exists the potential for in-orbit damage from micrometeoroid and orbital debris impact as well as different factors (weather, launch acoustics, shearing, etc.) during launch and re-entry. The GRC developed GRABER (Glenn Refractory Adhesive for Bonding and Exterior Repair) material has shown multiuse capability for repair of small cracks and damage in reinforced carbon-carbon (RCC) material. The concept consists of preparing an adhesive paste of desired ceramic with appropriate additives and then applying the paste to the damaged/cracked area of the RCC composites with an adhesive delivery system. The adhesive paste cures at 100-120 C and transforms into a high temperature ceramic during reentry conditions. A number of plasma torch and ArcJet tests were carried out to evaluate the crack repair capability of GRABER materials for Reinforced Carbon-Carbon (RCC) composites. For the large area repair applications, Integrated Systems for Tile and Leading Edge Repair (InSTALER) have been developed and evaluated under various ArcJet testing conditions. In this presentation, performance of the repair materials as applied to RCC is discussed. Additionally, critical in-space repair needs and technical challenges are reviewed.

Singh, M.↗

NASA NTRS2006

Repairing Chipped Silicide Coatings on Refractory Metal Substrates

The space shuttle orbiter s reaction control system (RCS) is a series of small thrusters that use hypergolic fuels to orient the orbiter in space. The RCS thrusters are constructed from a special niobium-based alloy -- the C-103. This alloy retains excellent mechanical properties from cryogenic temperature all the way up to 2,500 F (1,370 C). C-103 is susceptible to rapid oxidation at elevated temperatures. The authors have developed two methods to repair damaged R512a coatings on C-103. For the first repair technique, metal foundries, semiconductor manufacturers, and many other industries have developed and routinely use coatings that can easily be painted on metal to protect it from corrosion, including oxidation, to temperatures in excess of 2,500 F (1,370 C). This first repair technique is considered somewhat temporary. The second repair technique is based on using the native coating material of the RCS nozzles. the chipped area is ground out and a "green" R512a coating is applied to the repair area. Both repair techniques can be applied for moderate protection until the permanent laser-repair technique is available to the repair area.

Youngquist, Robert↗

NASA NTRS2010

Approach to In Situ Component Level Electronics Assembly Repair (CLEAR) for Constellation

Maintenance resupply is a significant issue for long duration space missions. Currently, the International Space Station (ISS) approaches maintenance primarily around replaceable modules called Orbital Replacement Units (ORU). While swapping out ORUs has served the ISS well keeping crew time for maintenance to a minimum, this approach assumes a substantial logistics capacity to provide replacement ORUs and return ORUs to Earth for repair. The ORUs used for ISS require relatively large blocks of replacement hardware even though the actual failed component may be several orders of magnitude smaller. The Component Level Electronics Assembly Repair (CLEAR) task was created to explore electronics repair down to the component level for future space missions. From 2006 to 2009, CLEAR was an activity under the Supportability project of the Exploration Technology Development Program. This paper describes the activities of CLEAR including making a case for component-level electronics repair, examination of current terrestrial repair hardware, and potential repair needs. Based on those needs, the CLEAR team proposes an architecture for an in-situ repair capability aboard a spacecraft or habitat. Additionally, this paper discusses recent progress toward developing in-space repair capabilities--including two spaceflight experiments-- and presents technology concepts which could help enable or benefit the same.

Struk, Peter M.↗

NASA NTRS2015

BioSentinel: Mission Development of a Radiation Biosensor to Gauge DNA Damage and Repair Beyond Low Earth Orbit on a 6U Nanosatellite.

