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NASA NTRS2010

Power MOSFET Thermal Instability Operation Characterization Support

Metal-oxide semiconductor field-effect transistors (MOSFETs) are used extensively in flight hardware and ground support equipment. In the quest for faster switching times and lower "on resistance," the MOSFETs designed from 1998 to the present have achieved most of their intended goals. In the quest for lower on resistance and higher switching speeds, the designs now being produced allow the charge-carrier dominated region (once small and outside of the area of concern) to become important and inside the safe operating area (SOA). The charge-carrier dominated region allows more current to flow as the temperature increases. The higher temperatures produce more current resulting in the beginning of thermal runaway. Thermal runaway is a problem affecting a wide range of modern MOSFETs from more than one manufacturer. This report contains information on MOSFET failures, their causes and test results and information dissemination.

Shue, John L.↗

NASA NTRS2014

Long Term Displacement Data of Woven Fabric Webbings Under Constant Load for Inflatable Structures

Inflatable modules for space applications offer weight and launch volume savings relative to current metallic modules. Limited data exist on the creep behavior of the restraint layer of inflatable modules. Long-term displacement and strain data of two high strength woven fabric webbings, Kevlar and Vectran, under constant load is presented. The creep behavior of webbings is required by designers to help determine service life parameters of inflatable modules. Four groups of different webbings with different loads were defined for this study. Group 1 consisted of 4K Kevlar webbings loaded to 33% ultimate tensile strength and 6K Vectran webbings loaded to 27% ultimate tensile strength, group 2 consisted of 6K Kevlar webbings loaded to 40% and 43% ultimate tensile strength, and 6K Vectran webbings loaded to 50% ultimate tensile strength, group 3 consisted of 6K Kevlar webbings loaded to 52% ultimate tensile strength and 6K Vectran webbings loaded to 60% ultimate tensile strength, and group 4 consisted of 12.5K Kevlar webbings loaded to 22% ultimate tensile strength, and 12.5K Vectran webbings loaded to 22% ultimate tensile strength. The uniquely designed test facility, hardware, displacement measuring devices, and test data are presented. Test data indicate that immediately after loading all webbings stretch an inch or more, however as time increases displacement values significantly decrease to fall within a range of several hundredth of an inch over the remainder of test period. Webbings in group 1 exhibit near constant displacements and strains over a 17-month period. Data acquisition was suspended after the 17th month, however webbings continue to sustain load without any local webbing damage as of the 21st month of testing. Webbings in group 2 exhibit a combination of initial constant displacement and subsequent increases in displacement rates over a 16-month period. Webbings in group 3 exhibit steady increases in displacement rates leading to webbing failure over a 3-month period. Five of six webbings experienced local damage and subsequent failure in group 3. Data from group 4 indicates increasing webbing displacements over a 7-month period. All webbings in groups 1, 2, and 4 remain suspended without any local damage as of the writing of this paper. Variations in facility temperatures over test period seem to have had limited effect on long-term webbing displacement data.

Kenner, Winfred S.↗

NASA NTRS1975

Manufacture and static firing of X259-E6 rocket motor serial number XJ04/0001

A single motor was cast and static fired to demonstrate the performance of high energy crosslinked double base (XLDB) propellant in standard X259 rocket motor hardware. Prior to motor fabrication, the motor was analyzed to predict the results of static firing the X259 motor loaded with XLDB propellant. As a result of the analyses, a forward dome shrinkage liner was added to the design. With this design change it was determined that adequate margins of safety existed. The motor, designated the X259-E6 model with serial number XJ04/0001, was fabricated using a slurry-casting technique and was assembled with a standard X259-B4 nozzle which had the nozzle throat machined to a smaller inside diameter than the B4 model and the exit cone cut short for Bacchus Works altitude expansion. The motor was static fired on 20 February 1974 with the nozzle failing during motor operation. Nozzle failure was attributed to spalling of the throat material leading to complete nozzle break-up. However, the propellant functioned as predicted in the motor chamber, ignition was normal, and char and erosion of the internal insulator were as expected.

