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NASA NTRS1986

Cost effective management of space venture risks

The development of a model for the cost-effective management of space venture risks is discussed. The risk assessment and control program of insurance companies is examined. A simplified system development cycle which consists of a conceptual design phase, a preliminary design phase, a final design phase, a construction phase, and a system operations and maintenance phase is described. The model incorporates insurance safety risk methods and reliability engineering, and testing practices used in the development of large aerospace and defense systems.

Giuntini, Ronald E.↗

NASA NTRS1996

Comparative Evaluation of Different Optimization Algorithms for Structural Design Applications

Non-linear programming algorithms play an important role in structural design optimization. Fortunately, several algorithms with computer codes are available. At NASA Lewis Research Centre, a project was initiated to assess the performance of eight different optimizers through the development of a computer code CometBoards. This paper summarizes the conclusions of that research. CometBoards was employed to solve sets of small, medium and large structural problems, using the eight different optimizers on a Cray-YMP8E/8128 computer. The reliability and efficiency of the optimizers were determined from the performance of these problems. For small problems, the performance of most of the optimizers could be considered adequate. For large problems, however, three optimizers (two sequential quadratic programming routines, DNCONG of IMSL and SQP of IDESIGN, along with Sequential Unconstrained Minimizations Technique SUMT) outperformed others. At optimum, most optimizers captured an identical number of active displacement and frequency constraints but the number of active stress constraints differed among the optimizers. This discrepancy can be attributed to singularity conditions in the optimization and the alleviation of this discrepancy can improve the efficiency of optimizers.

Patnaik, Surya N.↗

NASA NTRS2010

Depth Dose Distribution Study within a Phantom Torso after Irradiation with a Simulated Solar Particle Event at NSRL

The adequate knowledge of the radiation environment and the doses incurred during a space mission is essential for estimating an astronaut's health risk. The space radiation environment is complex and variable, and exposures inside the spacecraft and the astronaut's body are compounded by the interactions of the primary particles with the atoms of the structural materials and with the body itself Astronauts' radiation exposures are measured by means of personal dosimetry, but there remains substantial uncertainty associated with the computational extrapolation of skin dose to organ dose, which can lead to over- or underestimation of the health risk. Comparisons of models to data showed that the astronaut's Effective dose (E) can be predicted to within about a +10% accuracy using space radiation transport models for galactic cosmic rays (GCR) and trapped radiation behind shielding. However for solar particle event (SPE) with steep energy spectra and for extra-vehicular activities on the surface of the moon where only tissue shielding is present, transport models predict that there are large differences in model assumptions in projecting organ doses. Therefore experimental verification of SPE induced organ doses may be crucial for the design of lunar missions. In the research experiment "Depth dose distribution study within a phantom torso" at the NASA Space Radiation Laboratory (NSRL) at BNL, Brookhaven, USA the large 1972 SPE spectrum was simulated using seven different proton energies from 50 up to 450 MeV. A phantom torso constructed of natural bones and realistic distributions of human tissue equivalent materials, which is comparable to the torso of the MATROSHKA phantom currently on the ISS, was equipped with a comprehensive set of thermoluminescence detectors and human cells. The detectors are applied to assess the depth dose distribution and radiation transport codes (e.g. GEANT4) are used to assess the radiation field and interactions of the radiation field with the phantom torso. Lymphocyte cells are strategically embedded at selected locations at the skin and internal organs and are processed after irradiation to assess the effects of shielding on the yield of chromosome damage. The initial focus of the present experiment is to correlate biological results with physical dosimetry measurements in the phantom torso. Further on, the results of the passive dosimetry within the anthropomorphic phantoms represent the best tool to generate reliable data to benchmark computational radiation transport models in a radiation field of interest. The presentation will give first results of the physical dose distribution, the comparison with GEANT4 computer simulations based on a Voxel model of the phantom, and a comparison with the data from the chromosome aberration study.

