Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “high reliability”

Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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

At least 91 records · Page 5
All sourcesNASA NTRSDOE OSTI
NASA NTRS2013

Development of a High Reliability Compact Air Independent PEMFC Power System

Autonomous Underwater Vehicles (AUV's) have received increasing attention in recent years as military and commercial users look for means to maintain a mobile and persistent presence in the undersea world. Compact, neutrally buoyant power systems are needed for both small and large vehicles. Historically, batteries have been employed in these applications, but the energy density and therefore mission duration are limited with current battery technologies. Vehicles with stored energy requirements greater than approximately 10 kWh have an alternate means to get long duration power. High efficiency Proton Exchange Membrane (PEM) fuel cell systems utilizing pure hydrogen and oxygen reactants show the potential for an order of magnitude energy density improvement over batteries as long as the subsystems are compact. One key aspect to achieving a compact and energy dense system is the design of the fuel cell balance of plant (BOP). Recent fuel cell work, initially focused on NASA applications requiring high reliability, has developed systems that can meet target power and energy densities. Passive flow through systems using ejector driven reactant (EDR) circulation have been developed to provide high reactant flow and water management within the stack, with minimal parasitic losses compared to blowers. The ejectors and recirculation loops, along with valves and other BOP instrumentation, have been incorporated within the stack end plate. In addition, components for water management and reactant conditioning have been incorporated within the stack to further minimize the BOP. These BOP systems are thermally and functionally integrated into the stack hardware and fit into the small volumes required for AUV and future NASA applications to maximize the volume available for reactants. These integrated systems provide a compact solution for the fuel cell BOP and maximize the efficiency and reliability of the system. Designs have been developed for multiple applications ranging from less than 1 kWe to 70 kWe. These systems occupy a very small portion of the overall energy system, allowing most of the system volume to be used for reactants. The fuel cell systems have been optimized to use reactants efficiently with high stack efficiency and low parasitic losses. The resulting compact, highly efficient fuel cell system provides exceptional reactant utilization and energy density. Key design variables and supporting test data are presented. Future development activities are described.

Vasquez, Arturo↗
NASA NTRS1985

Design Evaluation of High Reliability Lithium Batteries

Within one year, a lithium battery design can be qualified for device use through the application of accelerated discharge testing, calorimetry measurements, real time tests and other supplemental testing. Materials and corrosion testing verify that the battery components remain functional during expected battery life. By combining these various methods, a high reliability lithium battery can be manufactured for applications which require zero defect battery performance.

Buchman, R. C.↗
NASA NTRS1999

High Reliability Engine Control Demonstrated for Aircraft Engines

For a dual redundant-control system, which is typical for short-haul aircraft, if a failure is detected in a control sensor, the engine control is transferred to a safety mode and an advisory is issued for immediate maintenance action to replace the failed sensor. The safety mode typically results in severely degraded engine performance. The goal of the High Reliability Engine Control (HREC) program was to demonstrate that the neural-network-based sensor validation technology can safely operate an engine by using the nominal closed-loop control during and after sensor failures. With this technology, engine performance could be maintained, and the sensor could be replaced as a conveniently scheduled maintenance action.

Guo, Ten-Huei↗
DOE OSTI2021

Challenges of Interpreting and Applying New IPC-J-STD-001 Cleanliness Standards in High-Reliability Applications

The electronics industry has rapidly and widely embraced the replacement of ROSE testing with an SIR-focused approach to testing for certification of a qualified manufacturing plan. These new cleanliness documentation standards, housed in IPC J-STD-001 Rev. H, have just begun to impact electronics manufacturers as design and production teams work through how to meet them. This research focuses on the particular challenges of applying these new standards in high-reliability product applications, through the lens of interpreting SIR test results and what they mean for process capability, repeatability and diagnosing a need for process changes. The experiments examined a variety of factors that influence SIR results and suggest areas where SIR test plans can be greatly improved.

