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At least 613 records · Page 34

Reliability of Sn/Pb and Lead-Free (SnAgCu) Solders of Surface Mounted Miniaturized Passive Components for Extreme Temperature (-185 C to +125 C) Space Missions

Surface mount electronic package test boards have been assembled using tin/lead (Sn/Pb) and lead-free (Pb-free or SnAgCu or SAC305) solders. The soldered surface mount packages include ball grid arrays (BGA), flat packs, various sizes of passive chip components, etc. They have been optically inspected after assembly and subsequently subjected to extreme temperature thermal cycling to assess their reliability or future deep space, long-term, extreme temperature environmental missions. In this study, the employed temperature range (-185oC to +125oC) covers military specifications (-55oC to +100oC), extreme old Martian (-120oC to +115oC), asteroid Nereus (-180oC to +25oC) and JUNO (-150oC to +120oC) environments. The boards were inspected at room temperature and at various intervals as a function of extreme temperature thermal cycling and bake duration. Electrical resistance measurements made at room temperature are reported and the tests to date have shown some change in resistance as a function of extreme temperature thermal cycling and some showed increase in resistance. However, the change in interconnect resistance becomes more noticeable with increasing number of thermal cycles. Further research work will be carried out to understand the reliability of packages under extreme temperature applications (-185oC to +125oC) via continuously monitoring the daisy chain resistance for BGA, Flat-packs, lead less chip packages, etc. This paper will describe the experimental reliability results of miniaturized passive components (01005, 0201, 0402, 0603, 0805, and 1206) assembled using surface mounting processes with tin-lead and lead-free solder alloys under extreme temperature environments.

extreme temperatures,↗

Catalytic Microtube Rocket Igniter

Devices that generate both high energy and high temperature are required to ignite reliably the propellant mixtures in combustion chambers like those present in rockets and other combustion systems. This catalytic microtube rocket igniter generates these conditions with a small, catalysis-based torch. While traditional spark plug systems can require anywhere from 50 W to multiple kW of power in different applications, this system has demonstrated ignition at less than 25 W. Reactants are fed to the igniter from the same tanks that feed the reactants to the rest of the rocket or combustion system. While this specific igniter was originally designed for liquid methane and liquid oxygen rockets, it can be easily operated with gaseous propellants or modified for hydrogen use in commercial combustion devices. For the present cryogenic propellant rocket case, the main propellant tanks liquid oxygen and liquid methane, respectively are regulated and split into different systems for the individual stages of the rocket and igniter. As the catalyst requires a gas phase for reaction, either the stored boil-off of the tanks can be used directly or one stream each of fuel and oxidizer can go through a heat exchanger/vaporizer that turns the liquid propellants into a gaseous form. For commercial applications, where the reactants are stored as gases, the system is simplified. The resulting gas-phase streams of fuel and oxidizer are then further divided for the individual components of the igniter. One stream each of the fuel and oxidizer is introduced to a mixing bottle/apparatus where they are mixed to a fuel-rich composition with an O/F mass-based mixture ratio of under 1.0. This premixed flow then feeds into the catalytic microtube device. The total flow is on the order of 0.01 g/s. The microtube device is composed of a pair of sub-millimeter diameter platinum tubes connected only at the outlet so that the two outlet flows are parallel to each other. The tubes are each approximately 10 cm long and are heated via direct electric resistive heating. This heating brings the gasses to their minimum required ignition temperature, which is lower than the auto-thermal ignition temperature, and causes the onset of both surface and gas phase ignition producing hot temperatures and a highly reacting flame. The combustion products from the catalytic tubes, which are below the melting point of platinum, are injected into the center of another combustion stage, called the primary augmenter. The reactants for this combustion stage come from the same source but the flows of non-premixed methane and oxygen gas are split off to a secondary mixing apparatus and can be mixed in a near-stoichiometric to highly lean mixture ratio. The primary augmenter is a component that has channels venting this mixed gas to impinge on each other in the center of the augmenter, perpendicular to the flow from the catalyst. The total crosssectional area of these channels is on a similar order as that of the catalyst. The augmenter has internal channels that act as a manifold to distribute equally the gas to the inward-venting channels. This stage creates a stable flame kernel as its flows, which are on the order of 0.01 g/s, are ignited by the combustion products of the catalyst. This stage is designed to produce combustion products in the flame kernel that exceed the autothermal ignition temperature of oxygen and methane.