Berger, Thomas↗

NASA NTRS2011

Experimental and Modeling Studies of the Combustion Characteristics of Conventional and Alternative Jet Fuels. Final Report

The objectives of this project have been to develop a comprehensive set of fundamental data regarding the combustion behavior of jet fuels and appropriately associated model fuels. Based on the fundamental study results, an auxiliary objective was to identify differentiating characteristics of molecular fuel components that can be used to explain different fuel behavior and that may ultimately be used in the planning and design of optimal fuel-production processes. The fuels studied in this project were Fischer-Tropsch (F-T) fuels and biomass-derived jet fuels that meet certain specifications of currently used jet propulsion applications. Prior to this project, there were no systematic experimental flame data available for such fuels. One of the key goals has been to generate such data, and to use this data in developing and verifying effective kinetic models. The models have then been reduced through automated means to enable multidimensional simulation of the combustion characteristics of such fuels in real combustors. Such reliable kinetic models, validated against fundamental data derived from laminar flames using idealized flow models, are key to the development and design of optimal combustors and fuels. The models provide direct information about the relative contribution of different molecular constituents to the fuel performance and can be used to assess both combustion and emissions characteristics.

Meeks, Ellen↗

NASA NTRS2012

NASA-ONERA Collaboration on Human Factors in Aviation Accidents and Incidents

Srivastava, Ashok N.↗

NASA NTRS2012

First Annual Report: NASA-ONERA Collaboration on Human Factors in Aviation Accidents and Incidents

This is the first annual report jointly prepared by NASA and ONERA on the work performed under the agreement to collaborate on a study of the human factors entailed in aviation accidents and incidents particularly focused on consequences of decreases in human performance associated with fatigue. The objective of this Agreement is to generate reliable, automated procedures that improve understanding of the levels and characteristics of flight-crew fatigue factors whose confluence will likely result in unacceptable crew performance. This study entails the analyses of numerical and textual data collected during operational flights. NASA and ONERA are collaborating on the development and assessment of automated capabilities for extracting operationally significant information from very large, diverse (textual and numerical) databases much larger than can be handled practically by human experts. This report presents the approach that is currently expected to be used in processing and analyzing the data for identifying decrements in aircraft performance and examining their relationships to decrements in crewmember performance due to fatigue. The decisions on the approach were based on samples of both the numerical and textual data that will be collected during the four studies planned under the Human Factors Monitoring Program (HFMP). Results of preliminary analyses of these sample data are presented in this report.

Srivastava, Ashok↗

NASA NTRSDate not supplied

CFD 2030 Grand Challenge: CFD-in-the-Loop Monte Carlo Flight Simulation for Space Vehicle Design

