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At least 19 records

Contamination Control in Hybrid Microelectronic Modules. Part 1: Identification of Critical Process and Contaminants

Various hybrid processing steps, handling procedures, and materials are examined in an attempt to identify sources of contamination and to propose methods for the control of these contaminants. It is found that package sealing, assembly, and rework are especially susceptible to contamination. Moisture and loose particles are identified as the worst contaminants. The points at which contaminants are most likely to enter the hybrid package are also identified, and both general and specific methods for their detection and control are developed. In general, the most effective controls for contaminants are: clean working areas, visual inspection at each step of the process, and effective cleaning at critical process steps. Specific methods suggested include the detection of loose particles by a precap visual inspection, by preseal and post-seal electrical testing, and by a particle impact noise test. Moisture is best controlled by sealing all packages in a clean, dry, inert atmosphere after a thorough bake-out of all parts.

Himmel, R. P.↗

Applying a Wearable Voice-Activated Computer to Instructional Applications in Clean Room Environments

The use of wearable computing technology in restrictive environments related to space applications offers promise in a number of domains. The clean room environment is one such domain in which hands-free, heads-up, wearable computing is particularly attractive for education and training because of the nature of clean room work We have developed and tested a Wearable Voice-Activated Computing (WEVAC) system based on clean room applications. Results of this initial proof-of-concept work indicate that there is a strong potential for WEVAC to enhance clean room activities.

Graves, Corey A.↗

Technology Development and Advanced Planning for Curation of Returned Mars Samples

NASA Johnson Space Center (JSC) curates extraterrestrial samples, providing the international science community with lunar rock and soil returned by the Apollo astronauts, meteorites collected in Antarctica, cosmic dust collected in the stratosphere, and hardware exposed to the space environment. Curation comprises initial characterization of new samples, preparation and allocation of samples for research, and clean, secure long-term storage. The foundations of this effort are the specialized cleanrooms (class 10 to 10,000) for each of the four types of materials, the supporting facilities, and the people, many of whom have been doing detailed work in clean environments for decades. JSC is also preparing to curate the next generation of extraterrestrial samples. These include samples collected from the solar wind, a comet, and an asteroid. Early planning and R\&D are underway to support post-mission sample handling and curation of samples returned from Mars. One of the strong scientific reasons for returning samples from Mars is to search for evidence of current or past life in the samples. Because of the remote possibility that the samples may contain life forms that are hazardous to the terrestrial biosphere, the National Research Council has recommended that all samples returned from Mars be kept under strict biological containment until tests show that they can safely be released to other laboratories. It is possible that Mars samples may contain only scarce or subtle traces of life or prebiotic chemistry that could readily be overwhelmed by terrestrial contamination . Thus, the facilities used to contain, process, and analyze samples from Mars must have a combination of high-level biocontainment and organic / inorganic chemical cleanliness that is unprecedented. JSC has been conducting feasibility studies and developing designs for a sample receiving facility that would offer biocontainment at least the equivalent of current maximum containment BSL-4 (BioSafety Level 4) laboratories, while simultaneously maintaining cleanliness levels equaling those of state-of-the-art cleanrooms. Unique requirements for the processing of Mars samples have inspired a program to develop handling techniques that are much more precise and reliable than the approach (currently used for lunar samples) of employing gloved human hands in nitrogen-filled gloveboxes. Individual samples from Mars are expected to be much smaller than lunar samples, the total mass of samples returned by each mission being 0.5- 1 kg, compared with many tens of kg of lunar samples returned by each of the six Apollo missions. Smaller samples require much more of the processing to be done under microscopic observation. In addition, the requirements for cleanliness and high-level containment would be difficult to satisfy while using traditional gloveboxes. JSC has constructed a laboratory to test concepts and technologies important to future sample curation. The Advanced Curation Laboratory includes a new-generation glovebox equipped with a robotic arm to evaluate the usability of robotic and teleoperated systems to perform curatorial tasks. The laboratory also contains equipment for precision cleaning and the measurement of trace organic contamination.

Lindstrom, David J.↗

Enhanced Cleaning of Genesis Solar Wind Sample 61348 for Film Residue Removal

The Genesis mission returned to Earth on September 8, 2004, experiencing a nonnominal reentry. During the recovery of the collector materials from the capsule, many of the collector fragments were placed on the adhesive protion of post-it notes to prevent the fragments from moving during transport back to Johnson Space Center. This unknowingly provided an additional contaminate that would prove difficult to remove with the limited chemistries allowed in the Genesis Curation Laboratory. Generally when collector material samples are prepared for allocation to PIs, the samples are cleaned front side only with Ultra-Pure Water (UPW) via megasonic dispersion to the collector surface to remove crash debris and contamination. While this cleaning method works well on samples that were not placed on post-its during recovery, it has caused movement of the residue on the back of the sample to be deposited on the front in at least two examples. Therefore, samples placed on the adhesive portion on post-it note, require enhanced cleaning methods since post-it residue has proved resistant to UPW cleaning.

