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NASA NTRS1994

Problems with aging wiring in Naval aircraft

The Navy is experiencing a severe aircraft electrical wiring maintenance problem as a result of the extensive use of an aromatic polyimide insulation that is deteriorating at a rate that was unexpected when this wire was initially selected. This problem has significantly affected readiness, reliability, and safety and has greatly increased the cost of ownership of Naval aircraft. Failures in wire harnesses have exhibited arcing and burning that will propagate drastically, to the interruption of many electrical circuits from a fault initiated by the failure of deteriorating wires. There is an urgent need for a capability to schedule aircraft rewiring in an orderly manner with a logically derived determination of which aircraft have aged to the point of absolute necessity. Excessive maintenance was demonstrated to result from the accelerated aging due to the parameters of moisture, temperature, and strain that exist in the Naval Aircraft environment. Laboratory studies have demonstrated that MIL-W-81381 wire insulation when aged at high humidities followed the classical Arrhenius thermal aging relationship. In an extension of the project a multifactor formula was developed that is now capable of predicting life under varying conditions of these service parameters. An automated test system has also been developed to analyze the degree of deterioration that has occurred in wires taken from an aircraft in order to obtain an assessment of remaining life. Since it is both physically and financially impossible to replace the wiring in all the Navy's aircraft at once, this system will permit expedient scheduling so that those aircraft that are most probable to have wiring failure problems can be overhauled first.

Campbell, Frank J.↗

NASA NTRS1999

Blood flow dynamics in heart failure

BACKGROUND: Exercise intolerance in heart failure (HF) may be due to inadequate vasodilation, augmented vasoconstriction, and/or altered muscle metabolic responses that lead to fatigue. METHODS AND RESULTS: Vascular and metabolic responses to rhythmic forearm exercise were tested in 9 HF patients and 9 control subjects (CTL) during 2 protocols designed to examine the effect of HF on the time course of oxygen delivery versus uptake (protocol 1) and on vasoconstriction during exercise with 50 mm Hg pressure about the forearm to evoke a metaboreflex (protocol 2). In protocol 1, venous lactate and H+ were greater at 4 minutes of exercise in HF versus CTL (P<0.05) despite similar blood flow and oxygen uptake responses. In protocol 2, mean arterial pressure increased similarly in each group during ischemic exercise. In CTL, forearm blood flow and vascular conductance were similar at the end of ischemic and ambient exercise. In HF, forearm blood flow and vascular conductance were reduced during ischemic exercise compared with the ambient trial. CONCLUSIONS: Intrinsic differences in skeletal muscle metabolism, not vasodilatory dynamics, must account for the augmented glycolytic metabolic responses to moderate-intensity exercise in class II and III HF. The inability to increase forearm vascular conductance during ischemic handgrip exercise, despite a normal pressor response, suggests that enhanced vasoconstriction of strenuously exercising skeletal muscle contributes to exertional fatigue in HF.

NASA Discipline Cardiopulmonary↗

NASA NTRS2005

Meeting the Challenges of Exploration Systems: Health Management Technologies for Aerospace Systems With Emphasis on Propulsion

The constraints of future Exploration Missions will require unique Integrated System Health Management (ISHM) capabilities throughout the mission. An ambitious launch schedule, human-rating requirements, long quiescent periods, limited human access for repair or replacement, and long communication delays all require an ISHM system that can span distinct yet interdependent vehicle subsystems, anticipate failure states, provide autonomous remediation, and support the Exploration Mission from beginning to end. NASA Glenn Research Center has developed and applied health management system technologies to aerospace propulsion systems for almost two decades. Lessons learned from past activities help define the approach to proper ISHM development: sensor selection- identifies sensor sets required for accurate health assessment; data qualification and validation-ensures the integrity of measurement data from sensor to data system; fault detection and isolation-uses measurements in a component/subsystem context to detect faults and identify their point of origin; information fusion and diagnostic decision criteria-aligns data from similar and disparate sources in time and use that data to perform higher-level system diagnosis; and verification and validation-uses data, real or simulated, to provide variable exposure to the diagnostic system for faults that may only manifest themselves in actual implementation, as well as faults that are detectable via hardware testing. This presentation describes a framework for developing health management systems and highlights the health management research activities performed by the Controls and Dynamics Branch at the NASA Glenn Research Center. It illustrates how those activities contribute to the development of solutions for Integrated System Health Management.

