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Presentation to support a Summit/TIM with various Stakeholders (Ground and Flight) to perform a GAP analysis associated with ground and spacecraft maintenance, maintainability, and availability activities in order to identify missing Agency planning and guidance materials.
Presentation to support a Summit/TIM with various Stakeholders (Ground and Flight) to perform a GAP analysis associated with ground and spacecraft maintenance, maintainability, and availability activities in order to identify missing Agency planning and guidance materials.
As NASA continues to impement its Faster, Better, Cheaper philosophy, new approaches for implementing Mission Assurance activities are being developed.
NASA's Code QE Test Effectiveness Program is funding a series of applied research activities focused on utilizing the principles of physics and engineering of failure along with those of engineering economics to assess and improve the value added by various validation and verification activities, with the primary emphasis being on testing.
The idea of a “digital twin” was born at NASA in the 1960s as a “living model” of the Apollo mission. In response to Apollo 13’s oxygen tank explosion and subsequent damage to the main engine, NASA employed multiple simulators to evaluate the failure and extended a physical model of the vehicle to include digital components. This “digital twin” was the first of its kind, allowing for a continuous ingestion of data to model the events leading to up to the accident for forensic analysis and exploration of next steps. Fast forward half a century and NASA, along with others in the aerospace community, continues to develop and utilize high-fidelity digital models of physical systems and components as well as the extreme environments in which they operate. NASA aims to travel further and stay longer in space as we realize the Artemis program, taking us from the moon to Mars by establishing a sustainable presence on the Moon to prepare for missions to Mars. We will no longer be able to rely on constant connectivity with an asset nor be in-the-loop for on-demand human intervention in the event of an anomaly. Further, the importance of digital twins is increasing as we seek alternatives for certification of structures so large that they cannot be fully evaluated in existing test facilities and autonomous systems that are not deterministic. The idea of a digital twin is not a new one. What is new is the scale, ordinality, and non-deterministic nature of the models that are critical to achieving NASA’s goals. Their number and autonomy from each other as well as the reference system is suggestive of a changing ecosystem, returning us the idea of a living model.
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Organosulfur electrolytes are promising candidates for enabling high-voltage cathodes due to their superior oxidative stability compared to conventional carbonate-based systems. However, their viscous nature and inability to passivate the anode necessitate the use of passivating agents and diluents to achieve meaningful charge/discharge rates. In this study, we investigate the use of cyclic fluorinated carbonates (CFCs) to form passivating interphases on electrode surfaces, aiming to optimize electrolyte performance in high-voltage systems. Electrolyte formulations containing 1.2 M LiPF 6 in a CFC:sulfone:1,1,2,2-tetrafluoroethyl-2,2,3,3-tetrafluoropropylether (TTE) mixture (2/5/3 V/V/V) were assessed in full-cell configurations with a LiNi 0.8 Mn 0.1 Co 0.1 O 2 (FCG-NMC) cathode and a 4.5 V upper cutoff potential. The results reveal that 3-3-3-trifluoropropylene carbonate (TFPC) combined with ethyl methyl sulfone (EMS) optimizes electrolyte performance, resulting in lower resistance buildup and reduced capacity loss compared to commercial electrolytes. We also explore the failure mechanisms of several carbonate/sulfone mixtures and identify key considerations for electrolyte compatibility in high-voltage systems. TFPC enhances cycling stability and lowers overall cell resistance, while fluoroethylene carbonate (FEC) formulations, despite higher ionic conductivity, fail to form adequate passivation layers, leading to rapid capacity loss. Additionally, EMS provides superior physical properties that avoid common failure modes seen with other sulfone solvents like methyl isopropyl sulfone and tetramethylene sulfone. Furthermore, this study underscores the importance of carefully selecting passivating carbonates and sulfone solvents to improve electrolyte performance and expand the viability of high-voltage electrolyte systems.
Results that illustrate the use of a video-image-correlation-based displacement and strain measurement system to assess the effects of material nonuniformities on the behavior of the sprayed-on foam insulation (SOFI) used for the thermal protection system on the Space Shuttle External Tank are presented. Standard structural verification specimens for the SOFI material with and without cracks and subjected to mechanical or thermal loading conditions were tested. Measured full-field displacements and strains are presented for selected loading conditions to illustrate the behavior of the foam and the viability of the measurement technology. The results indicate that significant strain localization can occur in the foam because of material nonuniformities. In particular, elongated cells in the foam can interact with other geometric or material discontinuities in the foam and develop large-magnitude localized strain concentrations that likely initiate failures. Furthermore, some of the results suggest that continuum mechanics and linear elastic fracture mechanics might not adequately represent the physical behavior of the foam, and failure predictions based on homogeneous linear material models are likely to be inadequate.