Flight qualification of space vehicles is markedly different from those typically employed for aircraft. The concept of an extensive flight test campaign for a space vehicle does not exist, and vehicle designers must look to alternative techniques for demonstrating robust and reliable performance of their vehicles prior to operational flight. A space vehicle may undergo only a handful of flight tests in its development cycle, with each flight representing a drastically different flight phase or flight configuration. For instance, NASA’s Space Launch System (SLS) launch vehicle and Orion spacecraft will only see a total of four flight demonstrations before flying a crew on its first operational mission, and each flight demonstrates a unique vehicle configuration and/or set of flight conditions. The SLS will be flown only one time before it becomes operational (Artemis 1). The Orion spacecraft Crew Module (CM) will have been tested twice, once on a Delta IV launch vehicle (Exploration Flight Test 1) and once as a fully integrated system with the SLS launch vehicle (Artemis 1). The Orion Launch abort system will have been tested twice, once in a pad abort scenario (Pad Abort 1) and once in an inflight abort scenario (Ascent Abort 2) on a modified Peacekeeper booster. Both of these latter tests involve only a boiler plate CM, not a functional Orion spacecraft. Thus, unlike aircraft, there is very little opportunity for engineers to assess and evaluate their preflight predictions. Instead, space vehicle designers rely on Monte Carlo flight simulations with detailed dispersions of predicted nominal flight behavior to determine how robust their design is to errors and uncertainties in the flight conditions their vehicle may encounter. These Monte Carlo analyses entail thousands of trajectory simulations to demonstrate that the vehicle can meet design requirements at a specified level of reliability. From an aerodynamics and aerothermodynamics perspective, these trajectory simulations are fueled by an extensive aerodynamic database that covers the complete range of expected flight conditions, vehicle configurations, and flight attitudes expected in a given mission. Today, these databases amount to a table of engineering parameters that can be quickly interrogated by the trajectory simulator. The aerodynamic and aerothermodynamic databases are assembled via a series of ground tests, empirical and analytical analysis, physics-based computational analysis, applicable past flight performance data, and in some cases, engineering judgment. These databases generally take years to assemble for a new space vehicle system and in the case of SLS/Orion, over a decade of test and analysis have been expended to develop the extensive databases required to cover the myriad of configurations and potential flight conditions required for the system. Recently, it has been proposed that Computational Fluid Dynamic (CFD) and computing capability may be reaching a point where it is foreseeable that CFD could be integrated directly into the production trajectory simulation tools used to design NASA’s space vehicles. To demonstrate this, NASA has embarked on two demonstrations of this type of capability, one where six degree of freedom flight trajectory simulation equations are embedded in an existing CFD solver and another where a production CFD solver is loosely coupled with a production trajectory simulation tool. These efforts represent an initial demonstration of a future approach to flight trajectory simulation, but they are a far cry from the capability required to perform a full-up CFD-in-the-loop Monte Carlo trajectory simulation. Therefore, this represents a viable grand challenge for computational methods addressing space vehicle design and development. The final paper/presentation will discuss the many hurdles, beyond simply raw computational power, to realizing this grand challenge and how they map directly to the CFD Vision 2030 ojectives. Among these are the wide range of flight conditions, including accelerating/decelerating flight, encountered by a space vehicle during launch and/or entry. The vehicle can also encounter numerous configuration changes, some of which can be quite drastic, during the course of its flight, so robust, automated geometry modeling, grid generation, and adaptation will play a huge role in reaching this goal. Multiply this by 1000’s of trajectory simulations occurring simultaneously in a given Monte Carlo analysis, and the problem readily scales to absorb virtually any size of supercomputer envisioned today. The concept of CFD-in-the-loop Monte Carlo trajectory simulation poses a formidable challenge for emerging and future computing systems, and it has the potential to shave years off the development cycle for aerodynamic and aerothermodynamic performance predictions as compared to today’s space vehicle design approach.

CFD 2030↗

NASA NTRS2001

Robust Strategy for Rocket Engine Health Monitoring

Monitoring the health of rocket engine systems is essentially a two-phase process. The acquisition phase involves sensing physical conditions at selected locations, converting physical inputs to electrical signals, conditioning the signals as appropriate to establish scale or filter interference, and recording results in a form that is easy to interpret. The inference phase involves analysis of results from the acquisition phase, comparison of analysis results to established health measures, and assessment of health indications. A variety of analytical tools may be employed in the inference phase of health monitoring. These tools can be separated into three broad categories: statistical, rule based, and model based. Statistical methods can provide excellent comparative measures of engine operating health. They require well-characterized data from an ensemble of "typical" engines, or "golden" data from a specific test assumed to define the operating norm in order to establish reliable comparative measures. Statistical methods are generally suitable for real-time health monitoring because they do not deal with the physical complexities of engine operation. The utility of statistical methods in rocket engine health monitoring is hindered by practical limits on the quantity and quality of available data. This is due to the difficulty and high cost of data acquisition, the limited number of available test engines, and the problem of simulating flight conditions in ground test facilities. In addition, statistical methods incur a penalty for disregarding flow complexity and are therefore limited in their ability to define performance shift causality. Rule based methods infer the health state of the engine system based on comparison of individual measurements or combinations of measurements with defined health norms or rules. This does not mean that rule based methods are necessarily simple. Although binary yes-no health assessment can sometimes be established by relatively simple rules, the causality assignment needed for refined health monitoring often requires an exceptionally complex rule base involving complicated logical maps. Structuring the rule system to be clear and unambiguous can be difficult, and the expert input required to maintain a large logic network and associated rule base can be prohibitive.