Robertson, D. R.↗

NASA NTRS1990

Effect of KOH concentration on LEO cycle life of IPV nickel-hydrogen flight battery cells

A breakthrough in low earth orbit (LEO) cycle life of individual pressure vessel (IPV) nickel hydrogen battery cells was reported. The cycle life of boiler plate cells containing 26 percent potassium hydroxide (KOH) electrolyte was about 40,000 LEO cycles compared to 3500 cycles for cells containing 31 percent KOH. The effect of KOH concentration on cycle life was studied. The cycle regime was a stressful accelerated LEO, which consisted of a 27.5 min charge followed by a 17.5 min charge (2 x normal rate). The depth of discharge (DOD) was 80 percent. The cell temperature was maintained at 23 C. The next step is to validate these results using flight hardware and a real time LEO test. NASA Lewis has a contract with the Naval Weapons Support Center (NWSC), Crane, Indiana, to validate the boiler plate test results. Six 48 A-hr Hughes recirculation design IPV nickel-hydrogen flight battery cells are being evaluated. Three of the cells contain 26 percent KOH (test cells) and three contain 31 percent KOH (control cells). They are undergoing real time LEO cycle life testing. The cycle regime is a 90-min LEO orbit consisting of a 54-min charge followed by a 36-min discharge. The depth-of-discharge is 80 percent. The cell temperature is maintained at 10 C. The cells were cycled for over 8000 cycles in the continuing test. There were no failures for the cells containing 26 percent KOH. There was two failures, however, for the cells containing 31 percent KOH.

Smithrick, John J.↗

NASA NTRS2012

Advanced Stirling Convertor Durability Testing: Plans and Interim Results

The U.S. Department of Energy (DOE), Lockheed Martin Corporation (LM), and NASA Glenn Research Center (GRC) have been developing the Advanced Stirling Radioisotope Generator (ASRG) for use as a power system for space science missions. In support of this program, GRC has been involved in testing Stirling convertors, including the Advanced Stirling Convertor (ASC), for use in the ASRG. This testing includes electromagnetic interference/compatibility (EMI/EMC), structural dynamics, advanced materials, organics, and unattended extended operation. The purpose of the durability tests is to experimentally demonstrate the margins in the ASC design. Due to the high value of the hardware, previous ASC tests focused on establishing baseline performance of the convertors within the nominal operating conditions. The durability tests present the first planned extension of the operating conditions into regions beyond those intended to meet the product spec, where the possibility exists of lateral contact, overstroke, or over-temperature events. These tests are not intended to cause damage that would shorten the life of the convertors, so they can transition into extended operation at the conclusion of the tests. This paper describes the four tests included in the durability test sequence: 1) start/stop cycling, 2) exposure to constant acceleration in the lateral and axial directions, 3) random vibration at increased piston amplitude to induce contact events, and 4) overstroke testing to simulate potential failures during processing or during the mission life where contact events could occur. The paper also summarizes the analysis and simulation used to predict the results of each of these tests.

Meer, David W.↗

NASA NTRS2012

Advanced Stirling Convertor Durability Testing: Plans and Interim Results

The U.S. Department of Energy (DOE), Lockheed Martin Corporation (LM), and NASA Glenn Research Center (GRC) have been developing the Advanced Stirling Radioisotope Generator (ASRG) for use as a power system for space science missions. In support of this program, NASA?s Glenn Research Center (GRC) has been involved in testing Stirling convertors, including the Advanced Stirling Convertor (ASC), for use in the ASRG. This testing includes electromagnetic interference/compatibility (EMI/EMC), structural dynamics, advanced materials, organics, and unattended extended operation. The purpose of the durability tests is to experimentally demonstrate the margins in the ASC design. Due to the high value of the hardware, previous ASC tests focused on establishing baseline performance of the convertors within the nominal operating conditions. The durability tests present the first planned extension of the operating conditions into regions beyond those intended to meet the product spec, where the possibility exists of lateral contact, overstroke, or over-temperature events. These tests are not intended to cause damage that would shorten the life of the convertors, so they can transition into extended operation at the conclusion of the tests. This paper describes the four tests included in the durability test sequence: 1) start/stop cycling, 2) exposure to constant acceleration in the lateral and axial directions, 3) random vibration at increased piston amplitude to induce contact events, and 4) overstroke testing to simulate potential failures during processing or during the mission life where contact events could occur. The paper also summarizes the analysis and simulation used to predict the results of each of these tests.

