Thermal design verification testing for the ATS-F and -G spacecraft.

NASA Technical Reports Server (NTRS)

Coyle, M.; Greenwell, J.

1972-01-01

There is a wide fluctuation in the internal power dissipation from the components within the earth viewing module (EVM). The electronic component functional reliability required for a two-to-five year mission is the most significant factor for the thermal design criteria. A mathematical thermal model of the EVM and the orbital environment is used to predict the performance of the thermal control system. Comparisons of the results obtained in chamber thermal balance tests with the data computed on the basis of the theoretical model provide the means for validating the thermal design.

Reliability Assessment of Advanced Flip-clip Interconnect Electronic Package Assemblies under Extreme Cold Temperatures (-190 and -120 C)

NASA Technical Reports Server (NTRS)

Ramesham, Rajeshuni; Ghaffarian, Reza; Shapiro, Andrew; Napala, Phil A.; Martin, Patrick A.

2005-01-01

Flip-chip interconnect electronic package boards have been assembled, underfilled, non-destructively evaluated and subsequently subjected to extreme temperature thermal cycling to assess the reliability of this advanced packaging interconnect technology for future deep space, long-term, extreme temperature missions. In this very preliminary study, the employed temperature range covers military specifications (-55 C to 100 C), extreme cold Martian (-120 C to 115 C) and asteroid Nereus (-180 C to 25 C) environments. The resistance of daisy-chained, flip-chip interconnects were measured at room temperature and at various intervals as a function of extreme temperature thermal cycling. Electrical resistance measurements are reported and the tests to date have not shown significant change in resistance as a function of extreme temperature thermal cycling. However, the change in interconnect resistance becomes more noticeable with increasing number of thermal cycles. Further research work has been carried out to understand the reliability of flip-chip interconnect packages under extreme temperature applications (-190 C to 85 C) via continuously monitoring the daisy chain resistance. Adaptation of suitable diagnostic techniques to identify the failure mechanisms is in progress. This presentation will describe the experimental test results of flip-chip testing under extreme temperatures.

Reliability assessment of ceramic column grid array (CCGA717) interconnect packages under extreme temperatures for space applications (-185°C to +125°C)

NASA Astrophysics Data System (ADS)

Ramesham, Rajeshuni

2010-02-01

Ceramic Column Grid Array packages have been increasing in use based on their advantages such as high interconnect density, very good thermal and electrical performance, compatibility with standard surface-mount packaging assembly processes, etc. CCGA packages are used in space applications such as in logics and microprocessor functions, telecommunications, flight avionics, payload electronics, etc. As these packages tend to have less solder joint strain relief than leaded packages, the reliability of CCGA packages is very important for short and long-term space missions. CCGA interconnect electronic package printed wiring boards (PWBs) of polyimide have been assembled, inspected non-destructively and subsequently subjected to extreme temperature thermal cycling to assess the reliability for future deep space, short and long-term, extreme temperature missions. In this investigation, the employed temperature range covers from -185°C to +125°C extreme thermal environments. The test hardware consists of two CCGA717 packages with each package divided into four daisy-chained sections, for a total of eight daisy chains to be monitored. The CCGA717 package is 33 mm × 33 mm with a 27×27 array of 80%/20% Pb/Sn columns on a 1.27 mm pitch. The resistance of daisy-chained, CCGA interconnects were continuously monitored as a function of thermal cycling. Electrical resistance measurements as a function of thermal cycling are reported and the tests to date have shown significant change in daisy chain resistance as a function of thermal cycling. The change in interconnect resistance becomes more noticeable with increasing number of thermal cycles. This paper will describe the experimental test results of CCGA testing under wide extreme temperatures. Standard Weibull analysis tools were used to extract the Weibull parameters to understand the CCGA failures. Optical inspection results clearly indicate that the solder joints of columns with the board and the ceramic package have failed as a function of thermal cycling. The first failure was observed at 137th thermal cycle and 63.2% failures of daisy chains have occurred at about 664 thermal cycles. The shape parameter extracted from Weibull plot was about 1.47 which indicates the failures were related to failures occurred during the flat region or useful life region of standard bath tub curve. Based on this experimental test data one can use the CCGAs for the temperature range studied for ~100 thermal cycles (ΔT = 310°C, 5oC/minute, and 15 minutes dwell) with high degree of confidence for high reliability space and other applications.