Schneider, Steven J.↗

Current-Sheet Formation and Reconnection at a Magnetic X Line in Particle-in-Cell Simulations

The integration of kinetic effects into macroscopic numerical models is currently of great interest to the heliophysics community, particularly in the context of magnetic reconnection. Reconnection governs the large-scale energy release and topological rearrangement of magnetic fields in a wide variety of laboratory, heliophysical, and astrophysical systems. We are examining the formation and reconnection of current sheets in a simple, two-dimensional X-line configuration using high-resolution particle-in-cell (PIC) simulations. The initial minimum-energy, potential magnetic field is perturbed by excess thermal pressure introduced into the particle distribution function far from the X line. Subsequently, the relaxation of this added stress leads self-consistently to the development of a current sheet that reconnects for imposed stress of sufficient strength. We compare the time-dependent evolution and final state of our PIC simulations with macroscopic magnetohydrodynamic simulations assuming both uniform and localized electrical resistivities (C. R. DeVore et al., this meeting), as well as with force-free magnetic-field equilibria in which the amount of reconnection across the X line can be constrained to be zero (ideal evolution) or optimal (minimum final magnetic energy). We will discuss implications of our results for understanding magnetic-reconnection onset and cessation at kinetic scales in dynamically formed current sheets, such as those occurring in the solar corona and terrestrial magnetotail.

Black, C.↗

Testing of an Integrated Reactor Core Simulator and Power Conversion System with Simulated Reactivity Feedback

A Direct Drive Gas-Cooled (DDG) reactor core simulator has been coupled to a Brayton Power Conversion Unit (BPCU) for integrated system testing at NASA Glenn Research Center (GRC) in Cleveland, OH. This is a closed-cycle system that incorporates an electrically heated reactor core module, turbo alternator, recuperator, and gas cooler. Nuclear fuel elements in the gas-cooled reactor design are replaced with electric resistance heaters to simulate the heat from nuclear fuel in the corresponding fast spectrum nuclear reactor. The thermodynamic transient behavior of the integrated system was the focus of this test series. In order to better mimic the integrated response of the nuclear-fueled system, a simulated reactivity feedback control loop was implemented. Core power was controlled by a point kinetics model in which the reactivity feedback was based on core temperature measurements; the neutron generation time and the temperature feedback coefficient are provided as model inputs. These dynamic system response tests demonstrate the overall capability of a non-nuclear test facility in assessing system integration issues and characterizing integrated system response times and response characteristics.

Bragg-Sitton, Shannon M.↗

Thermophysical Properties of 60-NITINOL for Mechanical Component Applications

The linear thermal expansion coefficient, specific heat capacity, electrical resistivity and thermal conductivity of 60- NITINOL were studied over a range of temperatures representing the operating environment of an oil-lubricated bearing. The behavior of this material appears to follow wellestablished theories applicable to either metal alloys, in general, or to intermetallic compounds, more specifically and the measured data were found to be comparable to those for conventional bearing alloys.

Stanford, Malcolm K.↗

Transparent and Electrically Conductive Carbon Nanotube-Polymer Nanocomposite Materials for Electrostatic Charge Dissipation