Santi, L. Michael↗

NASA NTRS1998

Advanced Air Bag Technology Assessment

As a result of the concern for the growing number of air-bag-induced injuries and fatalities, the administrators of the National Highway Traffic Safety Administration (NHTSA) and the National Aeronautics and Space Administration (NASA) agreed to a cooperative effort that "leverages NHTSA's expertise in motor vehicle safety restraint systems and biomechanics with NASAs position as one of the leaders in advanced technology development... to enable the state of air bag safety technology to advance at a faster pace..." They signed a NASA/NHTSA memorandum of understanding for NASA to "evaluate air bag to assess advanced air bag performance, establish the technological potential for improved technology (smart) air bag systems, and identify key expertise and technology within the agency (i.e., NASA) that can potentially contribute significantly to the improved effectiveness of air bags." NASA is committed to contributing to NHTSAs effort to: (1) understand and define critical parameters affecting air bag performance; (2) systematically assess air bag technology state of the art and its future potential; and (3) identify new concepts for air bag systems. The Jet Propulsion Laboratory (JPL) was selected by NASA to respond to the memorandum of understanding by conducting an advanced air bag technology assessment. JPL analyzed the nature of the need for occupant restraint, how air bags operate alone and with safety belts to provide restraint, and the potential hazards introduced by the technology. This analysis yielded a set of critical parameters for restraint systems. The researchers examined data on the performance of current air bag technology, and searched for and assessed how new technologies could reduce the hazards introduced by air bags while providing the restraint protection that is their primary purpose. The critical parameters which were derived are: (1) the crash severity; (2) the use of seat belts; (3) the physical characteristics of the occupants; (4) the proximity of the occupants to the airbag module; (5) the deployment time, which includes the time to sense the need for deployment, the inflator response parameters, the air bag response, and the reliability of the air bag. The requirements for an advanced air bag technology is discussed. These requirements includes that the system use information related to: (1) the crash severity; (2) the status of belt usage; (3) the occupant category; and (4) the proximity to the air bag to adjust air bag deployment. The parameters for the response of the air bag are: (1) deployment time; (2) inflator parameters; and (3) air bag response and reliability. The state of occupant protection advanced technology is reviewed. This review includes: the current safety restraint systems, and advanced technology characteristics. These characteristics are summarized in a table, which has information regarding the technology item, the potential, and an date of expected utilization. The use of technology and expertise at NASA centers is discussed. NASA expertise relating to sensors, computing, simulation, propellants, propulsion, inflatable systems, systems analysis and engineering is considered most useful. Specific NASA technology developments, which were included in the study are: (1) a capacitive detector; (2) stereoscopic vision system; (3) improved crash sensors; (4) the use of the acoustic signature of the crash to determine crash severity; and (5) the use of radar antenna for pre-crash sensing. Information relating to injury risk assessment is included, as is a summary of the areas of the technology which requires further development.

Phen, R. L.↗

NASA NTRS2015

Leakage Currents and Gas Generation in Advanced Wet Tantalum Capacitors

Currently, military grade, established reliability wet tantalum capacitors are among the most reliable parts used for space applications. This has been achieved over the years by extensive testing and improvements in design and materials. However, a rapid insertion of new types of advanced, high volumetric efficiency capacitors in space systems without proper testing and analysis of degradation mechanisms might increase risks of failures. The specifics of leakage currents in wet electrolytic capacitors is that the conduction process is associated with electrolysis of electrolyte and gas generation resulting in building up of internal gas pressure in the parts. The risk associated with excessive leakage currents and increased pressure is greater for high value advanced wet tantalum capacitors, but it has not been properly evaluated yet. In this work, in Part I, leakages currents in various types of tantalum capacitors have been analyzed in a wide range of voltages, temperatures, and time under bias. Gas generation and the level of internal pressure have been calculated in Part II for different case sizes and different hermeticity leak rates to assess maximal allowable leakage currents. Effects related to electrolyte penetration to the glass seal area have been studied and the possibility of failures analyzed in Part III. Recommendations for screening and qualification to reduce risks of failures have been suggested.

