SEARCH · Engineering Papers
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.
Thermal fatigue life testing of various electronic packaging technologies is being performed by the Reliability Technology Group at the Jet Propulsion Laboratory.
As deep space exploration continues to be the goal of NASAs human spaceflight program, verification of the performance of spaceflight hardware becomes increasingly critical. Suitable test methods for verifying the leak rate of sealing systems are identified in program qualification testing requirements. One acceptable method for verifying the air leak rate of gas pressure seals is the tracer gas leak detector method. In this method, a tracer gas (commonly helium) leaks past the test seal and is transported to the leak detector where the leak rate is quantified. To predict the air leak rate, a conversion factor of helium-to-air is applied depending on the magnitude of the helium flow rate. The conversion factor is based on either the molecular mass ratio or the ratio of the dynamic viscosities. The current work was aimed at validating this approach for permeation-level leak rates using a series of tests with a silicone elastomer O-ring. An established pressure decay method with constant differential pressure was used to evaluate both the air and helium leak rates of the O-ring under similar temperature and pressure conditions. The results from the pressure decay tests showed, for the elastomer O-ring, that neither the molecular flow nor the viscous flow helium-to-air conversion factors were applicable. Leak rate tests were also performed using nitrogen and argon as the test gas. Molecular mass and viscosity based helium-to-test gas conversion factors were applied, but did not correctly predict the measured leak rates of either gas. To further this study, the effect of pressure boundary conditions was investigated. Often, pressure decay leak rate tests are performed at a differential pressure of 101.3 kPa with atmospheric pressure on the downstream side of the test seal. In space applications, the differential pressure is similar, but with vacuum as the downstream pressure. The same O-ring was tested at four unique differential pressures ranging from 34.5 to 137.9 kPa. Up to six combinations of upstream and downstream pressures for each differential pressure were compared. For a given differential pressure, the various combinations of upstream and downstream dry air pressures did not significantly affect the leak rate. As expected, the leak rate of the O-ring increased with increasing differential pressure. The results suggested that the current leak test pressure conditions, used to verify spacecraft sealing systems with elastomer seals, produce accurate values even though the boundary conditions do not model the space application.
Telescopes and X-ray telescopes in particular, tested with nearby point sources of radiation. When point-source rays enter telescope through annular entrance pupil (and under conditions of spherical aberration), ring image produced. Deviation of ring image from perfect circular shape reveals misalinements and surface inaccuracies in telescope. Although particularly suited for grazing-incidence types of systems, this test method applied to other types of optical systems.
This paper serves to illustrate the testing methods necessary to classify the electrostatic properties of lunar dust using in situ instrumentation and the required techniques therein. A review of electrostatic classification of lunar simulant materials is provided as is its relevance to the success of future human lunar missions.
Performance criteria and test techniques are applied to stability augmentation systems (SAS) during ground testing to predict objectionable limit cycles and preclude structural resonance during flight. Factors that give rise to these problems, means of suppressing their effects, trade-offs to be considered, and ground test methods that have been developed are discussed. SAS performance predicted on the basis of these tests is compared with flight data obtained from three lifting body vehicles and the X-15 research airplane. Limit cycle and structural resonance test criteria, based upon ground and flight experience and data, were successfully applied to these vehicles. The criteria used were: The limit cycle amplitude (SAS gain multiplied by peak-to-peak angular rate) shall not exceed 0.5 deg for the highest product of control power and SAS gain that will be used in flight; the maximum in-flight SAS gain should never exceed 50 percent of the value at which a structural resonance can be sustained during ground test.
As Mil-Std-810G and subsequent versions have included multiple degree of freedom vibration test methodologies, it is important to understand the history and factors that drove the original decision in Mil-Std-810 to focus on single degree of freedom (SDOF) vibration testing. By assessing the factors and thought process of early Mil-Std-810 vibration test methods, it enables one to better consider the use of multiple degree of freedom testing now that it is feasible with today’s technology and documented in Mil-Std-810. This paper delves into the details of the decision made in the 1960s for the SDOF vibration testing standards in Mil-Std-810 beyond the limitations of technology at the time. We also consider the implications for effective test planning today considering the advances in test capabilities and improvements in understanding of the operational environment.
