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At least 685 records · Page 38
All sourcesNASA NTRSDOE OSTI
NASA NTRSDate not supplied

Evaluation of Automotive Grade Resistors for Space Flight

Over the past decade, electronic, electrical, and electromechanical (EEE) parts for space applications have undergone significant changes, largely driven by CubeSat and commercial space developers pushing the boundaries on the utilization of commercial parts in space. Global product shortages and shipping delays are still impacting space flight project deadlines. Many projects have turned to automotive grade resistors as an alternate to their MIL-SPEC counterparts to fulfill requirements. In addition, automotive grade resistors may offer designers a wider range of parts to consider. A recent NASA study recommended the use of high-volume manufactured commercial components for space applications provided these components show evidence of stringent fabrication controls and thorough reliability monitoring practices [1]. Automotive grade components have stringent qualification requirements per the Automotive Electronic Council (AEC). However, the end user usually does not have insight into the practices the manufacturer may use to reduce/eliminate infant mortality nor for compliance to all datasheet specifications. Screening, Life and Accelerated Life testing on a set of standard automotive-grade chip resistors is proposed to evaluate the reliability of these components. Requirements from both the AEC-Q (Automotive Electronic Council Qualification) and EEE-INST-002 (Instructions for EEE Parts Selection, Screening, Qualification, and Derating) for resistors is compared and discussed. The resistors have been tested by using a modified methodology from EEE-INST-002 to evaluate their reliability for space flight projects. The findings of this study indicate that the underlying degradation mechanisms at rated temperature and power are best represented by power law models with a fitted exponent between 0 and 1. A linear model is more conservative which compensates for potential model uncertainty given the wide range of design and materials used in automotive resistors, while still providing useful long-term resistance drift estimates. No electrical anomalies or failures were observed throughout the 1,000-hour Life Tests other than small in tolerance resistance drift aging. Degradation models were utilized to quantify and extrapolate the long-term resistance drift under operating conditions for the components. The models demonstrated that some automotive-grade resistors are likely to operate 10 years at nominal usage conditions while others might fail earlier.

Zainab Abdullahi↗
DOE OSTI2024

Adaptive Protection and Validated Models to Enable Deployment of High Penetrations of Solar PV (PV-MOD)