Melcher, Kevin J.↗

NASA NTRS2010

Simulated Service and Stress Corrosion Cracking Testing for Friction Stir Welded Spun Form Domes

Damage tolerance testing development was required to help qualify a new spin forming dome fabrication process for the Ares 1 program at Marshall Space Flight Center (MSFC). One challenge of the testing was due to the compound curvature of the dome. The testing was developed on a sub-scale dome with a diameter of approximately 40 inches. The simulated service testing performed was based on the EQTP1102 Rev L 2195 Aluminum Lot Acceptance Simulated Service Test and Analysis Procedure generated by Lockheed Martin for the Space Shuttle External Fuel Tank. This testing is performed on a specimen with an induced flaw of elliptical shape generated by Electrical Discharge Machining (EDM) and subsequent fatigue cycling for crack propagation to a predetermined length and depth. The specimen is then loaded in tension at a constant rate of displacement at room temperature until fracture occurs while recording load and strain. An identical specimen with a similar flaw is then proof tested at room temperature to imminent failure based on the critical offset strain achieved by the previous fracture test. If the specimen survives the proof, it is then subjected to cryogenic cycling with loads that are a percentage of the proof load performed at room temperature. If all cryogenic cycles are successful, the specimen is loaded in tension to failure at the end of the test. This standard was generated for flat plate, so a method of translating this to a specimen of compound curvature was required. This was accomplished by fabricating a fixture that maintained the curvature of the specimen rigidly with the exception of approximately one-half inch in the center of the specimen containing the induced flaw. This in conjunction with placing the center of the specimen in the center of the load train allowed for successful testing with a minimal amount of bending introduced into the system. Stress corrosion cracking (SCC) tests were performed using the typical double beam assembly and with 4-point loaded specimens under alternate immersion conditions in a 3.5% NaCl environment for 90 days. In addition, experiments were conducted to determine the threshold stress intensity factor for SCC (K1SCC) of Al-Li 2195 which to our knowledge has not been determined previously. The successful simulated service and stress corrosion testing helped to provide confidence to continue to Ares 1 scale dome fabrication.

Stewart, Thomas J.↗

NASA NTRS1999

Flight Software Design Choices Based on Criticality

This slide presentation reviews the rationale behind flight software design as a function of criticality. The requirements of human rated systems implies a high criticality for the flight support software. Human life is dependent on correct operation of the software. Flexibility should be permitted when the consequences of software failure are not life threatening. This is also relevant for selecting Commercial Off the Shelf (COTS) software.

Lee, Earl↗

NASA NTRS2019

Fracture Control for Additive Manufactured Spacecraft Structures

Final Paper is attached. This paper discusses how the intent of current NASA fracture control requirements may be applied to "fracture critical" additive manufactured spacecraft hardware. Fracture control is a multi-discipline design and certification methodology that is applied in order to mitigate catastrophic failure of structures resulting from growth of an undetected crack-like defect. The methodology is defined in existing spacecraft standards and is required by NASA on all human-rated space structures. Recently, standards have been published by NASA to define materials and processes requirements for certain metallic additive manufactured hardware, but procedures for fracture control implementation on additive manufactured parts are not yet addressed in detail in any standard or guidance document.The discussion contained herein is necessary at this time as new guidance in this area should be founded collaboratively by the technical community at large including industry, academia, and government. Three Fracture Control Certification Methods are proposed for discussion. Additionally, a concept for "Design for AM fracture control" is introduced. The goals of this paper are to further expose the need for maturing additive manufacturing fracture control guidance in the spacecraft industry and to generate discussion on what this guidance should consist of.