Meer, Dave↗

NASA NTRS2001

Models of an In-Situ Propellant Production Plant for Mars Exploration

An in-situ propellant production system (ISPP) is designed to make rocket fuel from chemicals in the Martian atmosphere in order to reduce the amount of materials that would need to be brought from Earth to support Mars missions. We have developed a description of a hypothetical ISPP system that we would like to make available to researchers who are interested in the problem of automatically diagnosing failures in complex NASA systems. This problem description will help researchers to investigate problems of interest to NASA. We would like to make the following material publicly available: (1) a 'common sense' model of an ISPP system; (2) low- and medium-fidelity simulations of the ISPP system written in Microsoft Excel and HCC; and (3) previously published data and diagrams concerning ISPP components. We do not believe there are any export considerations on these materials for the following reasons: (1) These models are not useful for guidance and real time control of vehicles, encrpytion, or any other software purpose categorized under the Export Control Classification Numbers; and (2) The models are very high level and would not by themselves enable real-time control of a real hardware system. The models are at the level of common sense. They capture, for example, that if a heater is turned on an increase in temperature should result(see the attached excerpt). We do not believe there is any commercial value to this material, given the low commercial demand for propellant plants on mars. We have spoken to acting Code IC Division Chief Dan Clancy, and he concurs with our desire to make these materials publicly available via a technical report.

Goodrich, Charlie↗

NASA NTRS2010

Design of Refractory Metal Life Test Heat Pipe and Calorimeter

Heat pipe life tests have seldom been conducted on a systematic basis. Typically, one or more heat pipes are built and tested for an extended period at a single temperature with simple condenser loading. Results are often reported describing the wall material, working fluid, test temperature, test duration, and occasionally the nature of any failure. Important information such as design details, processing procedures, material assay, power throughput, and radial power density are usually not mentioned. We propose to develop methods to generate carefully controlled data that conclusively establish heat pipe operating life with material-fluid combinations capable of extended operation. The test approach detailed in this Technical Publication will use 16 Mo-44.5%Re alloy/sodium heat pipe units that have an approximate12-in length and 5/8-in diameter. Two specific test series have been identified: (1) Long-term corrosion rates based on ASTM-G-68-80 (G-series) and (2) corrosion trends in a cross-correlation sequence at various temperatures and mass fluences based on a Fisher multifactor design (F-series). Evaluation of the heat pipe hardware will be performed in test chambers purged with an inert purified gas (helium or helium/argon mixture) at low pressure (10-100 torr) to provide thermal coupling between the heat pipe condenser and calorimeter. The final pressure will be selected to minimize the potential for voltage breakdown between the heat pipe and radio frequency (RF) induction coil (RF heating is currently the planned method of powering the heat pipes). The proposed calorimeter is constructed from a copper alloy and relies on a laminar flow water-coolant channel design to absorb and transport energy

Martin, J. J.↗

NASA NTRS2026

Reliability Models and Demonstration of a Fault-Tolerant Motor Concept for Vertical Takeoff and Landing Vehicles