The scratch test method is widely used for adhesion evaluation of thin films and coatings. Usual critical load criteria designed for scratch testing of coatings were not applicable to thin atomic layer deposition (ALD) films on silicon wafers. Thus, the bases for critical load evaluation were established and the critical loads suitable for ALD coating adhesion evaluation on silicon wafers were determined in this paper as L{sub CSi1}, L{sub CSi2}, L{sub CALD1}, and L{sub CALD2}, representing the failure points of the silicon substrate and the coating delamination points of the ALD coating. The adhesion performance of the ALD Al{sub 2}O{sub 3}, TiO{sub 2}, TiN, and TaCN+Ru coatings with a thickness range between 20 and 600 nm and deposition temperature between 30 and 410 °C on silicon wafers was investigated. In addition, the impact of the annealing process after deposition on adhesion was evaluated for selected cases. The tests carried out using scratch and Scotch tape test showed that the coating deposition and annealing temperature, thickness of the coating, and surface pretreatments of the Si wafer had an impact on the adhesion performance of the ALD coatings on the silicon wafer. There was also an improved load carrying capacity due to Al{sub 2}O{sub 3}, the magnitude of which depended on the coating thickness and the deposition temperature. The tape tests were carried out for selected coatings as a comparison. The results show that the scratch test is a useful and applicable tool for adhesion evaluation of ALD coatings, even when carried out for thin (20 nm thick) coatings.
A number of rotary wing flight tests have been conducted by the Army Aeroflightdynamics Directorate in cooperation with NASA which involved the use of night vision devices and simulated devices. The test set up and data analysis have been taken from two perspectives. Some of the flight tests were structured to look at aircraft handling qualities when the pilot's image quality was reduced from normal daylight levels. In this case, aircraft flight path information was given to the pilot as one input into the Handling Qualities Ratings. Other flight tests were structured to look at pilot and workload directly. In this second case, aircraft position was accurately measured and used as pilot performance data. This paper provides an overview of the test methods used, lessons learned, and recommendations for future tam of night vision devices.
Continuing efforts to improve the University of San Francisco/NASA toxicity screening test method have included the addition of exercise wheels to provide a different measure of incapacitation, and oxygen replenishment to offset any effect of oxygen depletion by the test animals. The addition of exercise wheels limited the number of animals in each test and doubled the required number of tests without any significant improvement in reproducibility. Oxygen replenishment appears to have an effect on survival in the last 5 minutes of the 30-minute test, but the effect is expected to be similar for most materials.
Statistical examination of animal response data obtained using Procedure B of the USF toxicity screening test method indicates that the data deviate only slightly from a normal or Gaussian distribution. This slight departure from normality is not expected to invalidate conclusions based on theoretical statistics. Comparison of times to staggering, convulsions, collapse, and death as endpoints shows that time to death appears to be the most reliable endpoint because it offers the lowest probability of missed observations and premature judgements.
In its mission to expand knowledge and improve aviation, NASA conducts research to address sonic boom noise, the prime barrier to overland supersonic flight. NASA is currently preparing for a community survey campaign to assess response to noise from the new X-59 aircraft. During each community survey, a substantial number of observations must be collected over a limited timeframe to generate a dose response relationship. A sample of residents will be recruited in advance to fill out a brief survey each time X-59 flies over, approximately 80 times throughout a month. In preparation NASA conducted a month-long test of survey methods in 2023. A sample of 800 residents was recruited from a simulated fly-over area. Because there were no actual X-59 fly-overs, respondents were asked about their reactions to noise from normal aircraft operations. The respondents chose whether to fill out the survey on the web or via a smartphone application. Evaluating response rates and how they evolved over time was a specific focus of the test. Also, a graduated incentive structure was implemented to keep respondents engaged. Finally, location data was collected from respondents since it will be needed to estimate individual noise exposure from X-59. The results of this survey test will help determine the design of the community survey campaign.
This viewgraph presentation reviews topics on test methods for space systems and operations safety through experimentation and analysis. The contents include: 1) Perception of reality through experimentation and analysis; 2) Measurements, methods, and correlations with real life; and 3) Correlating laboratory aerospace materials flammability data with data in spacecraft environments.
A method for spot test identification of magnesium and various magnesium alloys commonly used in aerospace applications is described. The spot test identification involves color codes obtained when several drops of 3 M hydrochloric acid are placed on the surface to be tested. After approximately thirty seconds, two drops of this reacted acid is transferred to each of two depressions in a spot plate for additions of other chemicals with subsequent color changes indicating magnesium or its alloy.