McElroy, Mark↗

NASA NTRS1984

Effects of Non-equilibrium Solidification on the Material Properties of Brick Silicon for Photovoltaics

Silicon ingot growth technologies like the Ubiquitous Crystallization Process (UCP) are solidified within a shaping crucible. The rate at which heat can be lost from this crucible minus the rate at which heat is input from an external source determines the rate at which crystallization will occur. Occasionally, when the process parameters for solidification are exceeded, the normally large multi-centimeter grain size material assocated with the UCP will break down into regions containing extremely small, millimeter or less, grain size material. Accompanying this breakdown in grain growth is the development of so called sinuous grain boundaries. The breakdown in grain growth which results in this type of small grain structure with sinuous boundaries is usually associated with the rapid crystallization that would accompany a system failure. This suggests that there are limits to the growth velocity that one can obtain and still expect to produce material that would possess good photovoltaic properties. It is the purpose to determine the causes behind the breakdown of this material and what parameters will determine the best rates of solidification.

Regnault, W. F.↗

NASA NTRS1979

Acoustic fluidization - A new geologic process

A number of geologic processes, particularly seismic faulting, impact crater slumping, and long runout landslides, require the failure of geologic materials under differential stresses much smaller than expected on the basis of conventional rock mechanics. This paper proposes that the low strengths apparent in these phenomena are due to a state of 'acoustic fluidization' induced by a transient strong acoustic wave field. The strain rates possible in such a field are evaluated, and it is shown that acoustically fluidized debris behaves as a newtonian fluid with a viscosity in the range 100,000 to 10,000,000 P for plausible conditions. Energy gains and losses in the acoustic field are discussed, and the mechanism is shown to be effective if internal dissipation in the field gives a Q approximately greater than 100. Whether such values for Q are realized is not known at present. However, acoustic fluidization provides a qualitatively correct description of the failure of rock debris under low differential stresses in the processes of faulting, crater slumping, and long runout landslides. Acoustic fluidization thus deserves serious consideration as a possible explanation of these phenomena.

Melosh, H. J.↗

NASA NTRS1988

Accelerated fatigue crack growth behavior of PWA 1480 single crystal alloy and its dependence on the deformation mode

An investigation of the fatigue crack growth (FCG) behavior of PWA 1480 single crystal nickel base superalloy was conducted. Typical Paris region behavior was observed above a delta K of 8 MPa sq rt of m. However, below that stress intensity range, the alloy exhibited highly unusual behavior. This behavior consisted of a region where the crack growth rate became essentially independent of the applied stress intensity. The transition in the FCG behavior was related to a change in the observed crack growth mechanisms. In the Paris region, fatigue failure occurred along (111) facets; however, at the lower stress intensities, (001) fatigue failure was observed. A mechanism was proposed, based on barriers to dislocation motion, to explain the changes in the observed FCG behavior. The FCG data were also evaluated in terms of a recently proposed stress intensity parameter, K sub rss. This parameter, based on the resolved shear stresses on the slip planes, quantified the crack driving force as well as the mode I delta K, and at the same time was also able to predict the microscopic crack path under different stress states.

Telesman, Jack↗

NASA NTRS1988

Tension fatigue analysis and life prediction for composite laminates

A tension fatigue life prediction methodology for composite laminates is presented. Tension fatigue tests were conducted on quasi-isotropic and orthotropic glass epoxy, graphite epoxy, and glass/graphite epoxy hybrid laminates. Edge delamination onset data were used to generate plots of strain energy release rate as a function of cycles to delamination onset. These plots were then used along with strain energy release rate analyses of delaminations initiating at matrix cracks to predict local delamination onset. Stiffness loss was measured experimentally to account for the accumulation of matrix cracks and for delamination growth. Fatigue failure was predicted by comparing the increase in global strain resulting from stiffness loss to the decrease in laminate failure strain resulting from delaminations forming at matrix cracks through the laminate thickness. Good agreement between measured and predicted lives indicated that the through-thickness damage accumulation model can accurately describe fatigue failure for laminates where the delamination onset behavior in fatigue is well characterized, and stiffness loss can be monitored in real time to account for damage growth.