Results that illustrate the use of a video-image-correlation-based displacement and strain measurement system to assess the effects of material nonuniformities on the behavior of the sprayed-on foam insulation (SOFI) used for the thermal protection system on the Space Shuttle External Tank are presented. Standard structural verification specimens for the SOFI material with and without cracks and subjected to mechanical or thermal loading conditions were tested. Measured full-field displacements and strains are presented for selected loading conditions to illustrate the behavior of the foam and the viability of the measurement technology. The results indicate that significant strain localization can occur in the foam because of material nonuniformities. In particular, elongated cells in the foam can interact with other geometric or material discontinuities in the foam and develop large-magnitude localized strain concentrations that likely initiate failures. Furthermore, some of the results suggest that continuum mechanics and linear elastic fracture mechanics might not adequately represent the physical behavior of the foam, and failure predictions based on homogeneous linear material models are likely to be inadequate.
In order to evaluate the feasibility of newly developed GaN devices in a cryogenically-cooled converter, this paper characterizes a 650 V enhancement-mode Gallium-Nitride high-electron-mobility transistor (GaN HEMT) at cryogenic temperatures. The characterization includes both static and dynamic behaviors. The results show that this GaN HEMT is an excellent device candidate to be applied in cryogenic-cooled applications. For example, transconductance at cryogenic temperature (93 K) is 2.5 times higher than one at room temperature (298 K), and accordingly, peak di/dt during turn-on transients at cryogenic temperature is around 2 times of that at room temperature. Moreover, the on-resistance of the channel at cryogenic temperature is only one-fifth of that at room temperature. The corresponding explanations of performance trends at cryogenic temperatures are also given from the view of semiconductor physics. In addition, several device failures were observed during the dynamic characterization of GaN HEMTs at cryogenic temperatures. The ultra-fast switching speed induced high di/dt and dv/dt at cryogenic temperatures amplifies the negative effects of parasitics inside the switching loop. Based on failure waveforms, two failure modes were classified, and detailed failure mechanisms caused by ultra-fast switching speed are given in this paper.
After almost four years of endurance testing of photovoltaic modules, no fundamental life-limiting mechanisms were identified that could prevent the twenty-year life goal from being met. The endure data show a continual decline in the failure rate with each new large-scale procurement. Cracked cells and broken interconnects continue to be the principal causes of failure. Although the modules are more adversely affected physically by hot, humid environments than by cool or dry environments there are insufficient data to correlate failure with environment. There is little connection between the outward physical condition of a module and changes in its electrical performance.
Scanning electron microscopy to study device failure and performance, discussing limitations and progress
The high reliability requirements for airborne systems requires fault-tolerant architectures to address failures in the presence of physical faults, and the elimination of design flaws during the specification and validation phase of the design cycle. Although much progress has been made in developing methods to address physical faults, design flaws remain a serious problem. Formal methods provides a mathematical basis for removing design flaws from digital systems. DRS (Derivational Reasoning System) is a formal design tool based on advanced research in mathematical modeling and formal synthesis. The system implements a basic design algebra for synthesizing digital circuit descriptions from high level functional specifications. DRS incorporates an executable specification language, a set of correctness preserving transformations, verification interface, and a logic synthesis interface, making it a powerful tool for realizing hardware from abstract specifications. DRS integrates recent advances in transformational reasoning, automated theorem proving and high-level CAD synthesis systems in order to provide enhanced reliability in designs with reduced time and cost.
This review is divided into complaints and correctives. Complaints are directed at: sloppy refereeing and editing; authors who fail to read or acknowledge what others have done; the mis-naming or mis-crediting of results; the misunderstanding and misuse of the Kirchhoff hypothesis; inflated claims of accuracy based on overly-simplified benchmark problems; the failure to appreciate the inherent errors in various shell models; the failure to appreciate that the physical response and mathematical structure of shell theory are fundamentally different from 3-dimensional elasticity; and the irrelevance of Cosserat-type theories. Correctives include a simple, straight-forward derivation of a general nonlinear dynamic shell theory with the following features: (1) the equations of motion and kinematics (and those of thermodynamics, if desired) are exact consequences of their 3-dimensional counterparts; (2) there are no asymptotic or series expansions through the thickness; (3) all approximations (including the Kirchhoff Hypothesis) occur in the constitutive relations; (4) in static problems, there is a mixed form of the governing equations involving a mixed-energy density and exhibiting remnants of the well-known static-geometric duality of linear theory which is numerically robust because the limiting cases of nonlinear membrane theory and inextensional bending theory fall out naturally. (These latter two special cases are known to produce numerical nightmares unless treated with great care); and (5) all equations may be expressed in coordinate-free form (although, sometimes, a hybrid form is shown to be superior).