The availability and validation of various PV models in commercial tools differ, with some models not yet thoroughly validated for advanced inverter functionalities and reliable performance under weak system conditions. Many existing models do not fully incorporate new inverter control functions, which can affect system stability. The increasing deployment of solar PV and other inverter-based resources (IBRs), including distributed energy resources (DERs), is influencing the reliable operation of protection schemes in distribution systems and microgrids. Emerging adaptive protection schemes (APS) offer new opportunities for protecting these systems during varying configurations and DER operating conditions, though their demonstration and validation remain limited. Adaptive protection schemes face similar challenges, as they are typically designed for specific configurations. There is a growing need for tools and methodologies to streamline the deployment of adaptive protection for safe and reliable DER integration. The project main objective was to develop and validate high-fidelity generic models of solar PV facilities for stability, protection, EMT, and QSTS analyses. This objective was achieved, and these models can now be integrated into commercial software tools, enabling utilities, vendors, and developers to study high-penetration PV systems more confidently. The project also demonstrated advanced applications of these models, including the design and deployment of adaptive protection schemes in high-penetration field applications and microgrids, supporting grid safety and reliability. Several milestones were reached by the end of the project. A sophisticated inverter test plan was developed, and inverters representative of the North American marketplace were selected. EPRI and NREL tested various inverters, conforming to IEEE standards. Improvements were made to existing generic models of IBR units, IBR plants, and aggregated feeders for various analyses. The first generic electromagnetic transient (EMT) model for a solar PV plant was developed, conforming to IEEE Std 2800™-2022 and validated against laboratory measurements of a 2.2 MVA large-scale battery energy storage system (BESS) inverter. That model was then used to produce reference responses illustrating examples of validated and verified IBR plant models that pass or fail tests for technical minimum capability and performance as specified in the IEEE standard. The developed, tested, and validated generic models can be used for transmission planning, stability assessments, expansion planning, and evaluating potential future IBR interconnection requirements. They can also support interconnection screens and conformity assessments of IBR plants, including solar PV. The project significantly contributed to the ongoing standardization and model-based representation and verification of IBR responses. The project further addressed challenges of common distribution protection schemes with increasing deployment of DER by developing, validating, and demonstrating adaptive protection schemes (APS) that can improve the reliable and safe integration of DER into distribution systems. New APS were designed using improved DER models for three common distribution systems: a radial feeder, a meshed network, and a microgrid. Modeling and hardware-in-the-loop (HIL) testing of the APS were conducted, successfully showing their effectiveness and selectivity. Proof-of-concept field demonstration was achieved for two APS, i.e., one on a radial feeder and another one in a microgrid. Field demonstration could not be achieved for the APS on a meshed network, primarily due apprehension of one utility partner and also due to limited access to the protective algorithms in the network protectors. Guidelines developed from the lessons learned in the project lay out the general process followed in the design, installation, and commissioning of APS for various distribution systems. Distribution utility partners’ apprehension about field demonstration of the new APS were addressed—with varying success—by taking a stepped risk-management approach of modeling of a wide range of sensitivities first, performing in-depth proof-of-concept testing in the laboratory including HIL next, and finally deliberately implementing and commissioning the actual protection equipment and algorithms into parts of—or in parallel operation to—the three real distribution systems. Future work should include pilot projects that further show the acceptable performance of the developed APS before these schemes be rolled out more widely. Inclusion of both utility and original equipment manufacturers (OEMs) in future projects could increase chances of successful field demonstration. Despite challenges in achieving the field demonstration goal of the project for all three APS, the research significantly contributed to the innovation of adaptive protection solutions for scalable and reliable DER integration into distribution systems. This project significantly enhances the understanding of the impact of using appropriate inverter models on distribution and transmission (T&D) systems. By addressing the limitations of existing generic models, the project introduces high-fidelity models for stability, protection, electromagnetic transient (EMT), and quasi-static time series (QSTS) analyses. These models, integrated into commercial software tools, enable utilities, vendors, and developers to confidently study high-penetration PV systems. The project also demonstrates advanced applications, including adaptive protection schemes (APS) for distribution systems and microgrids, ensuring grid safety and reliability. The technical effectiveness and economic feasibility of the methods are evident through the development and validation of sophisticated inverter test plans and the selection of representative inverters. Testing by EPRI and NREL on retail, commercial, and utility-scale inverters, conforming to IEEE standards, underscores the robustness of the models. Improvements to existing generic models for various analyses further enhance their validity and applicability. The project also identifies gaps in common distribution protection schemes and designed new APS using improved DER models, demonstrating their effectiveness through modeling and hardware-in-the-loop (HIL) testing. The project’s benefits to the public are manifold. By advancing the standardization and model-based representation of IBR response, it supports transmission planning, stability assessments, and future IBR interconnection requirements. The generic models can facilitate better communication between transmission planners and developers, supporting expected IBR plant capability and performance. Additionally, the development of APS for radial feeders, meshed networks, and microgrids supports the integration of distributed energy resources (DERs) into distribution systems, enhancing grid reliability and safety. The project’s emphasis on thorough testing and simplicity in design ensures practical and scalable solutions for DER integration.

14 SOLAR ENERGY↗
DOE OSTI2024

Photovoltaic Inverter Failure Mechanism Estimation Using Unsupervised Machine Learning and Reliability Assessment

This article introduces a data-driven approach to assessing failure mechanisms and reliability degradation in outdoor photovoltaic (PV) string inverters. The manufacturer's stated PV inverter lifetime can vary due to the impact of operating site conditions. To address limitations in degradation estimation through accelerated testing, condition monitoring, or degradation modeling, we propose a machine learning (ML) oriented approach. Utilizing data from a 1.4 MW PV power plant operational since 2016, with 46 string PV inverters tied to the grid, we employ the unsupervised one-class support vector machine ML technique to analyze inverter and sensor data, capable of classifying humidity cycling and temperature fluctuations as dominant failure mechanisms. Utilizing the anomaly alert relationship and alert details specific to the inverter, the level of PV inverter output is considered as its availability or available reliability. Subsequently, a continuous Markov model is applied to six-month alert data, revealing an average stated reliability of 20% after 20 years of continuous operation. These results support recommendations for time-bound preventive measures to enhance PV inverter reliability under diverse outdoor conditions. Furthermore, the approach provides a nondestructive, top–down, and generalized method for analyzing any commercial PV inverter exposed to outdoor conditions, contingent on the availability of relevant data.