We are designing and developing a "6U" (10 x 22 x 34 cm; 14 kg) nanosatellite as a secondary payload to fly aboard NASA's Space Launch System (SLS) Exploration Mission (EM) 1, scheduled for launch in late 2017. For the first time in over forty years, direct experimental data from biological studies beyond low Earth orbit (LEO) will be obtained during BioSentinel's 12- to 18- month mission. BioSentinel will measure the damage and repair of DNA in a biological organism and allow us to compare that to information from onboard physical radiation sensors. In order to understand the relative contributions of the space environment's two dominant biological perturbations, reduced gravity and ionizing radiation, results from deep space will be directly compared to data obtained in LEO (on ISS) and on Earth. These data points will be available for validation of existing biological radiation damage and repair models, and for extrapolation to humans, to assist in mitigating risks during future long-term exploration missions beyond LEO. The BioSentinel Payload occupies 4U of the spacecraft and will utilize the monocellular eukaryotic organism Saccharomyces cerevisiae (yeast) to report DNA double-strand-break (DSB) events that result from ambient space radiation. DSB repair exhibits striking conservation of repair proteins from yeast to humans. Yeast was selected because of 1) its similarity to cells in higher organisms, 2) the well-established history of strains engineered to measure DSB repair, 3) its spaceflight heritage, and 4) the wealth of available ground and flight reference data. The S. cerevisiae flight strain will include engineered genetic defects to prevent growth and division until a radiation-induced DSB activates the yeast's DNA repair mechanisms. The triggered culture growth and metabolic activity directly indicate a DSB and its successful repair. The yeast will be carried in the dry state within the 1-atm P/L container in 18 separate fluidics cards with each card having 16 independent culture microwells, with integral microchannels and filters to supply nutrients and reagents, confine the yeast to the wells, and enable optical measurement. The measurement subsystem will monitor each subgroup of culture wells continuously for several weeks, optically tracking DSBtriggered cell growth and metabolism. BioSentinel will also include physical radiation sensors based on the TimePix sensor, as implemented by JSC's RadWorks group, which record individual radiation events including estimates of their linear-energytransfer (LET) values. Radiation-dose and LET data will be compared directly to the rate of DSB-and-repair events measured by the S. cerevisiae biosentinels. The spacecraft bus will operate in a deep space environment with functions that include command and data handling, communications, power generation (via deployable solar panels) and storage, and attitude determination-and-control system with micropropulsion. Development of the BioSentinel spacecraft will mature and prove multiple nanosatellite advances in order to function well beyond LEO: Communications from distances of ≥ 500,000 km; Autonomous attitude control, momentum management, and safe mode of nanosatellites in deep space; Shielding-, hardening-, design-, and software-derived radiation tolerance for electronics; Reliable functionality for 12 - 18 months of key subsystems for biofluidics, memory, communications, power, etc.; Close integration of living biological radiation event monitors with miniature physical radiation spectrometers; Biological measurement of solar particle events beyond Earth orbit In addition to providing the first biological results from beyond LEO in over 4 decades, BioSentinel will provide an adaptable small-satellite instrument platform to perform a range of human-exploration-relevant measurements that characterize the biological consequences of multiple outer space environments. BioSentinel is being developed under NASA's Advanced Exploration Systems program.

DNA damage↗

NASA NTRS2015

BioSentinel: Mission Development of a Radiation Biosensor to Gauge DNA Damage and Repair Beyond Low Earth Orbit on a 6U Nanosatellite

We are designing and developing a 6U (10 x 22 x 34 cm; 14 kg) nanosatellite as a secondary payload to fly aboard NASAs Space Launch System (SLS) Exploration Mission (EM) 1, scheduled for launch in late 2017. For the first time in over forty years, direct experimental data from biological studies beyond low Earth orbit (LEO) will be obtained during BioSentinels 12- to 18-month mission. BioSentinel will measure the damage and repair of DNA in a biological organism and allow us to compare that to information from onboard physical radiation sensors. In order to understand the relative contributions of the space environments two dominant biological perturbations, reduced gravity and ionizing radiation, results from deep space will be directly compared to data obtained in LEO (on ISS) and on Earth. These data points will be available for validation of existing biological radiation damage and repair models, and for extrapolation to humans, to assist in mitigating risks during future long-term exploration missions beyond LEO. The BioSentinel Payload occupies 4U of the spacecraft and will utilize the monocellular eukaryotic organism Saccharomyces cerevisiae (yeast) to report DNA double-strand-break (DSB) events that result from ambient space radiation. DSB repair exhibits striking conservation of repair proteins from yeast to humans. Yeast was selected because of 1) its similarity to cells in higher organisms, 2) the well-established history of strains engineered to measure DSB repair, 3) its spaceflight heritage, and 4) the wealth of available ground and flight reference data. The S. cerevisiae flight strain will include engineered genetic defects to prevent growth and division until a radiation-induced DSB activates the yeasts DNA repair mechanisms. The triggered culture growth and metabolic activity directly indicate a DSB and its successful repair. The yeast will be carried in the dry state within the 1-atm PL container in 18 separate fluidics cards with each card having 16 independent culture microwells, with integral microchannels and filters to supply nutrients and reagents, confine the yeast to the wells, and enable optical measurement. The measurement subsystem will monitor each subgroup of culture wells continuously for several weeks, optically tracking DSB-triggered cell growth and metabolism. BioSentinel will also include physical radiation sensors based on the TimePix sensor, as implemented by JSCs RadWorks group, which record individual radiation events including estimates of their linear-energy-transfer (LET) values. Radiation-dose and LET data will be compared directly to the rate of DSB-and-repair events measured by the S. cerevisiae biosentinels.