Reliability of Ceramic Column Grid Array Interconnect Packages Under Extreme Temperatures

NASA Technical Reports Server (NTRS)

Ramesham, Rajeshuni

2011-01-01

A paper describes advanced ceramic column grid array (CCGA) packaging interconnects technology test objects that were subjected to extreme temperature thermal cycles. CCGA interconnect electronic package printed wiring boards (PWBs) of polyimide were assembled, inspected nondestructively, and, subsequently, subjected to ex - treme-temperature thermal cycling to assess reliability for future deep-space, short- and long-term, extreme-temperature missions. The test hardware consisted of two CCGA717 packages with each package divided into four daisy-chained sections, for a total of eight daisy chains to be monitored. The package is 33 33 mm with a 27 27 array of 80%/20% Pb/Sn columns on a 1.27-mm pitch. The change in resistance of the daisy-chained CCGA interconnects was measured as a function of the increasing number of thermal cycles. Several catastrophic failures were observed after 137 extreme-temperature thermal cycles, as per electrical resistance measurements, and then the tests were continued through 1,058 thermal cycles to corroborate and understand the test results. X-ray and optical inspection have been made after thermal cycling. Optical inspections were also conducted on the CCGA vs. thermal cycles. The optical inspections were conclusive; the x-ray images were not. Process qualification and assembly is required to optimize the CCGA assembly, which is very clear from the x-rays. Six daisy chains were open out of seven daisy chains, as per experimental test data reported. The daisy chains are open during the cold cycle, and then recover during the hot cycle, though some of them also opened during the hot thermal cycle..

Demonstration of Passive Fuel Cell Thermal Management Technology

NASA Technical Reports Server (NTRS)

Burke, Kenneth A.; Jakupca, Ian; Colozza, Anthony; Wynne, Robert; Miller, Michael; Meyer, Al; Smith, William

2012-01-01

The NASA Glenn Research Center is developing advanced passive thermal management technology to reduce the mass and improve the reliability of space fuel cell systems for the NASA Exploration program. The passive thermal management system relies on heat conduction within highly thermally conductive cooling plates to move the heat from the central portion of the cell stack out to the edges of the fuel cell stack. Using the passive approach eliminates the need for a coolant pump and other cooling loop components within the fuel cell system which reduces mass and improves overall system reliability. Previous development demonstrated the performance of suitable highly thermally conductive cooling plates and integrated heat exchanger technology to collect the heat from the cooling plates (Ref. 1). The next step in the development of this passive thermal approach was the demonstration of the control of the heat removal process and the demonstration of the passive thermal control technology in actual fuel cell stacks. Tests were run with a simulated fuel cell stack passive thermal management system outfitted with passive cooling plates, an integrated heat exchanger and two types of cooling flow control valves. The tests were run to demonstrate the controllability of the passive thermal control approach. Finally, successful demonstrations of passive thermal control technology were conducted with fuel cell stacks from two fuel cell stack vendors.

Reliability of high I/O high density CCGA interconnect electronic packages under extreme thermal environments

NASA Astrophysics Data System (ADS)

Ramesham, Rajeshuni

2012-03-01

Ceramic column grid array (CCGA) packages have been increasing in use based on their advantages such as high interconnect density, very good thermal and electrical performances, compatibility with standard surfacemount packaging assembly processes, and so on. CCGA packages are used in space applications such as in logic and microprocessor functions, telecommunications, payload electronics, and flight avionics. As these packages tend to have less solder joint strain relief than leaded packages or more strain relief over lead-less chip carrier packages, the reliability of CCGA packages is very important for short-term and long-term deep space missions. We have employed high density CCGA 1152 and 1272 daisy chained electronic packages in this preliminary reliability study. Each package is divided into several daisy-chained sections. The physical dimensions of CCGA1152 package is 35 mm x 35 mm with a 34 x 34 array of columns with a 1 mm pitch. The dimension of the CCGA1272 package is 37.5 mm x 37.5 mm with a 36 x 36 array with a 1 mm pitch. The columns are made up of 80% Pb/20%Sn material. CCGA interconnect electronic package printed wiring polyimide boards have been assembled and inspected using non-destructive x-ray imaging techniques. The assembled CCGA boards were subjected to extreme temperature thermal atmospheric cycling to assess their reliability for future deep space missions. The resistance of daisy-chained interconnect sections were monitored continuously during thermal cycling. This paper provides the experimental test results of advanced CCGA packages tested in extreme temperature thermal environments. Standard optical inspection and x-ray non-destructive inspection tools were used to assess the reliability of high density CCGA packages for deep space extreme temperature missions.