14 SOLAR ENERGY↗
NASA NTRS2017

Heroic Reliability Improvement in Manned Space Systems

System reliability can be significantly improved by a strong continued effort to identify and remove all the causes of actual failures. Newly designed systems often have unexpected high failure rates which can be reduced by successive design improvements until the final operational system has an acceptable failure rate. There are many causes of failures and many ways to remove them. New systems may have poor specifications, design errors, or mistaken operations concepts. Correcting unexpected problems as they occur can produce large early gains in reliability. Improved technology in materials, components, and design approaches can increase reliability. The reliability growth is achieved by repeatedly operating the system until it fails, identifying the failure cause, and fixing the problem. The failure rate reduction that can be obtained depends on the number and the failure rates of the correctable failures. Under the strong assumption that the failure causes can be removed, the decline in overall failure rate can be predicted. If a failure occurs at the rate of lambda per unit time, the expected time before the failure occurs and can be corrected is 1/lambda, the Mean Time Before Failure (MTBF). Finding and fixing a less frequent failure with the rate of lambda/2 per unit time requires twice as long, time of 1/(2 lambda). Cutting the failure rate in half requires doubling the test and redesign time and finding and eliminating the failure causes.Reducing the failure rate significantly requires a heroic reliability improvement effort.

life support↗
NASA NTRS1986

Reliability and maintenance simulation of the Hubble Space Telescope

An analytical approach is presented which was developed and implemented at MSFC specifically for the Space Telescope Program to provide comparisons of critical item failures, system downstates, on-orbit servicing versus return for ground maintenance, overall system downtime, and to obtain a measure of expected uptime for science functions.

Pizzano, F.↗
NASA NTRS1992

Profile of a cell test database and a corresponding reliability database

The development of computerized control, and data retrieval for aerospace cell testing affords an excellent opportunity to incorporate three specific concepts to both manage the test area and to track product performance on a real-time basis. The adoption and incorporation of precepts fostered by this total quality management (TQM) initiative are critical to us for retaining control of our business while substantially reducing the separate quality control inspection activity. Test discrepancies are all 'equally bad' in cell acceptance testing because, for example, we presently do not discriminate between 1 or 25 mV for an overvoltage condition. We must take leadership in classifying such discrepancies in order to expedite their clearance and redirect our resources for prevention activities. The development and use of engineering alerts (or guardbanding) which more closely match our product capabilities and are toleranced tighter than the required customer specification are paramount to managing the test unit in order to remain both quality and cost effective.

Brearley, George R.↗
NASA NTRS1990

Probabilistic simulation for flaw acceptance by dye-penetrant inspection

This paper examines the problems encountered in assessing the reliability of dye-penetrant nondestructive inspection (NDI) techniques in preventing failures due to undetected surface flaws, as well as from flaw acceptance (Fitness-For-Purpose). A Monte Carlo simulation procedure which includes the major variables of the problem is presented as a means of quantifying reliability. Some issues associated with distribution selection are examined. A methodology for selecting the penetrant type and flaw acceptance size for the specific components analyzed using the simulation is proposed. Current methodology limitations are discussed along with possible future effort. Penetrant selection and acceptable sizes of detected flaws are based on a probabilistic assessment of the effect of component and dye-penetrant system variables on structural reliability.

Russell, D. A.↗
DOE OSTI2020

Initial Assessment of Availability and Reliability for the PIP-II Superconducting Radio Frequency Linear Accelerator Facility

The Proton Improvement Plan -II (PIP-II) is a high intensity and high energy proton accelerator which will be used to support the neutrino program at Fermilab. The accelerator will deliver a 2 mA average beam current at a kinetic energy of 800 MeV. Due to the requirements from experiments, this accelerator is designed to be a highly reliable and available system. A target availability of the complete accelerator facility was prescribed to be 90%. An availability and reliability assessment of the accelerator was carried out to ascertain that the design can meet the target availability specification. The results were estimated for the nominal operational mode, when an 800 MeV beam is delivered on the target and for the critical operational mode, when a 600 MeV output beam was incident on the target. The design of a complete accel-erator system is a complex arrangement of a large number of components. To simplify the analysis, a few components were shortlisted and based on their functions, an accelerator model was created. The model is represented in the form of reliability block diagrams. Availability and reliability were estimated for each operational mode. To increase the availa-bility and reliability of the overall accelerator, redundancy of one cavity per section in the superconducting portion of the Linac was introduced.