Radiation Biosensor↗

DOE OSTI2023

Architecture-Preserving Provable Repair of Deep Neural Networks

Deep neural networks (DNNs) are becoming increasingly important components of software, and are considered the state-of-the-art solution for a number of problems, such as image recognition. However, DNNs are far from infallible, and incorrect behavior of DNNs can have disastrous real-world consequences. This paper addresses the problem of architecture-preserving V-polytope provable repair of DNNs. A V-polytope defines a convex bounded polytope using its vertex representation. V-polytope provable repair guarantees that the repaired DNN satisfies the given specification on the infinite set of points in the given V-polytope. An architecture-preserving repair only modifies the parameters of the DNN, without modifying its architecture. The repair has the flexibility to modify multiple layers of the DNN, and runs in polynomial time. It supports DNNs with activation functions that have some linear pieces, as well as fully-connected, convolutional, pooling and residual layers. To the best our knowledge, this is the first provable repair approach that has all of these features. We implement our approach in a tool called APRNN. Using MNIST, ImageNet, and ACAS Xu DNNs, we show that it has better efficiency, scalability, and generalization compared to PRDNN and REASSURE, prior provable repair methods that are not architecture preserving.

97 MATHEMATICS AND COMPUTING↗

NASA NTRS1981

Considerations on repeated repairing of weldments in Inconel 718 alloy

The effects of repeated weld repairs on the metallurgical characteristics, high cycle fatigue (HCF), and tensile properties of Inconel 718 butt weld joints were determined. A 1/4 in thick plate and a 1/2 in thick plate were used as well as tungsten inert gas welding, and Inconel 718 filler wire. Weld panels were subjected to 2, 6, and 12 repeated repairs and were made in a highly restrained condition. Post weld heat treatments were also conducted with the welded panel in the highly restrained condition. Results indicate that no significant metallurgical anomaly is evident as a result of up to twelve repeated weld repairs. No degradation in fatigue life is noted for up to twelve repeated repairs. Tensile results from specimens which contained up to twelve repeated weld repairs revealed no significant degradation in UTS and YS. However, a significant decrease in elongation is evident with specimens (solution treated and age hardened after welding) which contained twelve repeated repairs. The elongation loss is attributed to the presence of a severe notch on each side (fusion line) of the repair weld bead reinforcement.

Bayless, E. O.↗

NASA NTRS1989

Making on-orbit structural repairs to Space Station

One of the key factors dictating the safety and durability of the proposed U.S. Space Station is the ability to repair structural damage while remaining in orbit. Consequently, studies are conducted to identify the engineering problems associated with accomplishing structural repairs on orbit, due to zero gravity environment and exposure to extreme temperature variations. There are predominant forms of structural failure, depending on the metallic or composite material involved. Aluminum is the primary metallic material used in space vehicle applications. Welding processes on aluminum alloy structures were tested, resulting in final selection of electron beam welding as the primary technique for metallic material repair in Space. Several composite structure repair processes were bench-tested to define their applicability to on-orbit EVA requirements: induction heating prevailed. One of the unique problems identified as inherent in the on-orbit repair process is that of debris containment. The Maintenance Work Station concept provides means to prevent module contamination from repair debris and ensure the creation of a facility for crew members to work easily in a microgravity environment. Different technologies were also examined for application to EVA repair activities, and the concept selected was a spring-loaded, collapsible, box-like Debris Containement and Collection Device with incorporated fold-down tool boards and handholes in the front panel.

Haber, Harry S.↗

NASA NTRS1992

Compressive strength of damaged and repaired composite plates

Tests were performed assessing the effectiveness of repair in restoring the mechanical properties of damaged, solid composite plates made either of Fiberite T300/976 graphite-epoxy, Fiberite IM7/977-2 graphite-toughened epoxy, or ICI APC-2 graphite-PEEK. The plate length, the layup and the amount of damage were also varied. Damage was introduced in the plates either by impacting them with a solid projectile or by applying a transverse static load. Some (75 percent) or all (100 percent) of the damaged zone was then cut out, and the plate was repaired by plugging and patching the hole. The effectiveness of the repair was evaluated by measuring the compressive strengths of undamaged plates, damaged plates with no cutout, damaged plates with a cutout, and repaired plates. The data at an intermediate stage of repair provide information on the effect of each repair step on the compressive strength. The results indicated that for the solid plates used in these tests, the repair methods used herein did not improve the compressive strength of already damaged plates.

Finn, Scott R.↗