This report documents the completion of the Revolutionary Vertical Lift Technology Project Annual Performance Indicator 24-3.2.4.1: “Apply and document reliability prediction for high reliability motor concept.” Two modeling tools were completed for calculation of reliability of fault-tolerant (FT) motors, and key FT operations of a modular FT motor were demonstrated experimentally. The two models are complementary tools for the stakeholder and user community. Both models employ Markov chain theory. The first model is a time-homogeneous Markov chain model, and the second is a time-inhomogeneous Markov-Weibull model. This report’s main sections are as follows: 1.0 Introduction, 2.0 Theory, 3.0 Motor Reliability Models, 4.0 Validation of FT Operation by Hardware Demonstration, and 5.0 Concluding Remarks. Novel contributions to the field include development of a modular FT motor concept for electrified vertical takeoff and landing (eVTOL) application, solution methods to solve the reliability calculations, development of figures of merit, and the introduction of “linked chains” to formulate a building-block approach for time-inhomogeneous Markov-Weibull modeling of motor reliability. Example case studies have been completed, and results are provided and discussed herein. A four-module FT motor concept was developed to a preliminary-design level of detail. This eVTOL FT motor concept was designed for galvanic, magnetic, and thermal isolation of stator winding faults. The reliability of the concept motor was calculated using a time-inhomogeneous Markov chain model. Employing average failure rate as a metric, 570 times greater reliability was achieved as compared to a baseline motor without fault tolerance. A demonstrator motor was built and tested. The testing demonstrated the key features of FT operation and validated the essential premises of the FT motor concepts presented herein. The experiments included successful demonstration of the feasibility of the following four key FT features: (1) terminal open-circuit operation, (2) thermal isolation after fault, (3) terminal short-circuit operation, and (4) internal short-circuit operation. These works indicate that FT modular motor drives offer promise for addressing the daunting reliability gap that electric aircraft propulsor drives are facing relative to the best conventional motor drive technology that is available today.

Electric Motor↗

NASA NTRS1994

SLR 2000

SLR 2000 is a concept for a totally automated subcentimeter SLR system presently being studied at GSFC. If funding permits, a prototype would be installed and tested at the Goddard Geophysical and Astronomical Observatory (GCAO) in FY98 and a small number of automated stations would be fielded by the year 2000. Unlike present systems, the "SLR 2000" system is being designed to: 1) operate autonomously without the need for onsite operators; 2) present no hazards (i.e., optical, electrical, and/or chemical) to personnel in the vicinity or to overflying aircraft; and 3) have a mean time between failures (MTBF) of at least three months. It is assumed that the systems are located at "friendly" sites where some level of security is provided and where certain low level service functions (e.g. commercial power, communications, heat pump service cleaning, etc.) are available or can be contracted for locally on an as-needed basis. The main system consists of two parts - an optical head and electronics rack. The optical head contains the laser transmitter and power supply, transmit/receive switch, optical telescope, tracking angle sensor (intensified CCD camera), detector and power supply, two angular encoders, azimuth and elevation motors, and a protective dome. The optical head mounts directly to the top of a concrete pier which contains the geodetic monument and forms part of the environmental housing for the hardware and servicing personnel. It is equipped with electronic levels for leveling the mount and monitoring its stability.

Degnan, John J.↗

NASA NTRS1996

Mechanics of Granular Materials (MGM)

The constitutive behavior of uncemented granular materials such as strength, stiffness, and localization of deformations are to a large extend derived from interparticle friction transmitted between solid particles and particle groups. Interparticle forces are highly dependent on gravitational body forces. At very low effective confining pressures, the true nature of the Mohr envelope, which defines the Mohr-Coulomb failure criterion for soils, as well as the relative contribution of each of non-frictional components to soil's shear strength cannot be evaluated in terrestrial laboratories. Because of the impossibility of eliminating gravitational body forces on earth, the weight of soil grains develops interparticle compressive stresses which mask true soil constitutive behavior even in the smallest samples of models. Therefore the microgravity environment induced by near-earth orbits of spacecraft provides unique experimental opportunities for testing theories related to the mechanical behavior of terrestrial granular materials. Such materials may include cohesionless soils, industrial powders, crushed coal, etc. This paper will describe the microgravity experiment, 'Mechanics of Granular Materials (MGM)', scheduled to be flown on Space Shuttle-MIR missions. The paper will describe the experiment's hardware, instrumentation, specimen preparation procedures, testing procedures in flight, as well as a brief summary of the post-mission analysis. It is expected that the experimental results will significantly improve the understanding of the behavior of granular materials under very low effective stress levels.