43 PARTICLE ACCELERATORS↗
NASA NTRS2022

Reliability Assurance for COTS Capacitors

Burn-in (BI) and life testing (LT) are the most important reliability related elements of quality assurance for components used in space systems. This presentation discusses the need of transition from the existing approach to BI, LT, and destructive physical analysis (DPA) of COTS capacitors that is based on military specifications to an alternative approach that is based on Physics of Failure and HALT.

reliability↗
NASA NTRS1997

Multi-Disciplinary System Reliability Analysis

The objective of this study is to develop a new methodology for estimating the reliability of engineering systems that encompass multiple disciplines. The methodology is formulated in the context of the NESSUS probabilistic structural analysis code developed under the leadership of NASA Lewis Research Center. The NESSUS code has been successfully applied to the reliability estimation of a variety of structural engineering systems. This study examines whether the features of NESSUS could be used to investigate the reliability of systems in other disciplines such as heat transfer, fluid mechanics, electrical circuits etc., without considerable programming effort specific to each discipline. In this study, the mechanical equivalence between system behavior models in different disciplines are investigated to achieve this objective. A new methodology is presented for the analysis of heat transfer, fluid flow, and electrical circuit problems using the structural analysis routines within NESSUS, by utilizing the equivalence between the computational quantities in different disciplines. This technique is integrated with the fast probability integration and system reliability techniques within the NESSUS code, to successfully compute the system reliability of multi-disciplinary systems. Traditional as well as progressive failure analysis methods for system reliability estimation are demonstrated, through a numerical example of a heat exchanger system involving failure modes in structural, heat transfer and fluid flow disciplines.

Mahadevan, Sankaran↗
NASA NTRS2001

Multidisciplinary System Reliability Analysis

The objective of this study is to develop a new methodology for estimating the reliability of engineering systems that encompass multiple disciplines. The methodology is formulated in the context of the NESSUS probabilistic structural analysis code, developed under the leadership of NASA Glenn Research Center. The NESSUS code has been successfully applied to the reliability estimation of a variety of structural engineering systems. This study examines whether the features of NESSUS could be used to investigate the reliability of systems in other disciplines such as heat transfer, fluid mechanics, electrical circuits etc., without considerable programming effort specific to each discipline. In this study, the mechanical equivalence between system behavior models in different disciplines are investigated to achieve this objective. A new methodology is presented for the analysis of heat transfer, fluid flow, and electrical circuit problems using the structural analysis routines within NESSUS, by utilizing the equivalence between the computational quantities in different disciplines. This technique is integrated with the fast probability integration and system reliability techniques within the NESSUS code, to successfully compute the system reliability of multidisciplinary systems. Traditional as well as progressive failure analysis methods for system reliability estimation are demonstrated, through a numerical example of a heat exchanger system involving failure modes in structural, heat transfer and fluid flow disciplines.