In recent years, nanocomposite materials have been extensively studied because of their superior electrical, magnetic, and optical properties and large number of possible applications that range from nano-electronics, specialty coatings, electromagnetic shielding, and drug delivery. The aim of the present work is to study the electrical and optical properties of carbon nanotube(CNT)-polymer nanocomposite materials for electrostatic charge dissipation. Single and multi-wall carbon nanotubes were grown by catalytic chemical vapor deposition (CCVD) on metal/metal oxide catalytic systems using acetylene or other hydrocarbon feedstocks. After the purification process, in which amorphous carbon and non-carbon impurities were removed, the nanotubes were functionalized with carboxylic acid groups in order to achieve a good dispersion in water and various other solvents. The carbon nanostructures were analyzed, both before and after functionalization by several analytical techniques, including microscopy, Raman spectroscopy, and X-Ray photoelectron spectroscopy. Solvent dispersed nanotubes were mixed (1 to 7 wt %) into acrylic polymers by sonication and allowed to dry into 25 micron thick films. The electrical and optical properties of the films were analyzed as a function of the nanotubes' concentration. A reduction in electrical resistivity, up to six orders of magnitude, was measured as the nanotubes' concentration in the polymeric films increased, while optical transparency remained 85 % or higher relative to acrylic films without nanotubes.

Dervishi, E.↗

Manufacturing of Nanocomposite Carbon Fibers and Composite Cylinders

Pitch-based nanocomposite carbon fibers were prepared with various percentages of carbon nanofibers (CNFs), and the fibers were used for manufacturing composite structures. Experimental results show that these nanocomposite carbon fibers exhibit improved structural and electrical conductivity properties as compared to unreinforced carbon fibers. Composite panels fabricated from these nanocomposite carbon fibers and an epoxy system also show the same properties transformed from the fibers. Single-fiber testing per ASTM C1557 standard indicates that the nanocomposite carbon fiber has a tensile modulus of 110% higher, and a tensile strength 17.7% times higher, than the conventional carbon fiber manufactured from pitch. Also, the electrical resistance of the carbon fiber carbonized at 900 C was reduced from 4.8 to 2.2 ohm/cm. The manufacturing of the nanocomposite carbon fiber was based on an extrusion, non-solvent process. The precursor fibers were then carbonized and graphitized. The resultant fibers are continuous.

Tan, Seng↗

The MillSOT-A Spiral Orbit Tribometer on a Milling Machine

A spiral orbit tribometer (SOT) intended to characterize friction and wear phenomena has been constructed on a milling machine. The instrument, essentially a retainerless thrust bearing with one ball and flat races, is exceedingly simple and inexpensive to construct. The capabilities of the tribometer to measure both the coefficient of friction and contact electrical resistance are demonstrated with clean specimens as well as with well known lubricants such as molybdenum disulphide and Krytox oil. Operation in a purged environment of inert gas is also demonstrated. The results with these lubricants are quite close to what is obtained by other methods. Suggestions for extending the capabilities of the tribometer are given. This arrangement may find use in university mechanical engineering laboratories to introduce and study rolling contact motion as well as for research in contact mechanics and tribology.

Pepper, Stephen V.↗

Static Dissipative Cable Ties, Such as for Radiation Belt Storm Probes

Methods of cyclically heating and cooling an article formed of a static dissipative ETFE resin, such as to reduce an electrical resistivity and/or to increase a tensile strength of the article, and methods of irradiating an article formed of a static dissipative ETFE resin, such as to increase a tensile strength of the article. Also disclosed herein are articles formed of a static dissipative ETFE resin, and processed in accordance with methods disclosed herein. Such an article may include, for example and without limitation, a cable strap to wrap, support, and/or secure one or more wires or cables, such as a cable tie.

Langley, Patrick T.↗

A Thermal Analysis of a Hot-Wire Probe for Icing Applications

This paper presents a steady-state thermal model of a hot-wire instrument applicable to atmospheric measurement of water content in clouds. In this application, the power required to maintain the wire at a given temperature is used to deduce the water content of the cloud. The model considers electrical resistive heating, axial conduction, convection to the flow, radiation to the surroundings, as well as energy loss due to the heating, melting, and evaporation of impinging liquid and or ice. All of these parameters can be varied axially along the wire. The model further introduces a parameter called the evaporation potential which locally gauges the maximum fraction of incoming water that evaporates. The primary outputs of the model are the steady-state power required to maintain a spatially-average constant temperature as well as the variation of that temperature and other parameters along the wire. The model is used to understand the sensitivity of the hot-wire performance to various flow and boundary conditions including a detailed comparison of dry air and wet (i.e. cloud-on) conditions. The steady-state power values are compared to experimental results from a Science Engineering Associates (SEA) Multi-Element probe, a commonly used water-content measurement instrument. The model results show good agreement with experiment for both dry and cloud-on conditions with liquid water content. For ice, the experimental measurements under read the actual water content due to incomplete evaporation and splashing. Model results, which account for incomplete evaporation, are still higher than experimental results where the discrepancy is attributed to splashing mass-loss which is not accounted in the model.