Alshibli, Khalid A.↗

NASA NTRS2019

A Proposal for Standardized MMOD Shielding for Robotic Spacecraft

NASA robotic spacecraft are required to assess the potential for small debris induced failure for all disposal-critical components. Additional shielding might then be necessary in order to meet the acceptable risk requirement for the overall mission. Traditionally this requirement had been met with little or no additional shielding. Since the introduction of a high density debris population in ORDEM 3.0, some missions, especially those in higher portions of Low Earth Orbit, have needed additional MMOD-specific shielding in order for the mission to meet the requirement. This is a costly design effort when performed late in the project life cycle, which adds unexpected mass to the spacecraft components during the integration phase, and could disrupt thermal management.A proposal is discussed to develop a more cost-effective approach to MMOD-shielding, which can be employed earlier in the hardware design phase. The development and adoption of standardized shielding assemblies allows early tailoring of the shielding around a component, so that the mass is accounted for, as well as the small particle penetration risk, at a point in the design phase when the cost and schedule impact are more manageable. A set of several assemblies can be developed with a range of protection thresholds, in order to control mass where less shielding is needed. Such shielding assemblies would be developed in collaboration with blanket assembly specialists and thermal control engineers to ensure manufacturability and thermal performance challenges are known and acceptable. One clear benefit of such an approach is that hypervelocity testing can be performed on each of the standard shield assemblies to refine and confirm their performance prior to use.The challenges inherent in designing supplemental MMOD shielding will be discussed, including variations in the orbital debris environment and performance prediction. The benefits of a standardized shielding approach and example applications will also be presented.

Hull, Scott M.↗

NASA NTRSDate not supplied

NASA's Heliophysics Flight Opportunities in Research and Technology Program

The Heliophysics Flight Opportunities in Research and Technology (H-FORT) program performs space and science and science-enabling investigations that use platforms including Small Satellites, CubeSats, Hosted Rideshare Payloads, and International Space Station (ISS) attached payloads. The H-FORT program encourages the development of technologies that will enable investigation of heliophysics science questions. The program also encourages the use of innovation, commercially available spaceflight hardware, rideshare launch opportunities, and high risk to drive the cost of achieving science to a fraction of what was previously possible. H-FORT missions also provide an opportunity for preparing future leaders of NASA spaceflight missions and most missions are supported by academic institutions and involve both graduate and under-graduate students. Since starting the program in 2013, 27 missions have been awarded, twelve missions and seventeen spacecraft have flown, three missions are waiting for launch, eleven missions are in development, and one mission was not completed as planned. This paper will provide an overview of the Heliophysics Flight Opportunities in Research and Technology (H-FORT) program and will provide a summary of the missions that have been awarded. This will include mission successes, challenges, failures, and lessons learned.