Capen, William↗
NASA NTRS1994

Space Hardware Design for Long Life with High Reliability

In 1991, the Cassini Project at JPL funded a study to identify rules for design and test of hardware required to function reliably in space for very long lifetimes. The widest possible range of hardware issues were considered consistent with three constraints: (1) Software and mission rules were addressed only to the extent they affected hardware performance; (2) the rules developed were applicable to a single spacecraft, and multiple spacecraft to achieve mission success were not considered; and (3) high reliability rules were considered only in their relationship to long life. The study was subsequently published as a JPL document. One major conclusion of the workshop was that unattended space missions extending out to 25 years or more are feasible.

hardware↗
NASA NTRS2024

A High-Reliability Photoelectric Detection System for Mars Sample Return’s Orbiting Sample

The Mars Sample Return campaign is an endeavor of unprecedented technological complexity and coordination that attempts to answer fundamental questions about the habitability of Mars by returning the first samples of Martian material to Earth for analysis. The third mission in the campaign consists of the NASA-provided Capture, Containment, and Return System (CCRS) onboard the European Space Agency’s Earth Return Orbiter, which will retrieve the Orbiting Sample (OS) container from its orbit around Mars. Retrieving a passive sample container from a planetary orbit has never been attempted by any spacecraft and requires the development of new technology to succeed in this ambitious task. This paper introduces the high-reliability Capture Sensor Suite (CSS), a novel optical detection system that provides CCRS with the capability to autonomously detect the OS as it is captured. This article will discuss the challenges and requirements for the fault-tolerant design of the CSS.

planetary sampling↗
NASA NTRS1976

Investigation of low cost, high reliability sealing techniques for hybrid microcircuits, phase 1

A preliminary investigation was made to determine the feasibility of using adhesive package sealing for hybrid microcircuits. Major effort consisted of: (1) surveying representative hybrid manufacturers to assess the current use of adhesives for package sealing; (2) making a cost comparison of metallurgical versus adhesive package sealing; (3) determining the seal integrity of gold plated flatpack type packages sealed with selected adhesives, thermal shock, temperature cycling, mechanical shock, and constant acceleration test environments; and (4) defining a more comprehensive study to continue the evaluation of adhesives for package sealing. Results showed that 1.27 cm square gold plated flatpack type packages sealed with the film adhesives and the paste adhesive retained their seal integrity after all tests, and that similarly prepared 2.54 cm square packages retained their seal integrity after all tests except the 10,000 g's constant acceleration test. It is concluded that these results are encouraging, but by no means sufficient to establish the suitability of adhesives for sealing high reliability hybrid microcircuits.

Perkins, K. L.↗
DOE OSTI2014

High-reliability passivation of hydrogen-terminated diamond surface by atomic layer deposition of Al{sub 2}O{sub 3}

Although the two-dimensional hole gas (2DHG) of a hydrogen-terminated diamond surface provides a unique p-type conducting layer for high-performance transistors, the conductivity is highly sensitive to its environment. Therefore, the surface must be passivated to preserve the 2DHG, especially at high temperature. We passivated the surface at high temperature (450 °C) without the loss of C-H surface bonds by atomic layer deposition (ALD) and investigated the thermal reliability of the Al{sub 2}O{sub 3} film. As a result, C-H bonds were preserved, and the hole accumulation effect appeared after the Al{sub 2}O{sub 3} deposition by ALD with H{sub 2}O as an oxidant. The sheet resistivity and hole density were almost constant between room temperature and 500 °C by the passivation with thick Al{sub 2}O{sub 3} film thicker than 38 nm deposited by ALD at 450 °C. After the annealing at 550 °C in air The sheet resistivity and hole density were preserved. These results indicate the possibility of high-temperature application of the C-H surface diamond device in air. In the case of lower deposition temperatures, the sheet resistivity increased after air annealing, suggesting an insufficient protection capability of these films. Given the result of sheet resistivity after annealing, the increase in the sheet resistivity of these samples was not greatly significant. However, bubble like patterns were observed in the Al{sub 2}O{sub 3} films formed from 200 to 400 °C by air annealing at 550 °C for 1 h. On the other hand, the patterns were no longer observed at 450 °C deposition. Thus, this 450 °C deposition is the sole solution to enabling power device application, which requires high reliability at high temperatures.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2025