Allums, K. K.↗

NASA 5.2%-Scale Semispan High Lift Common Research Model Wind Tunnel Test at the 14- by 22-Foot Subsonic Tunnel

A wind tunnel test of the NASA 5.2%-scale Semispan High Lift Common Research Model (CRM-HL) was conducted at the 14- by 22-Foot Subsonic Tunnel (14x22) in the fall of 2022. The main purpose of the test was a model checkout before shipping it overseas. The model was shipped to Germany in the spring of 2023, and the team wanted to be sure that instrumentation in the model was working, all of the model parts fit together well, and model changes could be done smoothly, as designed while installed in a wind tunnel. Force and moment and pressure data were collected during the test, and while these data were a secondary objective, they can be used for for tunnel-to-tunnel verification of the model, and for database supplementation for the NASA CRM-HL ecosystem. The test was run from August 15, 2022 through September 8, 2022. Eight configurations were tested at Mach 0.2 and 0.26, over an alpha range from -4deg to +24deg. All of the configurations that were tested accomplished testing of all model parts. This test campaign was a unique opportunity to test a complicated model design in a wind tunnel that is less expensive to test in and has easier model access than the tunnel that it was designed to run in. The test was invaluable in providing lessons learned about building up and running the model, and the model was returned to the model manufacturer from December 2022 to February 2023 for updates to make model changes easier, to make design fixes on the model, and to do clean up work on the model.

CRM-HL↗

NASA 5.2%-Scale Semispan High Lift Common Research Model Wind Tunnel Test at the 14- by 22-Foot Subsonic Tunnel

A wind tunnel test of the NASA 5.2%-scale Semispan High Lift Common Research Model (CRM-HL) was conducted at the 14- by 22-Foot Subsonic Tunnel (14x22) in the fall of 2022. The main purpose of the test was a model checkout before shipping it overseas. The model was shipped to Germany in the spring of 2023, and the team wanted to be sure that instrumentation in the model was working, all of the model parts fit together well, and model changes could be done smoothly, as designed while installed in a wind tunnel. Force and moment and pressure data were collected during the test, and while these data were a secondary objective, they can be used for for tunnel-to-tunnel verification of the model, and for database supplementation for the NASA CRM-HL ecosystem. The test was run from August 15, 2022 through September 8, 2022. Eight configurations were tested at Mach 0.2 and 0.26, over an alpha range from -4deg to +24deg. All of the configurations that were tested accomplished testing of all model parts. This test campaign was a unique opportunity to test a complicated model design in a wind tunnel that is less expensive to test in and has easier model access than the tunnel that it was designed to run in. The test was invaluable in providing lessons learned about building up and running the model, and the model was returned to the model manufacturer from December 2022 to February 2023 for updates to make model changes easier, to make design fixes on the model, and to do clean up work on the model.

Semispan↗

A design of experiments test to define critical spray cleaning parameters for Brulin 815 GD and Jettacin cleaners

Experimental design testing was conducted to identify critical parameters of an aqueous spray process intended for cleaning solid rocket motor metal components (steel and aluminum). A two-level, six-parameter, fractional factorial matrix was constructed and conducted for two cleaners, Brulin 815 GD and Diversey Jettacin. The matrix parameters included cleaner temperature and concentration, wash density, wash pressure, rinse pressure, and dishwasher type. Other spray parameters: nozzle stand-off, rinse water temperature, wash and rinse time, dry conditions, and type of rinse water (deionized) were held constant. Matrix response testing utilized discriminating bond specimens (fracture energy and tensile adhesion strength) which represent critical production bond lines. Overall, Jettacin spray cleaning was insensitive to the range of conditions tested for all parameters and exhibited bond strengths significantly above the TCA test baseline for all bond lines tested. Brulin 815 was sensitive to cleaning temperature, but produced bond strengths above the TCA test baseline even at the lower temperatures. Ultimately, the experimental design database was utilized to recommend process parameter settings for future aqueous spray cleaning characterization work.