Thermal Analysis↗

Materials International Space Station Experiment (MISSE): Overview, Accomplishments and Future Needs

Materials and devices used on the exterior of spacecraft in low Earth orbit (LEO) are subjected to environmental threats that can cause degradation in material properties, possibly threatening spacecraft mission success. These threats include: atomic oxygen (AO), ultraviolet and x-ray radiation, charged particle radiation, temperature extremes and thermal cycling, micrometeoroid and debris impacts, and contamination. Space environmental threats vary greatly based on spacecraft materials, thicknesses and stress levels, and the mission environment and duration. For more than a decade the Materials International Space Station Experiment (MISSE) has enabled the study of the long duration environmental durability of spacecraft materials in the LEO environment. The overall objective of MISSE is to test the stability and durability of materials and devices in the space environment in order to gain valuable knowledge on the performance of materials in space, as well as to enable lifetime predictions of new materials that may be used in future space flight. MISSE is a series of materials flight experiments, which are attached to the exterior of the International Space Station (ISS). Individual experiments were loaded onto suitcase-like trays, called Passive Experiment Containers (PECs). The PECs were transported to the ISS in the Space Shuttle cargo bay and attached to, and removed from, the ISS during extravehicular activities (EVAs). The PECs were retrieved after one or more years of space exposure and returned to Earth enabling post-flight experiment evaluation. MISSE is a multi-organization project with participants from the National Aeronautics and Space Administration (NASA), the Department of Defense (DoD), industry and academia. MISSE has provided a platform for environmental durability studies for thousands of samples and numerous devices, and it has produced many tangible impacts. Ten PECs (and one smaller tray) have been flown, representing MISSE 1 through MISSE 8, yielding long-duration space environmental performance and durability data that enable material validation, processing recertification and space qualification; improved predictions of materials and component lifetimes in space; model verification and development; and correlation factors between space-exposure and ground-facilities enabling more accurate in-space performance predictions based on ground-laboratory testing. A few of the many experiment results and observations, and their impacts, are provided. Those highlighted include examples on improved understanding of atomic oxygen scattering mechanisms, LEO coating durability results, and polymer erosion yields and their impacts on spacecraft design. The MISSE 2 Atomic Oxygen Scattering Chamber Experiment discovered that the peak flux of scattered AO was determined to be 45 deg from normal incidence, not the model predicted cosine dependence. In addition, the erosion yield (E(sub y)) of Kapton H for AO scattered off oxidized-Al is 22% of the E(sub y) of direct AO impingement. These results were used to help determine the degradation mechanism of a cesium iodide detector within the Hubble Space Telescope Cosmic Origins Spectrograph Experiment. The MISSE 6 Indium Tin Oxide (ITO) Degradation Experiment measured surface electrical resistance of ram and wake ITO coated samples. The data confirmed that ITO is a stable AO protective coating, and the results validated the durability of ITO conductive coatings for solar arrays for the Atmosphere-Space Transition 2 Explorer program. The MISSE 2, 6 and 7 Polymer Experiments have provided LEO AO Ey data on over 120 polymer and composites samples. The flight E(sub y) values were found to range from 3.05 x 10(exp -26) cu cm/atom for the AO resistant polymer CORIN to 9.14 x 10(exp -26) cu cm/atom for polyoxymethylene (POM). In addition, flying the same polymers on different missions has advanced the understanding of the AO E(sub y) dependency on solar exposure for polymers containing fluorine. The MISSE polymer results are highly requested and have impacted spacecraft design for WorldView-2 & -3, the Global Precipitation Measurement-Microwave Imager, and other spacecraft. The flight data has enabled the development of an Atomic Oxygen Erosion Predictive Tool that allows the erosion prediction of new and non-flown polymers. The data has also been used to develop a new NASA Technical Standards Handbook "Spacecraft Polymers Atomic Oxygen Durability Handbook." Many intangible benefits have also been derived from MISSE. For example, over 40 students have collaborated on Glenn's MISSE experiments, which have resulted in greater than $80K in student scholarships and awards in national and international science fairs. Students have also given presentations and won poster competition awards at international space conferences.