Electric Drive Technologies Consortium (EDTC)/ Cost competitive, high-Performance, highly Reliable (CPR) Power Devices on 4H-SiC (Final Report)

4H-Silicon carbide (4H-SiC) is a wide bandgap semiconductor that offers superior material properties over silicon, including higher critical electric field, thermal conductivity, and electron saturation velocity. These advantages make 4H-SiC highly attractive for high-voltage, high-efficiency power electronics. However, realizing the full potential of SiC requires device technologies that are not only high-performing but also manufacturable and reliable under real-world operating conditions. This report summarizes the outcomes of a five-year R&D effort funded by the U.S. Department of Energy (DOE) under the Electric Drive Technologies Consortium (EDTC), focused on developing cost-competitive, high-performance, and highly reliable (CPR) power devices on 4H-SiC substrates. The program targeted scalable and manufacturable 1.2 kV-class SiC MOSFETs optimized for next-generation electric vehicles, renewable energy systems, and industrial power conversion. The project delivered transformative advancements in SiC power device performance and ruggedness. Particularly, Specific on-resistance (R on,sp ) was reduced by up to 37%, from ~4.0 m$\Omega \cdot$cm 2 in earlier designs to an industry-leading 2.40 m$\Omega \cdot$cm 2 , driven by optimized doping, refined JFET widths, and layout engineering. Breakdown voltages (BV) exceeded 1600 V, marking improvement over legacy baselines, and demonstrating the robustness of newly implemented junction profiles and edge terminations. Short-circuit withstand time (SCWT) saw a remarkable 4$\times$ increase, from ~2 $\mu$s to over 8 $\mu$s, achieved through the successful deployment of deep P-well structures (~1.8–2.0 $\mu$m) via channeling implantation. This innovative process breakthrough enabled precise junction formation without MeV-class implantation tools, reduced leakage under high field stress, and allowed even the shortest-channel devices (down to 0.3 $\mu$m) to achieve both high BV and excellent ruggedness—breaking the traditional trade-off between conduction efficiency and blocking capability. Several novel architectures pushed the performance envelope further. JBSFETs—featuring embedded Schottky portions—eliminated bipolar degradation and drastically reduced third-quadrant leakage, while Ladder MOSFETs introduced a clever orthogonal conduction path that achieved a 15.4% reduction in R on,sp over standard linear designs. Switching performance reached new benchmarks: short-channel devices showed a 31% reduction in total switching energy compared to 0.5 $\mu$m counterparts, while maintaining manageable gate drive requirements. Layout-optimized structures not only improved transconductance but also accelerated switching transitions, pointing to real-world benefits in converter-level efficiency. The devices also passed rigorous reliability validation. Stress-tested across TDDB, HTGB, HTRB, HVP, and burn-in, the devices screened under 30 V/10 hr and 43 V/1 s protocols consistently exhibited tighter lifetime distributions and long-term oxide robustness. These screening techniques proved effective in identifying latent defects and ensuring deployment-grade reliability. Meanwhile, advanced 3D TCAD simulations revealed and resolved electric field hotspots—particularly in HEXFET corners—where fields exceeding 4.8 MV/cm were mitigated through geometry-aware layout corrections. Overall, the results of this project demonstrate a manufacturable and scalable SiC power device platform that addresses key DOE performance targets for efficient, robust, and reliable 1.2kV 4H-SiC Power Devices. The developed technologies represent a meaningful step forward in the commercial readiness of high-voltage SiC solutions and provide a strong foundation for continued advancement in wide bandgap power electronics.