Mahadevan, Sankaran↗
NASA NTRS2007

SiC Multi-Chip Power Modules as Power-System Building Blocks

The term "SiC MCPMs" (wherein "MCPM" signifies "multi-chip power module") denotes electronic power-supply modules containing multiple silicon carbide power devices and silicon-on-insulator (SOI) control integrated-circuit chips. SiC MCPMs are being developed as building blocks of advanced expandable, reconfigurable, fault-tolerant power-supply systems. Exploiting the ability of SiC semiconductor devices to operate at temperatures, breakdown voltages, and current densities significantly greater than those of conventional Si devices, the designs of SiC MCPMs and of systems comprising multiple SiC MCPMs are expected to afford a greater degree of miniaturization through stacking of modules with reduced requirements for heat sinking. Moreover, the higher-temperature capabilities of SiC MCPMs could enable operation in environments hotter than Si-based power systems can withstand. The stacked SiC MCPMs in a given system can be electrically connected in series, parallel, or a series/parallel combination to increase the overall power-handling capability of the system. In addition to power connections, the modules have communication connections. The SOI controllers in the modules communicate with each other as nodes of a decentralized control network, in which no single controller exerts overall command of the system. Control functions effected via the network include synchronization of switching of power devices and rapid reconfiguration of power connections to enable the power system to continue to supply power to a load in the event of failure of one of the modules. In addition to serving as building blocks of reliable power-supply systems, SiC MCPMs could be augmented with external control circuitry to make them perform additional power-handling functions as needed for specific applications: typical functions could include regulating voltages, storing energy, and driving motors. Because identical SiC MCPM building blocks could be utilized in a variety of ways, the cost and difficulty of designing new, highly reliable power systems would be reduced considerably. Several prototype DC-to-DC power-converter modules containing SiC power-switching devices were designed and built to demonstrate the feasibility of the SiC MCPM concept. In anticipation of a future need for operation at high temperature, the circuitry in the modules includes high-temperature inductors and capacitors. These modules were designed to be stacked to construct a system of four modules electrically connected in series and/or parallel. The packaging of the modules is designed to satisfy requirements for series and parallel interconnection among modules, high power density, high thermal efficiency, small size, and light weight. Each module includes four output power connectors two for serial and two for parallel output power connections among the modules. Each module also includes two signal connectors, electrically isolated from the power connectors, that afford four zones for signal interconnections among the SOI controllers. Finally, each module includes two input power connectors, through which it receives power from an in-line power bus. This design feature is included in anticipation of a custom-designed power bus incorporating sockets compatible with snap-on type connectors to enable rapid replacement of failed modules.

Lostetter, Alexander↗
NASA NTRS1979

Clock performance, reliability and cost interrelationships

Problems encountered by clock manufacturers in attempting to supply reasonably priced, reliable clocks for critical aerospace applications arise from the inherent technical difficulties of designing and fabricating equipment to provide performance at the limits of the state of the art in demanding environments. The difficulties are compounded by inconsistent and unstandardized specification practices, and by an emphasis on initial acquisition costs, rather than on life cycle costs. Conventional parts stress analyses, which do not provide a useful indication of the reliability of a clock, lead to increased parts costs for high performance aerospace clocks without comensurate benefits in improved reliability or performance. The characterization of clocks in terms of the mean time between resynchronizations, facilitates the estimation of life cycle costs and provides a means to evaluate clocks in a realistic fashion for specific systems applications.

Levine, M. W.↗
DOE OSTI2020

Modeling Flexible Generator Operating Regions via Chance- constrained Stochastic Unit Commitment

Here, we introduce a novel chance-constrained stochastic unit commitment model to address uncertainty in renewables' production uncertainty in power systems operation. For most thermal generators,underlying technical constraints that are universally treated as "hard" by deterministic unit commitment models are in fact based on engineering judgments, such that system operators can periodically request operation outside these limits in non-nominal situations, e.g., to ensure reliability. We incorporate this practical consideration into a chance-constrained stochastic unit commitment model, specifically by in-frequently allowing minor deviations from the minimum and maximum thermal generator power output levels. We demonstrate that an extensive form of our model is computationally tractable for medium-sized power systems given modest numbers of scenarios for renewables' production. We show that the model is able to potentially save significant annual production costs by allowing infrequent and controlled violation of the traditionally hard bounds imposed on thermal generator production limits. Finally, we conduct a sensitivity analysis of optimal solutions to our model under two restricted regimes and observe similar qualitative results.

42 ENGINEERING↗
DOE OSTI2021

Propagation of Input Uncertainties in Numerical Simulations of Laser Powder Bed Fusion

Laser powder bed fusion has the potential of redefining state-of-the-art processing and production methods, but defect formation and inconsistent build quality have limited the implementation of this process. Numerical models are widely used to study this process and predict the formation of these defects. Presently, the uncertainties of model input parameters and thermophysical properties used by these numerical simulations have not been investigated. In the present study, the uncertainty in these input parameters and material properties are quantified for laser powder bed fusion, with and without a simulated powder bed, to determine their influence on the predictive accuracy of an experimentally validated numerical model. Accounting for all possible sources of uncertainty quickly becomes computationally expensive on account of the curse of dimensionality. Uncertainty in laser absorption, solid, and liquid specific heat of the metal were found to have the largest effect on model prediction reliability with or without the use of a powder bed. Results also illustrate that accounting for these three uncertain parameters still captures the majority of model prediction uncertainty. Furthermore, the methodology of this study may be used to understand the uncertainty in as-built microstructure through propagation to microstructure prediction models, or applied under processing conditions where high Péclet numbers are observed and the thermal convection and fluid flow within the molten pool are substantial.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2022