A lightweight thermal heat switch for redundant cryocooling on satellites

NASA Astrophysics Data System (ADS)

Dietrich, M.; Euler, A.; Thummes, G.

2017-04-01

A previously designed cryogenic thermal heat switch for space applications has been optimized for low mass, high structural stability, and reliability. The heat switch makes use of the large linear thermal expansion coefficient (CTE) of the thermoplastic UHMW-PE for actuation. A structure model, which includes the temperature dependent properties of the actuator, is derived to be able to predict the contact pressure between the switch parts. This pressure was used in a thermal model in order to predict the switch performance under different heat loads and operating temperatures. The two models were used to optimize the mass and stability of the switch. Its reliability was proven by cyclic actuation of the switch and by shaker tests.

Thermal behavior of crumb-rubber modified asphalt concrete mixtures

NASA Astrophysics Data System (ADS)

Epps, Amy Louise

Thermal cracking is one of the primary forms of distress in asphalt concrete pavements, resulting from either a single drop in temperature to an extreme low or from multiple temperature cycles above the fracture temperature of the asphalt-aggregate mixture. The first mode described is low temperature cracking; the second is thermal fatigue. The addition of crumb-rubber, manufactured from scrap tires, to the binder in asphalt concrete pavements has been suggested to minimize both types of thermal cracking. Four experiments were designed and completed to evaluate the thermal behavior of crumb-rubber modified (CRM) asphalt-aggregate mixtures. Modified and unmodified mixture response to thermal stresses was measured in four laboratory tests. The Thermal Stress Restrained Specimen Test (TSRST) and the Indirect Tensile Test (IDT) were used to compare mixture resistance to low temperature cracking. Modified mixtures showed improved performance, and cooling rate did not affect mixture resistance according to the statistical analysis. Therefore results from tests with faster rates can predict performance under slower field rates. In comparison, predicted fracture temperatures and stresses (IDT) were generally higher than measured values (TSRST). In addition, predicted fracture temperatures from binder test results demonstrated that binder testing alone is not sufficient to evaluate CRM mixtures. Thermal fatigue was explored in the third experiment using conventional load-induced fatigue tests with conditions selected to simulate daily temperature fluctuations. Test results indicated that thermal fatigue may contribute to transverse cracking in asphalt pavements. Both unmodified and modified mixtures had a finite capacity to withstand daily temperature fluctuations coupled with cold temperatures. Modified mixtures again exhibited improved performance. The fourth experiment examined fracture properties of modified and unmodified mixtures using a common fracture toughness test. Results showed no effect from modification, but the small experiment size may have masked this effect. Reliability concepts were introduced to include risk and uncertainty in a comparison of mixture response measured in the laboratory and estimated environmental conditions. This comparison provided evidence that CRM mixtures exhibit improved resistance to both types of thermal cracking at high levels of reliability. In conclusion, a mix design and analysis framework for evaluating thermal behavior was recommended.

Degradation Characterization of Thermal Interface Greases

DOE Office of Scientific and Technical Information (OSTI.GOV)

DeVoto, Douglas J; Major, Joshua; Paret, Paul P

Thermal interface materials (TIMs) are used in power electronics packaging to minimize thermal resistance between the heat generating component and the heat sink. Thermal greases are one such class. The conformability and thin bond line thickness (BLT) of these TIMs can potentially provide low thermal resistance throughout the operation lifetime of a component. However, their performance degrades over time due to pump-out and dry-out during thermal and power cycling. The reliability performance of greases through operational cycling needs to be quantified to develop new materials with superior properties. NREL, in collaboration with DuPont, has performed thermal and reliability characterization ofmore » several commercially available thermal greases. Initial bulk and contact thermal resistance of grease samples were measured, and then the thermal degradation that occurred due to pump-out and dry-out during temperature cycling was monitored. The thermal resistances of five different grease materials were evaluated using NREL's steady-state thermal resistance tester based on the ASTM test method D5470. Greases were then applied, utilizing a 2.5 cm x 2.5 cm stencil, between invar and aluminum plates to compare the thermomechanical performance of the materials in a representative test fixture. Scanning Acoustic microscopy, thermal, and compositional analyses were performed periodically during thermal cycling from -40 degrees Celcius to 125 degrees Celcius. Completion of this characterization has allowed for a comprehensive evaluation of thermal greases both for their initial bulk and contact thermal performance, as well as their degradation mechanisms under accelerated thermal cycling conditions.« less

Degradation Characterization of Thermal Interface Greases: Preprint

DOE Office of Scientific and Technical Information (OSTI.GOV)