degradation mechanisms↗

NASA NTRS1973

Study to validate the Non-Interference Performance Assessment (NIPA) technique

The NIPA (Non-Interference Performance Assessment) technique involves direct observation of group verbal activities by trained observers who rate the emotional content (affect) of each verbal interaction as either positive, negative, or neutral. During the test, in which four men were confined for 90 consecutive days, feasibility of the NIPA technique was demonstrated and observer reliability was verified. However, the validity of the test was not proved because an independent criterion measure of morale for the confined crew was lacking. There were indications, however, that NIPA measures were tracking changes in crew morale. At approximately the two-thirds point (Days 60 to 70), morale apparently fell dramatically for a period of about ten days, and simultaneously NIPA measure of positive verbalization decreased in number. A need was indicated for a separate study to apply the NIPA technique under experimental conditions and using a clearly defined criterion measure against which the ability of NIPA observations to truly measure morale changes could be determined.

Seeman, J. S.↗

NASA NTRS1985

The impact of the FGGE observing systems in the Southern Hemisphere

Results of studies carried out at the Australian Numerical Meteorology Research Centre (ANMRC) and the Australian Bureau of Meteorology to assess the impact of FGGE on numerical weather prediction in the Southern Hemisphere are presented. These studies inducate that the FGGE data base had a significant impact on analysis and numerical weather prediction. From the operational standpoint, the most outstanding contribution was made by the drifting buoy data that enabled reliable routine surface pressure analyses to be made over the entire hemisphere. The results of a limited study using the MNMRC data assimilation scheme show that the quality of prediction to 48 hours hinges crucially on both the buoy pressure data and satellite temperature soundings with single level satellite winds having a small impact.

Puri, K.↗

NASA NTRS1991

System concepts for a large UV/optical/IR telescope on the moon

To assess the systems and technological requirements for constructing lunar telescopes in conjunction with the buildup of a lunar base for scientific exploration and as a waypoint for travel to Mars, the NASA Marshall Space Flight Center conducted concept studies of a 16-m-aperture large lunar telescope (LLT) and a 4-m-aperture precursor telescope, both operating in the UV/visible/IR spectral region. The feasibility of constructing a large telescope on the lunar surface is assessed, and its systems and subsystems are analyzed. Telescope site selection, environmental effects, and launch and assembly scenarios are also evaluated. It is argued that key technical drivers for the LLT must be tested in situ by precursor telescopes to evaluate such areas as the operations and long-term reliability of active optics, radiation protection of instruments, lunar dust mitigation, and thermal shielding of the telescope systems. For a manned lunar outpost or an LLT to become a reality, a low-cost dependable transportation system must be developed.

Nein, Max E.↗

NASA NTRS1999

Low-Storage, Explicit Runge-Kutta Schemes for the Compressible Navier-Stokes Equations

The derivation of storage explicit Runge-Kutta (ERK) schemes has been performed in the context of integrating the compressible Navier-Stokes equations via direct numerical simulation. Optimization of ERK methods is done across the broad range of properties, such as stability and accuracy efficiency, linear and nonlinear stability, error control reliability, step change stability, and dissipation/dispersion accuracy, subject to varying degrees of memory economization. Following van der Houwen and Wray, 16 ERK pairs are presented using from two to five registers of memory per equation, per grid point and having accuracies from third- to fifth-order. Methods have been assessed using the differential equation testing code DETEST, and with the 1D wave equation. Two of the methods have been applied to the DNS of a compressible jet as well as methane-air and hydrogen-air flames. Derived 3(2) and 4(3) pairs are competitive with existing full-storage methods. Although a substantial efficiency penalty accompanies use of two- and three-register, fifth-order methods, the best contemporary full-storage methods can be pearl), matched while still saving two to three registers of memory.