42 ENGINEERING↗
NASA NTRS1994

An Integrated Fault Tolerant Robotic Controller System for High Reliability and Safety

This paper describes the concepts and features of a fault-tolerant intelligent robotic control system being developed for applications that require high dependability (reliability, availability, and safety). The system consists of two major elements: a fault-tolerant controller and an operator workstation. The fault-tolerant controller uses a strategy which allows for detection and recovery of hardware, operating system, and application software failures.The fault-tolerant controller can be used by itself in a wide variety of applications in industry, process control, and communications. The controller in combination with the operator workstation can be applied to robotic applications such as spaceborne extravehicular activities, hazardous materials handling, inspection and maintenance of high value items (e.g., space vehicles, reactor internals, or aircraft), medicine, and other tasks where a robot system failure poses a significant risk to life or property.

robotics fault-tolerant control systems↗
NASA NTRS2011

Optimized Biasing of Pump Laser Diodes in a Highly Reliable Metrology Source for Long-Duration Space Missions

Non Planar Ring Oscillator (NPRO) lasers are highly attractive for metrology applications. NPRO reliability for prolonged space missions is limited by reliability of 808 nm pump diodes. Combined laser farm aging parameter allows comparing different bias approaches. Monte-Carlo software developed to calculate the reliability of laser pump architecture, perform parameter sensitivity studies To meet stringent Space Interferometry Mission (SIM) Lite lifetime reliability / output power requirements, we developed a single-mode Laser Pump Module architecture that: (1) provides 2 W of power at 808 nm with >99.7% reliability for 5.5 years (2) consists of 37 de-rated diode lasers operating at -5C, with outputs combined in a very low loss 37x1 all-fiber coupler

laser communications↗
NASA NTRS2019

Trends in Human Spaceflight: Failure Tolerance, High Reliability and Correlated Failure History

In a half century of human spaceflight, NASA has continuously refined agency safety and reliability requirements in response to mission demands, critical failures, and technology development. Early spacecraft, including Mercury, Gemini and Apollo vehicles, were highly reliant on dissimilar redundancy and demonstrated test margins. Later programs, such as the reusable Space Transportation System (STS) and International Space Station (ISS), introduced probabilistic studies and isolated two-failure tolerance to improve robustness at the expense of added complexity. More recently, the Orion Multi-Program Crew Vehicle (MPCV) program adopted universal single-failure tolerance with two categorical exceptions; Zero-Failure Tolerant (0FT) and Design for Minimum Risk (DFMR) hardware. Failure tolerance variances are defined and managed in accordance with agency human-rating requirements, and require concurrence from program Technical Authorities (TA) as well as the MPCV Safety and Mission Assurance Safety and Engineering Review Panel (MSERP). To understand and reaffirm standards applied to Apollo, Space Shuttle and Orion vehicles, Orion and Deep Space Gateway Safety and Mission Assurance (S&MA) representatives conducted accelerated research to compare unique safety and reliability criteria against ground and flight anomalies, based on information contained in post-mission reports and the Problem Reporting and Corrective Action (PRACA) database. In some cases, high-profile failures and narrow escapes have reinforced decisions to maintain or adapt safety requirements. In others, empirical trends have highlighted the need for vigilance and innovative safety guidelines. Given the inability to achieve absolute compliance with evolving safety and reliability requirements, the team conducted a targeted review of DFMR and 0FT propulsion elements within the framework of changing system design, inspection, materials and process developments to formulate conclusions on technological maturity, failure density, and net changes in safety risk. Based on the aggregate performance of high-reliability and failure-tolerant systems, the authors have attempted to establish best practices and guidelines to inform future program decisions. On a somewhat cautionary note, this study is not intended to direct a universal set of requirements for future missions based on prior lessons learned. Spacecraft safety is a multi-variable problem, and attempts to mitigate past failures will not guarantee future success. However, this assessment offers a retrospective review of policy changes, implementation and effectiveness. In the future, NASA, European Space Agency (ESA) and industry partners may benefit from a more robust correlation between requirements and performance, as space-faring nations work toward more challenging, complex and long-duration commercial and deep-space ventures.