Keen, Jill M.↗

Active cleaning technique for removing contamination from optical surfaces in space

An active cleaning technique for removing contaminants from optical surfaces in space was investigated with emphasis on the feasibility of using plasma exposure as a means of in-situ cleaning. The major work accomplished includes: (1) development of an in-situ reflectometer for use in conjunction with the contaminant film deposition/cleaning facility; (2) completion of Apollo Telescope Mount (ATM) filter treatment experiments to assess the effects of plasma exposure on the UV transmittance; (3) attempts to correlate the atomic oxygen flux with cleaning rate; (4) completion of in-situ butadien contamination/plasma cleaning/UV reflectance measurement experiments; (5) carbon cleaning experiments using various gases; (6) completion of silicone contamination/cleaning experiments; and (7) experiments conducted at low chamber pressures to determine cleaning rate distribution and contamination of surfaces adjacent to those being cleaned.

Shannon, R. L.↗

The structure and formation of natural categories

Categorization and concept formation are critical activities of intelligence. These processes and the conceptual structures that support them raise important issues at the interface of cognitive psychology and artificial intelligence. The work presumes that advances in these and other areas are best facilitated by research methodologies that reward interdisciplinary interaction. In particular, a computational model is described of concept formation and categorization that exploits a rational analysis of basic level effects by Gluck and Corter. Their work provides a clean prescription of human category preferences that is adapted to the task of concept learning. Also, their analysis was extended to account for typicality and fan effects, and speculate on how the concept formation strategies might be extended to other facets of intelligence, such as problem solving.

Fisher, Douglas↗

STS-99 SRTM Lift and Insert into Canister

The primary objective of the STS-99 mission was to complete high resolution mapping of large sections of the Earth's surface using the Shuttle Radar Topography Mission (SRTM), a specially modified radar system. This radar system produced unrivaled 3-D images of the Earth's Surface. The mission was launched at 12:31 on February 11, 2000 onboard the space shuttle Endeavour. and led by Commander Kevin Kregel. The crew was Pilot Dominic L. Pudwill Gorie and Mission Specialists Janet L. Kavandi, Janice E. Voss, Mamoru Mohri from the National Space Development Agency (Japanese Space Agency), and Gerhard P. J. Thiele from DARA (German Space Agency). This videotape shows clean room technicians working on a part of the 200 foot long mast that will hold the SRTM in position during the mission. This videotape also shows the lowering of the SRTM into the canister.

Source record↗

Evolution of the Lunar Receiving Laboratory to the Astromaterial Sample Curation Facility: Technical Tensions Between Containment and Cleanliness, Between Particulate and Organic Cleanliness

The Lunar Receiving Laboratory (LRL) was planned and constructed in the 1960s to support the Apollo program in the context of landing on the Moon and safely returning humans. The enduring science return from that effort is a result of careful curation of planetary materials. Technical decisions for the first facility included sample handling environment (vacuum vs inert gas), and instruments for making basic sample assessment, but the most difficult decision, and most visible, was stringent biosafety vs ultra-clean sample handling. Biosafety required handling of samples in negative pressure gloveboxes and rooms for containment and use of sterilizing protocols and animal/plant models for hazard assessment. Ultra-clean sample handling worked best in positive pressure nitrogen environment gloveboxes in positive pressure rooms, using cleanable tools of tightly controlled composition. The requirements for these two objectives were so different, that the solution was to design and build a new facility for specific purpose of preserving the scientific integrity of the samples. The resulting Lunar Curatorial Facility was designed and constructed, from 1972-1979, with advice and oversight by a very active committee comprised of lunar sample scientists. The high precision analyses required for planetary science are enabled by stringent contamination control of trace elements in the materials and protocols of construction (e.g., trace element screening for paint and flooring materials) and the equipment used in sample handling and storage. As other astromaterials, especially small particles and atoms, were added to the collections curated, the technical tension between particulate cleanliness and organic cleanliness was addressed in more detail. Techniques for minimizing particulate contamination in sample handling environments use high efficiency air filtering techniques typically requiring organic sealants which offgas. Protocols for reducing adventitious carbon on sample handling surfaces often generate particles. Further work is needed to achieve both minimal particulate and adventitious carbon contamination. This paper will discuss these facility topics and others in the historical context of nearly 50 years' curation experience for lunar rocks and regolith, meteorites, cosmic dust, comet particles, solar wind atoms, and asteroid particles at Johnson Space Center.