Kennedy, Chistopher A.↗

NASA NTRSDate not supplied

TPSAS-NF1676L-13013-DND

Description, capabilities and utilization of the NASA Langley Aerothermodynamics Laboratory (LAL) are presented. The LAL consists of four hypersonic, blow-down-to-vacuum wind tunnels that collectively provide a range of Mach number from 6 to 10 (18 simulation), unit Reynolds number from 0.05 to 8 million per foot and, most importantly for blunt configurations, normal shock density ratio from 4 to 12. These wide ranges of hypersonic simulation parameters are due, in part, to the use of two different test gases (air and tetrafluoromethane, CF4), thereby making the facilities unique. The complex represents half of the conventional (as opposed to impulse) -type hypersonic wind tunnels operational in this country. LAL facilities are used to assess and optimize the hypersonic aerodynamic performance and aeroheating characteristics of aerospace vehicle concepts and to provide benchmark aerodynamic/aeroheating data for generating the flight aerodynamic databook and final design of the thermal protection system (TPS). Modifications and enhancements of LAL hardware components and instrumentation have been pursued to increase capability, reliability, and productivity in support of programmatic goals. The facilities are utilized to generate essentially all of the experimental hypersonic aerodynamic and aeroheating information for high-priority, fast-paced Agency programs and were a major contributor to the Shuttle Columbia Accident Investigation, space shuttle Return-to-Flight program and Hypersonic Thermodynamic Infrared Measurements (HYTHIRM) project. The LAL has also contributed to the development of the Orion Crew Exploration Vehicle, Ares launch system, Mars Science Laboratory, Genesis Sample Return Capsule and supported DOD programs including HIFiRE, X-37, Falcon HTV-2 and X-51A.

John R Micol↗

NASA NTRSDate not supplied

The Containment Assurance Risk Framework of the Mars Sample Return Program

The Mars Sample Return campaign aims at bringing rock and atmospheric samples from Mars to Earth through a series of robotic missions. These missions would collect the samples being cached and deposited on Martian soil by the Perseverance rover, place them in a container, and launch them into Martian orbit for subsequent capture by an orbiter that would bring them back. Given there exists a non-zero probability that the samples contain biological material, precautions are being taken to design systems that would break the chain of contact between Mars and Earth. These include techniques such as sterilization of Martian particles, redundant containment vessels, and a robust reentry capsule capable of accurate landings without a parachute. Requirements exist that the probability of containment not assured of Martian-contaminated material into Earth’s biosphere be less than one in a million. To demonstrate compliance with this strict requirement, a statistical framework was developed to assess the likelihood of containment loss during each sample return phase and make a statement about the total combined mission probability of containment not assured. The work presented here describes this framework, which considers failure modes or fault conditions that can initiate failure sequences ultimately leading to containment not assured. Reliability estimates are generated from databases, design heritage, component specifications, or expert opinion in the form of probability density functions or point estimates and provided as inputs to the mathematical models that simulate the different failure sequences. The probabilistic outputs are then combined following the logic of several fault trees to compute the ultimate probability of containment not assured. Given the multidisciplinary nature of the problem and the different types of mathematical models used, the statistical tools needed for analysis are required to be computationally efficient. While standard Monte Carlo approaches are used for fast models, a multi-fidelity approach to rare event probabilities is proposed for expensive models. In this paradigm, inexpensive low-fidelity models are developed for computational acceleration purposes while the expensive high-fidelity model is kept in the loop to retain accuracy in the results. This work presents an example of end-to-end application of this framework highlighting the computational benefits of a multi-fidelity approach.