Standard operating procedures for the comprehensive and reliable analysis of cannabis terpenes

Terpenes are the primary determinants of cannabis flower aroma, and ongoing research tests their potential for impacting the overall experience. Frustratingly, despite the importance of terpenes in cannabis physiology and commercial uses, literature reports vary widely regarding the major constituents of volatile blends and the concentrations of individual terpenes. Here, in this article, we provide detailed descriptions of complementary approaches that will allow researchers to determine the identity and quantity of cannabis terpenes unequivocally and reliably. These standard operating procedures will guide decisions about which method to employ to address specific analytical goals. We are including two application examples to illustrate the utility of different approaches for tackling the analysis of terpenes in cannabis flower samples.

Polito, Joshua↗
DOE OSTI2026

“One Table to Rule Them All”: How a Single Table can Enable Extensive Insights, Analytics and Assessment on Human Mobility Data

While much research has been conducted in Human Mobility Science, most studies on the analytics/insights part generally focus on one of the following: processing and analytics on human stop-trip behavior, design of individual mobility metrics (often in silos), calculation and characterization of only a handful (typically 5-6) of human mobility metrics on geospatial-temporal human mobility data of interest. Although human mobility research offers a vast and diverse array of available metrics, most individual studies typically compute only a small subset of five or six metrics at a time when analyzing trajectory datasets of human mobility across different areas of interest. This paper is motivated by the critical need to repeatedly compute an extensive array of human mobility metrics across several trajectory datasets and perform individual metric-level benchmarking to establish a new, standardized Test and Evaluation (T&E) suite for the field of Human Mobility Science. We first present our findings on the minimal yet sufficient pre-processing required to reliably and efficiently compute a wide range of human mobility metrics. The key findings are specifically related to the proposed Composite Stop Locations table, which serves as a core pre-processing data layer. Subsequently, we present a case study demonstrating how the Composite Stop Locations table facilitates computation of at least 14 distinct human mobility metrics (unlike 5-6 different set of metrics used for studies in the literature) using the popular and open-source OpenPFLOW dataset. Finally, we have also presented an example of our benchmarking methodology to evaluate the quality and performance of the trajectory dataset of interest, assessed across multiple human mobility metrics.

De, Debraj [ORNL] (ORCID:0000000233630020)↗
DOE OSTI2026

Flash electropolishing for TEM: Reducing FIB‐induced defects in tungsten with protocols for new materials

Focused ion beam (FIB) milling has become the dominant approach for site-specific transmission electron microscopy (TEM) specimen preparation; however, FIB damage remains a critical limitation for reliable microstructural characterisation, particularly in radiation effects studies. Tungsten is especially susceptible to FIB damage due to its high nuclear stopping power, which promotes the formation and strong diffraction contrast of FIB-induced ‘black spot’ defects that are indistinguishable from very fine irradiation-induced loops/defects resulting from low to intermediate temperature neutron irradiation. In this work, flash electropolishing is systematically evaluated as a post-FIB treatment for minimising preparation-induced artefacts for TEM analysis of tungsten-based alloys. Using a range of non-, ion-, and neutron-irradiated tungsten materials, the effectiveness of flash electropolishing has been assessed through direct comparison with conventional FIB and plasma-FIB preparation including low-energy Ga, Ar, Xe ion cleaning. The results demonstrate that flash electropolishing effectively removes FIB-damaged layers and ‘black spot’ defects, thereby enabling reliable observation of irradiation-induced dislocation structures. Key processing parameters governing flash electropolishing quality – including lamella thickness, applied voltage, polishing duration, electrolyte chemistry, and cathode geometry – have been systematically evaluated, and clear criteria were established for determining when flash electropolishing is required to ensure reliable microstructural analysis. This work also provides practical guidance for implementing flash electropolishing as an artefact-controlled specimen-preparation approach for TEM characterisation of FIB-produced specimens. The systematic protocol can be extended to other, non-tungsten materials.

TEM sample preparation↗