Green, Carrie↗
DOE OSTI2022

Automatic Detection of Defects in High-Reliability Components

Disastrous consequences can result from defects in manufactured parts—particularly the high consequence parts developed at Sandia. Identifying flaws in as-built parts can be done with nondestructive means, such as X-ray Computed Tomography (CT). However, due to artifacts and complex imagery, the task of analyzing the CT images falls to humans. Human analysis is inherently unreproducible, unscalable, and can easily miss subtle flaws. We hypothesized that deep learning methods could improve defect identification, increase the number of parts that can effectively be analyzed, and do it in a reproducible manner. We pursued two methods: 1) generating a defect-free version of a scan and looking for differences (PandaNet), and 2) using pre-trained models to develop a statistical model of normality (Feature-based Anomaly Detection System: FADS). Both PandaNet and FADS provide good results, are scalable, and can identify anomalies in imagery. In particular, FADS enables zero-shot (training-free) identification of defects for minimal computational cost and expert time. It significantly outperforms prior approaches in computational cost while achieving comparable results. FADS’ core concept has also shown utility beyond anomaly detection by providing feature extraction for downstream tasks.

47 OTHER INSTRUMENTATION↗
DOE OSTI2023

Reliable, High Power Density Inverters for Heavy Equipment Applications

With this final report, the combined team of the University of Arkansas (UA), University of Illinois, Urbana-Champaign (UIUC), Wolfspeed, Caterpillar, and Ampaire have successfully met all of their project objectives. Noteworthy for the heavy equipment portion of the project with Caterpillar is that the team made its project milestones two years into the project by designing a power dense motor drive for a permanent magnet synchronous machine. Upon finding out that Caterpillar had pivoted to switched-reluctance machines (SRMs), the team subsequently redesigned and implemented the SRM drive with a coolant temperature of 105°C! The other major task that the UA, UIUC, and Wolfspeed teams took on was the design of a PMSM drive for a hybrid aircraft that was flown on Feb. 20, 2023 by Ampaire after extensive testing and evaluation. While there were also technical objectives in thermal management, integrated gate drivers, reliability studies, and high temperature capacitors with integrated bussing, each of these have been fully reported on in quarterly reports. In brief, advances in thermal management and high temperature capacitors were utilized in order to achieve a 105°C motor drive. The integrated gate driver work resulted in a higher density drive with no loss of efficiency. Most of the last year, during a no-cost extension, was spent waiting for the Ampaire motor drive to be tested (outside of our project). Many months passed with the device just sitting in California while the company dealt with battery-related issues. This delayed the integration and testing activities until Fall 2022. Once those began, then the process took about 4-5 months to complete culminating in the test flight in Feb. 2023. By providing technical advances and integration into final platforms, the barrier to economic impact has been lowered. This project benefits the public by overcoming key technical barriers to electrified and hybrid electric heavy equipment and aircraft. This, in turn, leads to lower greenhouse gas emissions and a cleaner environment. This final report summarizes the integrated gate driver work and the Ampaire hybrid electric aircraft integration and test flight efforts. All other information has been previously reported in quarterly reports. A summary of the motor drives created during this project is provided along with a listing of publications.

42 ENGINEERING↗
NASA NTRS2010

Constellation Ground Systems Launch Availability Analysis: Enhancing Highly Reliable Launch Systems Design

Success of the Constellation Program's lunar architecture requires successfully launching two vehicles, Ares I/Orion and Ares V/Altair, within a very limited time period. The reliability and maintainability of flight vehicles and ground systems must deliver a high probability of successfully launching the second vehicle in order to avoid wasting the on-orbit asset launched by the first vehicle. The Ground Operations Project determined which ground subsystems had the potential to affect the probability of the second launch and allocated quantitative availability requirements to these subsystems. The Ground Operations Project also developed a methodology to estimate subsystem reliability, availability, and maintainability to ensure that ground subsystems complied with allocated launch availability and maintainability requirements. The verification analysis developed quantitative estimates of subsystem availability based on design documentation, testing results, and other information. Where appropriate, actual performance history was used to calculate failure rates for legacy subsystems or comparative components that will support Constellation. The results of the verification analysis will be used to assess compliance with requirements and to highlight design or performance shortcomings for further decision making. This case study will discuss the subsystem requirements allocation process, describe the ground systems methodology for completing quantitative reliability, availability, and maintainability analysis, and present findings and observation based on analysis leading to the Ground Operations Project Preliminary Design Review milestone.

Gernand, Jeffrey L.↗