Flight Experiment↗

Growth of CdZnTe Crystals for Radiation Detector Applications by Directional Solidification

Advances in Cadmium Zinc Telluride (Cd(sub 1-x)Zn(sub x)Te) growth techniques are needed for the production of large-scale arrays of gamma and x-ray astronomy. The research objective is to develop crystal growth recipes and techniques to obtain large, high quality CdZnTe single crystal with reduced defects, such as charge trapping, twinning, and tellurium precipitates, which degrade the performance of CdZnTe and, at the same time, to increase the yield of usable material from the CdZnTe ingot. A low gravity material experiment, "Crystal Growth of Ternary Compound Semiconductors in Low Gravity Environment", will be performed in the Material Science Research Rack (MSRR) on International Space Station (ISS). One section of the flight experiment is the melt growth of CdZnTe ternary compounds. This talk will focus on the ground-based studies on the growth of Cd(sub 0.80)Zn(sub 0.20)Te crystals for radiation detector applications by directional solidification. In this investigation, we have improved the properties that are most critical for the detector applications (electrical properties and crystalline quality): a) Electrical resistivity: use high purity starting materials (with reproducible impurity levels) and controlled Cd over pressure during growth to reproducibly balance the impurity levels and Cd vacancy concentration b) Crystalline quality: use ultra-clean growth ampoule (no wetting after growth), optimized thermal profile and ampoule design, as well as a technique for supercool reduction to growth large single crystal with high crystalline quality

Su, Ching-Hua↗

N-type Doped PbTe and PbSe Alloys for Thermoelectric Applications

The present invention demonstrates that weak scattering of carriers leads to a high mobility and therefore helps achieve low electric resistivity with high Seebeck coefficient for a thermoelectric material. The inventors demonstrate this effect by obtaining a thermoelectric figure of merit, zT, higher than 1.3 at high temperatures in n-type PbSe, because of the weak scattering of carriers in the conduction band as compared with that in the valence band. The invention further demonstrates favorable thermoelectric transport properties of n-type PbTe.sub.1-xI.sub.x with carrier concentrations ranging from 5.8.times.10.sup.18-1.4.times.10.sup.20 cm.sup.-3.

Snyder, G. Jeffrey↗

Static Dissipative Cable Ties, Such as for Radiation Belt Storm Probes

An article, such as, but not limited to, a cable strap to wrap, support, or secure one or more wires or cables, is formed by cyclically heating and cooling and/or irradiating an article formed of a static dissipative ethylene tetrafluoroethylen (ETFE) resin, to reduce an electrical resistivity and/or to increase a tensile strength of the article.

Langley, Patrick T.↗

Environmental Durability and Stress Rupture of EBC/CMCs

This research focuses on the strength and creep performance of SiC fiber-reinforced SiC ceramic matrix composite (CMC) environmental barrier coating (EBC) systems under complex simulated engine environments. Tensile-strength and stress-rupture testing was conducted to illustrate the material properties under isothermal and thermal gradient conditions. To determine material durability, further testing was conducted under exposure to thermal cycling, thermal gradients and simulated combustion environments. Emphasis is placed on experimental techniques as well as implementation of non-destructive evaluation, including modal acoustic emission and electrical resistivity monitoring, to characterize strength degradation and damage mechanisms. Currently, little is known about the behavior of EBC-CMCs under these conditions; consequently, this work will prove invaluable in the development of structural components for use in high temperature applications.