NASA's Advanced Composite Technology (ACT) Program was initiated in 1990 with the purpose of developing less costly composite aircraft structures. A number of innovative materials and processes were evaluated as a part of this effort. Chief among them are composite materials reinforced with textile preforms. These new forms of composite materials bring with them potential testing problems. Methods currently in practice were developed over the years for composite materials made from prepreg tape or simple 2-D woven fabrics. A wide variety of 2-D and 3-D braided, woven, stitched, and knit preforms were suggested for application in the ACT program. The applicability of existing test methods to the wide range of emerging materials bears investigation. The overriding concern is that the values measured are accurate representations of the true material response. The ultimate objective of this work is to establish a set of test methods to evaluate the textile composites developed for the ACT Program.
High dose rate irradiation with hydrogen stress is proposed as an accelerated total dose test method for bipolar linear circuits. The method is validated across process and circuit technologies with five parts that are commonly used in space: a comparator (LM193 from National Semi-conductor), a voltage regulator (HSYE-117 RH from Intersil), a voltage reference (LT1019 from Linear Technology), a JFET input op amp (OP42 from Analog Devices) and a temperature transducer (AD590 from Analog Devices). The testing technique could rapidly establish an upper bound to the low dose rate response of parts in space and help with the part selection process in the design phase of a mission. The technology dependence and the viability of this technique are qualitatively explored using a physical model describing the dose rate response and the effect of hydrogen in bipolar technologies. The model uses four core processes: 1) space charge effects, 2) free electron/hole pair recombination, hole-hydrogen defect reactions in the oxides and 4) proton depassivation of dangling bonds at the Si/SiO2 interface. Radiation hardness assurance implications are discussed.
A graphite-epoxy composite material system is used to evaluate the performance of three popular shear tests - the 10-deg off-axis, the +/-45-deg tension, and the Iosipescu specimen tested in the modified Wyoming fixture. A comparison of the shear stress-strain response for each test method is made using a conventional strain gage instrument and moire interferometry. The uniformity and purity of the strain fields in the test sections of the specimens are discussed, and the shear responses obtained from each test are presented and compared. It is shown that the shear stress-strain responses obtained by instrumenting only one face of the 90-deg Iosipescu specimen could give erroneous results. The +/-45-deg tensile and 0-deg Iosipescu specimens were not affected by front-to-back face shear strain variations. Correction factors could be applied to bring all responses together, within the limits of the material uniformity, which was itself documented in the moire fringe patterns.
The Simplified Model Test (SMT) approach is an alternative creep-fatigue evaluation method that no longer requires the use of the damage interaction diagram, or D-diagram. The reason is that the combined effects of creep and fatigue are accounted for in the test data by means of a SMT specimen that is designed to replicate or bound the stress and strain redistribution that occurs in actual components when loaded in the creep regime. However, creep-fatigue experiments on SMT key feature articles are specialized and difficult to perform by the general research community. In this paper, two innovative SMT based creep-fatigue experimental methods are developed and implemented. These newly-developed SMT test methods have resolved all the critical challenges in the SMT key feature article testing and enable the potential of further development of the SMT based creep-fatigue evaluation method into a standard testing method. Scoping test results on Alloy 617 and SS 316H using the newly developed SMT methods are summarized and discussed. The concepts of the SMT methodology for creep-fatigue evaluation are explained.
An experimental testing procedure is proposed for generating creep-dominant creep-fatigue interaction in Alloy 617 at 950 °C. Most experimental studies on Alloy 617 at elevated temperatures employ a purely strain-controlled loading waveform with a tensile hold period. Strain-controlled loading can only generate interaction in the fatigue-dominant regime of the damage interaction diagram, due to the saturation effect of increasing hold time on cycle life. This saturation is caused by the rapid stress relaxation of Alloy 617 at high temperatures. Design codes for components undergoing creep-fatigue interaction at high temperatures require creep-fatigue testing data in the creep-dominant regime. Here this study investigates multiple creep-fatigue loading waveforms with the objective of producing creep-dominant interaction. The custom loading waveforms are implemented on a servo-hydraulic load frame with a furnace. A hybrid-control scheme with strain-controlled ramps and load-controlled hold periods is proposed due to its flexibility in generating varying proportions of creep and fatigue damage. Experimental data is presented and different loading schemes are compared. Special emphasis is on the creep and fatigue damage contributions by the newly proposed testing method. Several conclusions are discussed and an extension of this current work is suggested to improve the damage interaction diagram for design purposes.