Thomas E. Johnson↗

NASA NTRS2019

A Proposal for Standardized MMOD Shielding for Robotic Spacecraft

NASA robotic spacecraft are required to assess the potential for small debris induced failure for all disposal-critical components. Additional shielding might then be necessary in order to meet the acceptable risk requirement for the overall mission. Traditionally this requirement had been met with little or no additional shielding. Since the introduction of a high density debris population in ORDEM 3.0, some missions, especially those in higher portions of Low Earth Orbit, have needed additional MMOD-specific shielding in order for the mission to meet the requirement. This is a costly design effort when performed late in the project life cycle, which adds unexpected mass to the spacecraft components during the integration phase, and could disrupt thermal management. A proposal is discussed to develop a more cost-effective approach to MMOD-shielding, which can be employed earlier in the hardware design phase. The development and adoption of standardized shielding assemblies allows early tailoring of the shielding around a component, so that the mass is accounted for, as well as the small particle penetration risk, at a point in the design phase when the cost and schedule impact are more manageable. A set of several assemblies can be developed with a range of protection thresholds, in order to control mass where less shielding is needed. Such shielding assemblies would be developed in collaboration with blanket assembly specialists and thermal control engineers to ensure manufacturability and thermal performance challenges are known and acceptable. One clear benefit of such an approach is that hypervelocity testing can be performed on each of the standard shield assemblies to refine and confirm their performance prior to use.The challenges inherent in designing supplemental MMOD shielding will be discussed, including variations in the orbital debris environment and performance prediction. The benefits of a standardized shielding approach and example applications will also be presented.

Hull, Scott M.↗

NASA NTRSDate not supplied

The Repair Maintenance and Fabrication Facility in the Common Habitat Architecture

The Common Habitat Architecture seeks to increase the habitability of long-duration human spaceflight systems. A key aspect of this is vehicle survivability. Missions beyond low Earth orbit need onboard capabilities for Repair, Maintenance, And Fabrication (RMAF) to overcome potential contingency scenarios. Strategies employed in historic human spaceflight such as redundancy management, reliability, sparing, orbital replacement units, and aborts may be insufficient by themselves. Based on subject matter input, a list of 53 critical failures defining a set of incidents that can render a key spacecraft subsystem inoperable were generated. A subsequent analysis found that a robust in-space RMAF system capable of performing 14 key functions can potentially repair a subsystem plagued by any of these failures. An ancillary benefit is this capability may provide psychological benefits to the crew, by enabling greater self-sufficiency in earth-independent problem solving. A basic RMAF facility has been defined for the Common Habitat, consisting of five workstations. A work bench and computer workstation provide a multipurpose horizontal work surface, computing interface, and tools storage. A CNC machining center provides a subtractive manufacturing capability for metals and plastics. A multi-material 3D printing facility provides additive manufacturing capabilities for plastic, metals, and printed electronics. A welding facility is used for joining metal components where a higher strength is needed than can be achieved with fasteners or adhesives. A glovebox facility is used to perform work that is too hazardous for any of the other workstations. This may include hardware brought in from outside the spacecraft that could potentially contaminate the cabin environment. Forward work includes considering the accommodation of additional manufacturing processes not modeled in the current system, assessing the ability of systems to operate in partial gravity and microgravity environments, incorporation of the system into the Common Habitat Computer Aided Design (CAD) model, bottoms-up mass estimating, and a crew time analysis.

Habitat↗

NASA NTRS2005

Artificial Neural Network Test Support Development for the Space Shuttle PRCS Thrusters

A significant anomaly, Fuel Valve Pilot Seal Extrusion, is affecting the Shuttle Primary Reaction Control System (PRCS) Thrusters, and has caused 79 to fail. To help address this problem, a Shuttle PRCS Thruster Process Evaluation Team (TPET) was formed. The White Sands Test Facility (WSTF) and Boeing members of the TPET have identified many discrete valve current trace characteristics that are predictive of the problem. However, these are difficult and time consuming to identify and trend by manual analysis. Based on this exhaustive analysis over months, 22 thrusters previously delivered by the Depot were identified as high risk for flight failures. Although these had only recently been installed, they had to be removed from Shuttles OV103 and OV104 for reprocessing, by directive of the Shuttle Project Office. The resulting impact of the thruster removal, replacement, and valve replacement was significant (months of work and hundreds of thousands of dollars). Much of this could have been saved had the proposed Neural Network (NN) tool described in this paper been in place. In addition to the significant benefits to the Shuttle indicated above, the development and implementation of this type of testing will be the genesis for potential Quality improvements across many areas of WSTF test data analysis and will be shared with other NASA centers. Future tests can be designed to incorporate engineering experience via Artificial Neural Nets (ANN) into depot level acceptance of hardware. Additionally, results were shared with a NASA Engineering and Safety Center (NESC) Super Problem Response Team (SPRT). There was extensive interest voiced among many different personnel from several centers. There are potential spin-offs of this effort that can be directly applied to other data acquisition systems as well as vehicle health management for current and future flight vehicles.