The United States National Aeronautics and Space Administration (NASA) is in the midst of a space exploration program intended for sending crew and cargo to the international Space Station (ISS), to the moon, and beyond. This program is called Constellation. As part of the Constellation program, NASA is developing new launch vehicles aimed at significantly increase safety and reliability, reduce the cost of accessing space, and provide a growth path for manned space exploration. Achieving these goals requires a rigorous process that addresses reliability, safety, and cost upfront and throughout all the phases of the life cycle of the program. This paper discusses the "Design for Reliability and Safety" approach for the NASA new crew launch vehicle called ARES I. The ARES I is being developed by NASA Marshall Space Flight Center (MSFC) in support of the Constellation program. The ARES I consists of three major Elements: A solid First Stage (FS), an Upper Stage (US), and liquid Upper Stage Engine (USE). Stacked on top of the ARES I is the Crew exploration vehicle (CEV). The CEV consists of a Launch Abort System (LAS), Crew Module (CM), Service Module (SM), and a Spacecraft Adapter (SA). The CEV development is being led by NASA Johnson Space Center (JSC). Designing for high reliability and safety require a good integrated working environment and a sound technical design approach. The "Design for Reliability and Safety" approach addressed in this paper discusses both the environment and the technical process put in place to support the ARES I design. To address the integrated working environment, the ARES I project office has established a risk based design group called "Operability Design and Analysis" (OD&A) group. This group is an integrated group intended to bring together the engineering, design, and safety organizations together to optimize the system design for safety, reliability, and cost. On the technical side, the ARES I project has, through the OD&A environment, implemented a probabilistic approach to analyze and evaluate design uncertainties and understand their impact on safety, reliability, and cost. This paper focuses on the use of the various probabilistic approaches that have been pursued by the ARES I project. Specifically, the paper discusses an integrated functional probabilistic analysis approach that addresses upffont some key areas to support the ARES I Design Analysis Cycle (DAC) pre Preliminary Design (PD) Phase. This functional approach is a probabilistic physics based approach that combines failure probabilities with system dynamics and engineering failure impact models to identify key system risk drivers and potential system design requirements. The paper also discusses other probabilistic risk assessment approaches planned by the ARES I project to support the PD phase and beyond.
A proposed family of devices for inducing fatigue in bolts in order to break the bolts would incorporate piezoelectric actuators into resonant fixtures as in ultrasonic/ sonic drills/corers and similar devices described in numerous prior NASA Tech Briefs articles. These devices were originally intended primarily for use as safer, more-reliable, more-versatile alternatives to explosive bolts heretofore used to fasten spacecraft structures that must subsequently be separated from each other quickly on command during flight. On Earth, these devices could be used for accelerated fatigue testing of bolts. Fatigue theory suggests that a bolt subjected to both a constant-amplitude dynamic (that is, oscillatory) stress and a static tensile stress below the ultimate strength of the bolt material will fail faster than will a bolt subjected to only the dynamic stress. This suggestion would be applied in a device of the proposed type. The device would be designed so that the device and the bolt to be fatigue-tested or broken would be integral parts of an assembly (see figure). The static tension in the tightened bolt would apply not only the clamping force to hold the joined structures (if any) together but also the compression necessary for proper operation of the piezoelectric actuators as parts of a resonant structural assembly. The constant-amplitude dynamic stress would be applied to the bolt by driving the piezoelectric actuators with a sinusoidal voltage at the resonance frequency of longitudinal vibration of the assembly. The amplitude of the excitation would be made large enough so that the vibration would induce fatigue in the bolt within an acceptably short time. In the spacecraft applications or in similar terrestrial structural-separation applications, devices of the proposed type would offer several advantages over explosive bolts: Unlike explosive bolts, the proposed devices would be reusable, could be tested before final use, and would not be subject to catastrophic misfire. In fatigue-testing applications, devices of the proposed type would offer advantages of compactness and low cost, relative to conventional fatigue- testing apparatuses. In both structural- separation and fatigue-testing applications, bolts to be broken or tested could be instrumented with additional ultrasonic transducers for monitoring of pertinent physical properties and of fatigue failure processes.
This report presents an extension of the Clad Damage Propagation (CDAP) model implemented in the MOOSE SubChannel Module (SCM) to capture post-failure fission-gas dispersal and two-phase flow effects in sodium-cooled fast reactor assemblies. The extended model tracks discharged gas axially and radially, computes channel-averaged flow quality and void fraction using a Lockhart–Martinelli framework, evaluates two-phase frictional pressure-drop multipliers, determines inlet mass-flow degradation under fixed core pressures, and applies an intensified-void-based heat-transfer degradation to affected fuel pins. Radial plume expansion is parameterized using mineral-oil jet experiments mapped to sodium conditions via Reynolds–Weber similarity. Implementation details are documented, along with the new methods and user inputs needed to control plume mapping and two-phase behavior. Demonstration simulations for 19- and 37-pin bundles show that breach size and inlet velocity strongly influence propagation potential: small breaches (≤0.5 mm) produce limited degradation while larger breaches (~1 mm) can drive oscillatory temperature spikes and enhanced failure propagation, especially at higher velocities. These results demonstrate that the extended CDAP model provides a more complete framework for quantifying cladding damage propagation and evaluating propagation potential in transient scenarios. The approach remains computationally efficient, consistent with subchannel-level analysis, yet incorporates sufficient physics to bridge localized post-failure effects with bundle- and assembly-scale degradation.