Giuseppe Cataldo↗

NASA NTRS1992

High-temperature strain measurement techniques: Current developments and challenges

Since 1987, a very substantial amount of R&D has been conducted in an attempt to develop reliable strain sensors for the measurements of structural strains during ground testing and hypersonic flight, at temperatures up to at least 2000 deg F. Much of the effort has been focused on requirements of the NASP Program. This presentation is limited to the current sensor development work and characterization studies carried out within that program. It is basically an assessment as to where we are now and what remains to be done in the way of technical accomplishments to meet the technical challenges posed by the requirements and constraints established for the NASP Program. The approach for meeting those requirements and constraints has been multi-disciplinary in nature. It was recognized early on that no one sensor could meet all these requirements and constraints, largely because of the large temperature range (cryogenic to at least 2000 deg F) and many other factors, including the most challenging requirement that the sensor system be capable of obtaining valid 'first cycle data'. Present candidate alloys for resistance-type strain gages include Fe-Cr-Al and Pd-Cr. Although they have superior properties regarding withstanding very high temperatures, they exhibit large apparent strains that must either be accounted for or cancelled out by various techniques, including the use of a dual-element, half-bridge dummy gage, or electrical compensation networks. A significant effort is being devoted to developing, refining, and evaluating the effectiveness of those techniques over a broad range in temperature and time. In the quest to obtain first-cycle data, ways must be found to eliminate the need to prestabilize or precondition the strain gage, before it is attached to the test article. It should be noted that present NASP constraints do not permit prestabilization of the sensor, in situ. Gages are currently being 'heat treated' during manufacture in both the wire- and foil-type resistance strain gages, and evaluation is in progress. In addition, the 'gage-on-shim' concept is being revisited. That concept will permit heat treatment of the gage during manufacture, before attachment on the test article. Also, it may permit the individual calibration of each gage regarding gage factor and apparent strain. Candidate alloys for the NASP include titanium metal-matrix and carbon-carbon composites. Although those materials have very attractive properties at elevated temperatures in terms of strength and weight, they pose significant attachment problems. Methods for making reliable strain gage and thermocouple attachments to them are currently under development. Experience to date indicates that Rokide attachment of the sensor directly to the protective coating is easier than to the base material itself. However, interpreting strain data from gages attached in this way may prove difficult because of possible cracks in the coating that form 'islands' and the mobility of those 'islands'. It is concluded, therefore, that major technical challenges lie ahead as we proceed to meet the stringent strain sensor requirements and constraints of the NASP Program.

Lemcoe, M. M.↗

NASA NTRS2022

Recommendations on the Use of Commercial-Off-The-Shelf (COTS) Electrical, Electronic, and Electromechanical (EEE) Parts for NASA Missions - Phase II