Allton, J. H.↗

Alternative, Green Processes for the Precision Cleaning of Aerospace Hardware

Precision cleaning is necessary to ensure the proper functioning of aerospace hardware, particularly those systems that come in contact with liquid oxygen or hypergolic fuels. Components that have not been cleaned to the appropriate levels may experience problems ranging from impaired performance to catastrophic failure. Traditionally, this has been achieved using various halogenated solvents. However, as information on the toxicological and/or environmental impacts of each came to light, they were subsequently regulated out of use. The solvent currently used in Kennedy Space Center (KSC) precision cleaning operations is Vertrel MCA. Environmental sampling at KSC indicates that continued use of this or similar solvents may lead to high remediation costs that must be borne by the Program for years to come. In response to this problem, the Green Solvents Project seeks to develop state-of-the-art, green technologies designed to meet KSCs precision cleaning needs.Initially, 23 solvents were identified as potential replacements for the current Vertrel MCA-based process. Highly halogenated solvents were deliberately omitted since historical precedents indicate that as the long-term consequences of these solvents become known, they will eventually be regulated out of practical use, often with significant financial burdens for the user. Three solvent-less cleaning processes (plasma, supercritical carbon dioxide, and carbon dioxide snow) were also chosen since they produce essentially no waste stream. Next, experimental and analytical procedures were developed to compare the relative effectiveness of these solvents and technologies to the current KSC standard of Vertrel MCA. Individually numbered Swagelok fittings were used to represent the hardware in the cleaning process. First, the fittings were cleaned using Vertrel MCA in order to determine their true cleaned mass. Next, the fittings were dipped into stock solutions of five commonly encountered contaminants and were weighed again showing typical contaminant deposition levels of approximately 0.00300g per part. They were then cleaned by the solvent or process being tested and then weighed a third time which allowed for the calculation of the cleaning efficiency of the test solvent or process.Based on preliminary experiments, five solvents (ethanol, isopropanol, acetone, ethyl acetate, and tert-butyl acetate) were down selected for further testing. When coupled with ultrasonic agitation, these solvents removed hydrocarbon contaminants as well as Vertrel MCA and showed improved removal of perfluorinated greases. Supercritical carbon dioxide did an excellent job dissolving each of the five contaminants but did a poor job of removing Teflon particles found in the perfluorinated greases. Plasma cleaning efficiency was found to be dependent on which supply gas was used, exposure time, and gas pressure. Under optimized conditions it was found that breathing air, energized to the plasma phase, was able to remove nearly 100% of the contamination.These findings indicate that alternative cleaning methods are indeed able to achieve precision levels of cleanliness. Currently, our team is working with a commercial cleaning company to get independent verification of our results. We are also evaluating the technical and financial aspects of scaling these processes to a size capable of supporting the future cleaning needs of KSC.

Vertrel MCA↗

JDD, Inc. Database

JDD Inc, is a maintenance and custodial contracting company whose mission is to provide their clients in the private and government sectors "quality construction, construction management and cleaning services in the most efficient and cost effective manners, (JDD, Inc. Mission Statement)." This company provides facilities support for Fort Riley in Fo,rt Riley, Kansas and the NASA John H. Glenn Research Center at Lewis Field here in Cleveland, Ohio. JDD, Inc. is owned and operated by James Vaughn, who started as painter at NASA Glenn and has been working here for the past seventeen years. This summer I worked under Devan Anderson, who is the safety manager for JDD Inc. in the Logistics and Technical Information Division at Glenn Research Center The LTID provides all transportation, secretarial, security needs and contract management of these various services for the center. As a safety manager, my mentor provides Occupational Health and Safety Occupation (OSHA) compliance to all JDD, Inc. employees and handles all other issues (Environmental Protection Agency issues, workers compensation, safety and health training) involving to job safety. My summer assignment was not as considered "groundbreaking research" like many other summer interns have done in the past, but it is just as important and beneficial to JDD, Inc. I initially created a database using a Microsoft Excel program to classify and categorize data pertaining to numerous safety training certification courses instructed by our safety manager during the course of the fiscal year. This early portion of the database consisted of only data (training field index, employees who were present at these training courses and who was absent) from the training certification courses. Once I completed this phase of the database, I decided to expand the database and add as many dimensions to it as possible. Throughout the last seven weeks, I have been compiling more data from day to day operations and been adding the information to the database. It now consists of seven different categories of data (carpet cleaning, forms, NASA Event Schedules, training certifications, wall and vent cleaning, work schedules, and miscellaneous) . I also did some field inspecting with the supervisors around the site and was present at all of the training certification courses that have been scheduled since June 2004. My future outlook for the JDD, Inc. database is to have all of company s information from future contract proposals, weekly inventory, to employee timesheets all in this same database.

Miller, David A., Jr.↗