DeVoto, Douglas J; Major, Joshua; Paret, Paul P

Thermal interface materials (TIMs) are used in power electronics packaging to minimize thermal resistance between the heat generating component and the heat sink. Thermal greases are one such class. The conformability and thin bond line thickness (BLT) of these TIMs can potentially provide low thermal resistance throughout the operation lifetime of a component. However, their performance degrades over time due to pump-out and dry-out during thermal and power cycling. The reliability performance of greases through operational cycling needs to be quantified to develop new materials with superior properties. NREL, in collaboration with DuPont, has performed thermal and reliability characterization ofmore » several commercially available thermal greases. Initial bulk and contact thermal resistance of grease samples were measured, and then the thermal degradation that occurred due to pump-out and dry-out during temperature cycling was monitored. The thermal resistances of five different grease materials were evaluated using NREL's steady-state thermal resistance tester based on the ASTM test method D5470. Greases were then applied, utilizing a 2.5 cm x 2.5 cm stencil, between invar and aluminum plates to compare the thermomechanical performance of the materials in a representative test fixture. Scanning Acoustic microscopy, thermal, and compositional analyses were performed periodically during thermal cycling from -40 degrees Celcius to 125 degrees Celcius. Completion of this characterization has allowed for a comprehensive evaluation of thermal greases both for their initial bulk and contact thermal performance, as well as their degradation mechanisms under accelerated thermal cycling conditions.« less

Degradation Characterization of Thermal Interface Greases

DOE Office of Scientific and Technical Information (OSTI.GOV)

Major, Joshua; Narumanchi, Sreekant V; Paret, Paul P

Thermal interface materials (TIMs) are used in power electronics packaging to minimize thermal resistance between the heat generating component and the heat sink. Thermal greases are one such class. The conformability and thin bond line thickness (BLT) of these TIMs can potentially provide low thermal resistance throughout the operation lifetime of a component. However, their performance degrades over time due to pump-out and dry-out during thermal and power cycling. The reliability performance of greases through operational cycling needs to be quantified to develop new materials with superior properties. NREL, in collaboration with DuPont, has performed thermal and reliability characterization ofmore » several commercially available thermal greases. Initial bulk and contact thermal resistance of grease samples were measured, and then the thermal degradation that occurred due to pump-out and dry-out during temperature cycling was monitored. The thermal resistances of five different grease materials were evaluated using NREL's steady-state thermal resistance tester based on the ASTM test method D5470. Greases were then applied, utilizing a 2.5 cm x 2.5 cm stencil, between invar and aluminum plates to compare the thermomechanical performance of the materials in a representative test fixture. Scanning Acoustic microscopy, thermal, and compositional analyses were performed periodically during thermal cycling from -40 degrees C to 125 degrees C. Completion of this characterization has allowed for a comprehensive evaluation of thermal greases both for their initial bulk and contact thermal performance, as well as their degradation mechanisms under accelerated thermal cycling conditions.« less

Considerations in STS payload environmental verification

NASA Technical Reports Server (NTRS)

Keegan, W. B.

1978-01-01

Considerations regarding the Space Transportation System (STS) payload environmental verification are reviewed. It is noted that emphasis is placed on testing at the subassembly level and that the basic objective of structural dynamic payload verification is to ensure reliability in a cost-effective manner. Structural analyses consist of: (1) stress analysis for critical loading conditions, (2) model analysis for launch and orbital configurations, (3) flight loads analysis, (4) test simulation analysis to verify models, (5) kinematic analysis of deployment/retraction sequences, and (6) structural-thermal-optical program analysis. In addition to these approaches, payload verification programs are being developed in the thermal-vacuum area. These include the exposure to extreme temperatures, temperature cycling, thermal-balance testing and thermal-vacuum testing.

Impact Foam Testing for Multi-Mission Earth Entry Vehicle Applications

NASA Technical Reports Server (NTRS)

Glaab, Louis J.; Agrawal, Paul; Hawbaker, James

2013-01-01

Multi-Mission Earth Entry Vehicles (MMEEVs) are blunt-body vehicles designed with the purpose of transporting payloads from outer space to the surface of the Earth. To achieve high-reliability and minimum weight, MMEEVs avoid use of limited-reliability systems, such as parachutes and retro-rockets, instead using built-in impact attenuators to absorb energy remaining at impact to meet landing loads requirements. The Multi-Mission Systems Analysis for Planetary Entry (M-SAPE) parametric design tool is used to facilitate the design of MMEEVs and develop the trade space. Testing was conducted to characterize the material properties of several candidate impact foam attenuators to enhance M-SAPE analysis. In the current effort, two different Rohacell foams were tested to determine their thermal conductivity in support of MMEEV design applications. These applications include thermal insulation during atmospheric entry, impact attenuation, and post-impact thermal insulation in support of thermal soak analysis. Results indicate that for these closed-cell foams, the effect of impact is limited on thermal conductivity due to the venting of the virgin material gas and subsequent ambient air replacement. Results also indicate that the effect of foam temperature is significant compared to data suggested by manufacturer's specifications.