Obrien, T. K.↗

NASA NTRS1988

Accelerated fatigue crack growth behavior of PWA 1480

Telesman, Jack↗

NASA NTRS1994

Galileo mission planning for Low Gain Antenna based operations

The Galileo mission operations concept is undergoing substantial redesign, necessitated by the deployment failure of the High Gain Antenna, while the spacecraft is on its way to Jupiter. The new design applies state-of-the-art technology and processes to increase the telemetry rate available through the Low Gain Antenna and to increase the information density of the telemetry. This paper describes the mission planning process being developed as part of this redesign. Principal topics include a brief description of the new mission concept and anticipated science return (these have been covered more extensively in earlier papers), identification of key drivers on the mission planning process, a description of the process and its implementation schedule, a discussion of the application of automated mission planning tool to the process, and a status report on mission planning work to date. Galileo enhancements include extensive reprogramming of on-board computers and substantial hard ware and software upgrades for the Deep Space Network (DSN). The principal mode of operation will be onboard recording of science data followed by extended playback periods. A variety of techniques will be used to compress and edit the data both before recording and during playback. A highly-compressed real-time science data stream will also be important. The telemetry rate will be increased using advanced coding techniques and advanced receivers. Galileo mission planning for orbital operations now involves partitioning of several scarce resources. Particularly difficult are division of the telemetry among the many users (eleven instruments, radio science, engineering monitoring, and navigation) and allocation of space on the tape recorder at each of the ten satellite encounters. The planning process is complicated by uncertainty in forecast performance of the DSN modifications and the non-deterministic nature of the new data compression schemes. Key mission planning steps include quantifying resource or capabilities to be allocated, prioritizing science observations and estimating resource needs for each, working inter-and intra-orbit trades of these resources among the Project elements, and planning real-time science activity. The first major mission planning activity, a high level, orbit-by-orbit allocation of resources among science objectives, has already been completed; and results are illustrated in the paper. To make efficient use of limited resources, Galileo mission planning will rely on automated mission planning tools capable of dealing with interactions among time-varying downlink capability, real-time science and engineering data transmission, and playback of recorded data. A new generic mission planning tool is being adapted for this purpose.

Gershman, R.↗

NASA NTRS2007

Use of Thermoregulatory Models to Enhance Space Shuttle and Space Station operations and Review of Human Thermoregulatory Control

Thermoregulation in the space environment is critical for survival, especially in off- nominal operations. In such cases, mathematical models of thermoregulation are frequently employed to evaluate safety-of-flight issues in various human mission scenarious. In this study, the 225-node Wissler model and the 41-Node Metabolic Man model are employed to evaluate the effects of such a scenario. Metabolic loads on astronauts wearing the advanced crew escape suit (ACES) and liquid cooled ventilation garment (LCVG) are imposed on astronauts exposed to elevated cabin temperatures resulting from a systems failure. The study indicates that the performance of the ACES/LCVG cooling system is marginal. Increases in workload and or cabin temperature above nominal will increase rectal temperature, stored heat load, heart rate, and sweating, which could lead to deficits in the performance of cognitive and motor tasks. This is of concern as the ACES/LCVG is employed during Shuttle decent when the likelihood of a safe landing may be compromised. The study indicates that the most effective mitigation strategy would be to decrease the LCVG inlet temperature.

Pisacane, V. L.↗

NASA NTRS2014

Application of Fault Management Theory to the Quantitative Selection of a Launch Vehicle Abort Trigger Suite

This paper describes the quantitative application of the theory of System Health Management and its operational subset, Fault Management, to the selection of abort triggers for a human-rated launch vehicle, the United States' National Aeronautics and Space Administration's (NASA) Space Launch System (SLS). The results demonstrate the efficacy of the theory to assess the effectiveness of candidate failure detection and response mechanisms to protect humans from time-critical and severe hazards. The quantitative method was successfully used on the SLS to aid selection of its suite of abort triggers.

Lo, Yunnhon↗

NASA NTRS2014

Application of Fault Management Theory to the Quantitative Selection of a Launch Vehicle Abort Trigger Suite

This paper describes the quantitative application of the theory of System Health Management and its operational subset, Fault Management, to the selection of Abort Triggers for a human-rated launch vehicle, the United States' National Aeronautics and Space Administration's (NASA) Space Launch System (SLS). The results demonstrate the efficacy of the theory to assess the effectiveness of candidate failure detection and response mechanisms to protect humans from time-critical and severe hazards. The quantitative method was successfully used on the SLS to aid selection of its suite of Abort Triggers.