Lehr, Mark E.↗

NASA NTRS1994

A psychologist's view of validating aviation systems

All systems, no matter what they are designed to do, have shortcomings that may make them less productive than was hoped during the initial development. Such shortcomings can arise at any stage of development: from conception to the end of the implementation life cycle. While systems failure and errors of a lesser magnitude can occur as a function of mechanical or software breakdown, the majority of such problems, in aviation are usually laid on the shoulders of the human operator and, to a lesser extent, on human factors. The operator bears the responsibility and blame even though, from a human factors perspective, error may have been designed into the system. Human factors is not a new concept in aviation. The name may be new, but the issues related to operators in the loop date back to the industrial revolution of the nineteenth century and certainly to the aviation build-up for World War I. During this first global confrontation, military services from all sides discovered rather quickly that poor selection and training led to drastically increased personnel losses. While hardware design became an issue later, the early efforts were primarily focused on increased care in pilot selection and on their training. This actually involved early labor-intensive simulation, using such devices as sticks and chairs mounted on rope networks which could be manually moved in response to control input. The use of selection criteria and improved training led to more viable person-machine systems. More pilots survived training and their first ten missions in the air, a rule of thumb arrived at by experience which predicted ultimate survival better than any other. This rule was to hold through World War II. At that time, personnel selection and training became very sophisticated based on previous standards. Also, many psychologists were drafted into Army Air Corps programs which were geared towards refining the human factor. However, despite the talent involved in these programs and the tremendous build-up of aviation during the war, there were still aircraft designs that were man killers (no sexism implied since all combat pilots were men). One classic design error that was identified fifty years ago was the multipointer altimeter, which could easily be misread especially by a pilot under considerable task load. It has led to flying fully operational aircraft into the terrain. The authors of the research which formally identified this problem put 'Human Errors' in quotes to express their dissatisfaction with the traditional approach to accident investigation. It traditionally places the burden of guilt on the operator. Some of these altimeters still exist in older aircraft to this day.

Stein, Earl S.↗

NASA NTRS2016

Failure Simulation Testing of the Z-1 Spacesuit Titanium Bearing Assemblies

The Z-2 is a candidate for NASA's next generation spacesuit, designed for a range of possible missions with enhanced mobility for spacewalks both on planetary surfaces and in microgravity. Increased mobility was accomplished through innovations in shoulder and hip joints, using a number of new bearings to allow spacesuit wearers to dip, walk, and bend with ease; all important tasks for a planetary explorer collecting samples or traveling over rough terrain. The Advanced Spacesuit Development Team of NASA Johnson Space Center requested that the NASA White Sands Test Facility (WSTF) perform a series failure simulation tests on three titanium bearing assemblies, an elemental part of the joint construction used in new spacesuit designs. This testing simulated two undetected failures within the bearings and as a result the objective of this test program was to evaluate whether a failed or failing bearing could result in ignition of the titanium race material due to friction. The first failure was an inner seal leak sufficient to pressurize the race with +99 percent oxygen. The second failure was an improperly installed or mismatched ball port that created a protrusion in the ball bearing race, partially obstructing the nominal rolling path of each ball bearing. When the spacesuit bearings are assembled, bearing balls are loaded into the assembly via a ball port. The ball port is specific and unique to each bearing assembly (matched pair). The simulated mismatched ball port is a significant source of friction, which would be caused by an assembly error. To evaluate this risk, the bearings were cycled in a simulated worst-case scenario environment, with operational loads, and potential flaw conditions. During test the amount of actuation torque required and heat generated through continuous operation were measured and the bearings were observed for sparks or burning events. This paper provides detailed descriptions of the test hardware, methodology, and results.

de Baca, Richard C.↗