Capacitor bonding techniques and reliability. [thermal cycling tests

NASA Technical Reports Server (NTRS)

Kinser, D. L.; Graff, S. M.; Allen, R. V.; Caruso, S. V.

1974-01-01

The effect of thermal cycling on the mechanical failure of bonded ceramic chip capacitors mounted on alumina substrates is studied. It is shown that differential thermal expansion is responsible for the cumulative effects which lead to delayed failure of the capacitors. Harder or higher melting solders are found to be less susceptible to thermal cycling effects, although they are more likely to fail during initial processing operations.

Column Grid Array Rework for High Reliability

NASA Technical Reports Server (NTRS)

Mehta, Atul C.; Bodie, Charles C.

2008-01-01

Due to requirements for reduced size and weight, use of grid array packages in space applications has become common place. To meet the requirement of high reliability and high number of I/Os, ceramic column grid array packages (CCGA) were selected for major electronic components used in next MARS Rover mission (specifically high density Field Programmable Gate Arrays). ABSTRACT The probability of removal and replacement of these devices on the actual flight printed wiring board assemblies is deemed to be very high because of last minute discoveries in final test which will dictate changes in the firmware. The questions and challenges presented to the manufacturing organizations engaged in the production of high reliability electronic assemblies are, Is the reliability of the PWBA adversely affected by rework (removal and replacement) of the CGA package? and How many times can we rework the same board without destroying a pad or degrading the lifetime of the assembly? To answer these questions, the most complex printed wiring board assembly used by the project was chosen to be used as the test vehicle, the PWB was modified to provide a daisy chain pattern, and a number of bare PWB s were acquired to this modified design. Non-functional 624 pin CGA packages with internal daisy chained matching the pattern on the PWB were procured. The combination of the modified PWB and the daisy chained packages enables continuity measurements of every soldered contact during subsequent testing and thermal cycling. Several test vehicles boards were assembled, reworked and then thermal cycled to assess the reliability of the solder joints and board material including pads and traces near the CGA. The details of rework process and results of thermal cycling are presented in this paper.

Investigation of reliability attributes and accelerated stress factors of terrestrial solar cells. First annual report

DOE Office of Scientific and Technical Information (OSTI.GOV)

Prince, J.L.; Lathrop, J.W.

1979-05-01

The results of accelerated stress testing of four different types of silicon terrestrial solar cells are discussed. The accelerated stress tests used included bias-temperature tests, bias-temperature-humidity tests, thermal cycle and thermal shock tests, and power cycle tests. Characterization of the cells was performed before stress testing and at periodic down-times, using electrical measurement, visual inspection, and metal adherence pull tests. Electrical parameters measured included short-circuit current, I/sub sc/, open circuit voltage, V/sub oc/, and output power, voltage, and current at the maximum power point, P/sub m/, V/sub m/, and I/sub m/ respectively. Incorporated in the report are the distributions ofmore » the prestress electrical data for all cell types. Data was also obtained on cell series and shunt resistance. Significant differences in the response to the various stress tests was observed between cell types. On the basis of the experience gained in this research work, a suggested Reliability Qualification Test Schedule was developed.« less

Accelerated testing of module-level power electronics for long-term reliability

DOE Office of Scientific and Technical Information (OSTI.GOV)