Lo, Yunnhon↗

NASA NTRS2014

Addressing Challenges to the Design & Test of Operational Lighting Environments for the International Space Station

In our day to day lives, the availability of light, with which to see our environment, is often taken for granted. The designers of land based lighting systems use sunlight and artificial light as their toolset. The availability of power, quantity of light sources, and variety of design options are often unlimited. The accessibility of most land based lighting systems makes it easy for the architect and engineer to verify and validate their design ideas. Failures with an implementation, while sometimes costly, can easily be addressed by renovation. Consider now, an architectural facility orbiting in space, 260 miles above the surface of the earth. This human rated architectural facility, the International Space Station (ISS) must maintain operations every day, including life support and appropriate human comforts without fail. The facility must also handle logistics of regular shipments of cargo, including new passengers. The ISS requires accommodations necessary for human control of machine systems. Additionally, the ISS is a research facility and supports investigations performed inside and outside its livable volume. Finally, the facility must support remote operations and observations by ground controllers. All of these architectural needs require a functional, safe, and even an aesthetic lighting environment. At Johnson Space Center, our Habitability and Human Factors team assists our diverse customers with their lighting environment challenges, via physical test and computer based analysis. Because of the complexity of ISS operational environment, our team has learned and developed processes that help ISS operate safely. Because of the dynamic exterior lighting environment, uses computational modeling to predict the lighting environment. The ISS' orbit exposes it to a sunrise every 90 minutes, causing work surfaces to quickly change from direct sunlight to earthshine to total darkness. Proper planning of vehicle approaches, robotics operations, and crewed Extra Vehicular Activities are mandatory to ensure safety to the crew and all others involved. Innovation in testing techniques is important as well. The advent of Solid State Lighting technology and the lack of stable national and international standards for its implementation pose new challenges on how to design, test and verify individual light fixtures and the environment that uses them. The ISS will soon be replacing its internal fluorescent lighting system to a solid state LED system. The Solid State Lighting Assembly will be used not only for general lighting, but also as a medical countermeasure to control the circadian rhythm of the crew. The new light source has performance criteria very specific to its spectral fingerprint, creating new challenges that were originally not as significant during the original design of the ISS. This presentation will showcase findings and toolsets our team is using to assist in the planning of tasks, and design of operational lighting environments on the International Space Station.

Clark, Toni A.↗

NASA NTRS2015

Leakage Currents in Low-Voltage PME and BME Ceramic Capacitors

Introduction of BME capacitors to high-reliability electronics as a replacement for PME capacitors requires better understanding of changes in performance and reliability of MLCCs to set justified screening and qualification requirements. In this work, absorption and leakage currents in various lots of commercial and military grade X7R MLCCs rated to 100V and less have been measured to reveal difference in behavior of PME and BME capacitors in a wide range of voltages and temperatures. Degradation of leakage currents and failures in virgin capacitors and capacitors with introduced cracks has been studied at different voltages and temperatures during step stress highly accelerated life testing. Mechanisms of charge absorption, conduction and degradation have been discussed and a failure model in capacitors with defects suggested.

base metal electrode capacitor (BME)↗

NASA NTRS2010

Interpreting Space-Mission LET Requirements for SEGR in Power MOSFETs

Single-event gate rupture (SEGR) is a potentially catastrophic failure mechanism of power MOSFETs biased in the off-state. In part due to the severity of-SEGR consequences and in part due to the difficulty of accurated SEGR rate estimation, SEGR mitigation me1hodologies emphasize risk avoidance, using heavy-ion accelerator testing to define safe operating conditions for a surface-incident linear energy transfer {LET). This "safe-operating area" (SOA) within which the device may be biased without experiencing SEGR is then often derated by a prescribed factor to ensure low risk of SEGR. Although research in 1996 indicated that such LET-based SEGR hardness requiremen1s could provide false assurance of safe operation unless one also considered· ion energy], most mission SEGR requirements are still specified in terms of surface-incident LET. Moreover, terrestrial SEGR tests at a given surface-incident LET are limited by the small number of ion species and energies available at heavy-ion accelerators. In comparison, the on-orbit radiation environment is composed of all of the naturally-occurring elements with peak fluxes at nearly GeV/nucleon energies. The primary objective of this study is to examine whether typical derating of high-energy heavy-ion accelerator test data bounds the risk for SEGR from higher-energy on-orbit ions with the mission LET requirement.

Lauenstein, Jean-Marie↗