Appleby, Matthew↗

Mechanical Properties and Real-Time Damage Evaluations of Environmental Barrier Coated SiC/SiC CMCs Subjected to Tensile Loading Under Thermal Gradients

SiC/SiC ceramic matrix composites (CMCs) require new state-of-the art environmental barrier coatings (EBCs) to withstand increased temperature requirements and high velocity combustion corrosive combustion gasses. The present work compares the response of coated and uncoated SiC/SiC CMC substrates subjected to simulated engine environments followed by high temperature mechanical testing to asses retained properties and damage mechanisms. Our focus is to explore the capabilities of electrical resistance (ER) measurements as an NDE technique for testing of retained properties under combined high heat-flux and mechanical loading conditions. Furthermore, Acoustic Emission (AE) measurements and Digital Image Correlation (DIC) were performed to determine material damage onset and accumulation.

Ceramic matrix composites↗

Body of Knowledge (BOK) for Copper Wire Bonds

Copper wire bonds have replaced gold wire bonds in the majority of commercial semiconductor devices for the latest technology nodes. Although economics has been the driving mechanism to lower semiconductor packaging costs for a savings of about 20% by replacing gold wire bonds with copper, copper also has materials property advantages over gold. When compared to gold, copper has approximately: 25% lower electrical resistivity, 30% higher thermal conductivity, 75% higher tensile strength and 45% higher modulus of elasticity. Copper wire bonds on aluminum bond pads are also more mechanically robust over time and elevated temperature due to the slower intermetallic formation rate - approximately 1/100th that of the gold to aluminum intermetallic formation rate. However, there are significant tradeoffs with copper wire bonding - copper has twice the hardness of gold which results in a narrower bonding manufacturing process window and requires that the semiconductor companies design more mechanically rigid bonding pads to prevent cratering to both the bond pad and underlying chip structure. Furthermore, copper is significantly more prone to corrosion issues. The semiconductor packaging industry has responded to this corrosion concern by creating a palladium coated copper bonding wire, which is more corrosion resistant than pure copper bonding wire. Also, the selection of the device molding compound is critical because use of environmentally friendly green compounds can result in internal CTE (Coefficient of Thermal Expansion) mismatches with the copper wire bonds that can eventually lead to device failures during thermal cycling. Despite the difficult problems associated with the changeover to copper bonding wire, there are billions of copper wire bonded devices delivered annually to customers. It is noteworthy that Texas Instruments announced in October of 2014 that they are shipping microcircuits containing copper wire bonds for safety critical automotive applications. An evaluation of copper wire bond technology for applicability to spaceflight hardware may be warranted along with concurrently compiling a comprehensive understanding of the failure mechanisms involved with copper wire bonded semiconductor devices.

Body of Knowledge (BOK)↗

Thermophysical Properties of Cold and Vacuum Plasma Sprayed Cu-Cr-X Alloys, NiAl and NiCrAlY Coatings: Specific Heat Capacity - Part 2

Part I of the paper discussed the temperature dependencies of the electrical resistivities, thermal conductivities, thermal diffusivities and total hemispherical emissivities of several vacuum plasma sprayed (VPS) and cold sprayed copper alloy monolithic coatings, VPS NiAl, VPS NiCrAlY, extruded GRCop-84 and as-cast Cu-17(wt.%)Cr-5%Al. Part II discusses the temperature dependencies of the constant pressure specific heat capacities, CP, of these coatings. The data were empirically were regression-fitted with the equation: CP = AT4 + BT3 + CT2 + DT +E where T is the absolute temperature and A, B, C, D and E are regression constants. The temperature dependencies of the molar enthalpy, molar entropy and Gibbs molar free energy determined from experimental values of molar specific heat capacity are reported. Calculated values of CP using the Neumann-Kopp (NK) rule were in poor agreement with experimental data. Instead, a modification of the Neumann-Kopp rule was found to predict values closer to the experimental data with an absolute deviation less than 6.5%. The specific molar heat capacities for all the alloys did not agree with the Dulong-Petit law, and CP is greater than 3R, where R is the universal gas constant, were measured for all the alloys except NiAl for which CP is less than 3R at all temperatures.

Raj, S. V.↗