This assessment had two Phases. Phase I captured NASA Centers’ current practices for commercial-off-the-shelf (COTS) Electrical, Electronic, and Electromechanical (EEE) parts 1 used in spaceflight systems and ground support equipment (available at https://ntrs.nasa.gov/citations/20205011579) [ref. 1]. The Phase II report provides guidance for selecting and using COTS parts in NASA missions. The approaches proposed in this report differ from current agency practices. This top-level executive summary touches on these new approaches for using COTS parts but does not provide the detailed information that is critical in understanding the rationale behind these new approaches. Readers will need to read the entire report to gain full understanding and effectively use the recommendations herein. NASA’s historical approach to selecting and applying parts has been to define certain parts, primarily specific classes of military specification (MIL-SPEC) parts, as “standard”, leaving all others, including COTS parts, as nonstandard. Standard parts typically are used without further testing (“use-as-is”). Nonstandard parts are subjected to initial screening and subsequent lot acceptance testing of representative samples from each procured lot per MIL-SPEC or similar requirements. Decades later, top-tier commercial part manufacturers have evolved significant manufacturing, statistical control, and technological improvements that can now provide parts as reliable or more reliable than MIL-SPEC parts, when used within their datasheet limits. Concurrently, the space science and exploration community’s needs demand technological advances unavailable with MIL-SPEC parts. This ongoing change necessitates using COTS parts for space missions. Properly selected COTS parts in appropriate applications can offer performance and supply availability advantages compared to MIL-SPEC parts. Their utility and demonstrated reliability result from large volumes and automated production and testing processes. However, careful review and a thorough understanding of their specifications (i.e., datasheet limitations) is needed, and verifying that manufacturer specifications and reliability meet space hardware application needs are necessary. This report recommends MIL-SPEC screening and non-radiation-related lot acceptance testing be reduced or eliminated in cases where evidence of sufficient quality and reliability exists for COTS parts. The extent of NASA's insight into COTS manufacturers and the amount and nature of the needed evidence will differ by mission and will likely be driven by a mission's resources and associated risk posture. To facilitate this goal, two new terminologies have been defined and described: “Industry Leading Parts Manufacturer (ILPM)” and “Established COTS parts.” An ILPM is a COTS manufacturer that produces high quality and reliable parts. Some parts produced by ILPMs, defined as Established COTS parts, do not need any additional MIL-SPEC or NASA screening and lot acceptance testing to be used in space applications. This report provides guidance for selecting, procuring, and applying COTS parts and for performing part-, board-, and system-level COTS parts verification. The recommendation to select Established COTS parts from ILPMs will assure those COTS parts will have comparable quality to corresponding MIL-SPEC parts. Selecting, applying, and verifying Established COTS parts from ILPMs requires a holistic team approach, engaging parts engineers, circuit designers, quality, reliability, and systems engineers, procurement specialists, radiation specialists, avionics leads, and program/project managers. A mission-specific approach tailored to a project’s Mission, Environment, Applications and Lifetime (MEAL) [ref. 2] requirements should be developed and approved by program/project managers. Any associated risks should be clearly identified, quantified, mitigated, and/or accepted. Different approaches are recommended according to program/project Risk Classes A, B, C, and D [ref. 3] and human-rated missions [ref. 4]: 1. Recommend Classes A and B and human-rated missions consider a “MIL-SPEC parts- based design” approach. ”MIL-SPEC parts-based design” approach is one in which most parts are MIL-SPEC parts and Established COTS parts from ILPMs are used only when an equivalent MIL-SPEC part does not meet functional or size, weight, and power (SWaP) or performance requirements, or is not available. 2. Recommend Classes D and Sub-D missions consider a “System of COTS” approach. “System of COTS” approach is one which most parts are Established COTS parts from ILPMs. 3. Recommend Class C missions determine which approach is the best for their projects; that is, use either a “MIL-SPEC parts-based design” approach, “System of COTS” approach, or a combined approach utilizing elements of both. This report intends to provide guidance in using COTS parts for NASA missions with risk classifications of A through D and human-rated missions; but it does not address the costs of using COTS parts. Costs of using COTS parts in different NASA mission classes can vary significantly even if the same parts are used in different risk postures, due to differing verification levels needed. The guidance does not distinguish between critical or non-critical systems, and a given project will need to apply the appropriate guidance based on their risk posture. The intended audience of this report are NASA personnel and commercial practitioners who support NASA’s spaceflight missions, including spaceflight program or project managers, parts engineers, parts manufacturers, radiation engineers, avionics engineers, system engineers, circuit design engineers, reliability engineers, safety and mission assurance (SMA) personnel, and parts procurement specialists. The NEPP Program will perform a pathfinder study to explore implementing the guidance in this NESC report. An ILPM verification process is not the same as conventional vendor qualification processes performed according to military standards and specifications. This NESC report intends to provide guidance in utilizing available parts data from ILPM manufacturers for parts assurance assessments needed for NASA missions. The report also captured the current practices from DoD and Federal Aviation Administration (FAA) in Section 10. Note each DoD and FAA report was provided by the corresponding agencies regarding their practices, which are independent from the NESC recommendations in the report.

Commercial-Off-The-Shelf↗