Flicker, Jack David; Tamizhmani, Govindasamy; Moorthy, Mathan Kumar

This work has applied a suite of long-term-reliability accelerated tests to a variety of module-level power electronics (MLPE) devices (such as microinverters and optimizers) from five different manufacturers. This dataset is one of the first (only the paper by Parker et al. entitled “Dominant factors affecting reliability of alternating current photovoltaic modules,” in Proc. 42nd IEEE Photovoltaic Spec. Conf., 2015, is reported for reliability testing in the literature), as well as the largest, experimental sets in public literature, both in the sample size (five manufacturers including both dc/dc and dc/ac units and 20 units for each test) and the numbermore » of experiments (six different experimental test conditions) for MLPE devices. The accelerated stress tests (thermal cycling test per IEC 61215 profile, damp heat test per IEC 61215 profile, and static temperature tests at 100 and 125 °C) were performed under powered and unpowered conditions. The first independent long-term experimental data regarding damp heat and grid transient testing, as well as the longest term (>9 month) testing of MLPE units reported in the literature for thermal cycling and high-temperature operating life, are included in these experiments. Additionally, this work is the first to show in situ power measurements, as well as periodic efficiency measurements over a series of experimental tests, demonstrating whether certain tests result in long-term degradation or immediate catastrophic failures. Lastly, the result of this testing highlights the performance of MLPE units under the application of several accelerated environmental stressors.« less

Accelerated testing of module-level power electronics for long-term reliability

DOE PAGES

Flicker, Jack David; Tamizhmani, Govindasamy; Moorthy, Mathan Kumar; ...

2016-11-10

This work has applied a suite of long-term-reliability accelerated tests to a variety of module-level power electronics (MLPE) devices (such as microinverters and optimizers) from five different manufacturers. This dataset is one of the first (only the paper by Parker et al. entitled “Dominant factors affecting reliability of alternating current photovoltaic modules,” in Proc. 42nd IEEE Photovoltaic Spec. Conf., 2015, is reported for reliability testing in the literature), as well as the largest, experimental sets in public literature, both in the sample size (five manufacturers including both dc/dc and dc/ac units and 20 units for each test) and the numbermore » of experiments (six different experimental test conditions) for MLPE devices. The accelerated stress tests (thermal cycling test per IEC 61215 profile, damp heat test per IEC 61215 profile, and static temperature tests at 100 and 125 °C) were performed under powered and unpowered conditions. The first independent long-term experimental data regarding damp heat and grid transient testing, as well as the longest term (>9 month) testing of MLPE units reported in the literature for thermal cycling and high-temperature operating life, are included in these experiments. Additionally, this work is the first to show in situ power measurements, as well as periodic efficiency measurements over a series of experimental tests, demonstrating whether certain tests result in long-term degradation or immediate catastrophic failures. Lastly, the result of this testing highlights the performance of MLPE units under the application of several accelerated environmental stressors.« less

Thermal Management and Packaging Reliability (Text Version) |

Science.gov Websites

Transportation Research | NREL Thermal Management and Packaging Reliability (Text Version ) Thermal Management and Packaging Reliability (Text Version) Learn how NREL's thermal management and ;Boosting Thermal Management & Reliability of Vehicle Power Electronics." Better power electronics

Enhancing thermal reliability of fiber-optic sensors for bio-inspired applications at ultra-high temperatures

NASA Astrophysics Data System (ADS)

Kang, Donghoon; Kim, Heon-Young; Kim, Dae-Hyun

2014-07-01

The rapid growth of bio-(inspired) sensors has led to an improvement in modern healthcare and human-robot systems in recent years. Higher levels of reliability and better flexibility, essential features of these sensors, are very much required in many application fields (e.g. applications at ultra-high temperatures). Fiber-optic sensors, and fiber Bragg grating (FBG) sensors in particular, are being widely studied as suitable sensors for improved structural health monitoring (SHM) due to their many merits. To enhance the thermal reliability of FBG sensors, thermal sensitivity, generally expressed as αf + ξf and considered a constant, should be investigated more precisely. For this purpose, the governing equation of FBG sensors is modified using differential derivatives between the wavelength shift and the temperature change in this study. Through a thermal test ranging from RT to 900 °C, the thermal sensitivity of FBG sensors is successfully examined and this guarantees thermal reliability of FBG sensors at ultra-high temperatures. In detail, αf + ξf has a non-linear dependence on temperature and varies from 6.0 × 10-6 °C-1 (20 °C) to 10.6 × 10-6 °C-1 (650 °C). Also, FBGs should be carefully used for applications at ultra-high temperatures due to signal disappearance near 900 °C.

Reliability of CGA/LGA/HDI Package Board/Assembly (Final Report)

NASA Technical Reports Server (NTRS)

Ghaffaroam. Reza

2014-01-01

Package manufacturers are now offering commercial-off-the-shelf column grid array (COTS CGA) packaging technologies in high-reliability versions. Understanding the process and quality assurance (QA) indicators for reliability are important for low-risk insertion of these advanced electronics packages. The previous reports, released in January of 2012 and January of 2013, presented package test data, assembly information, and reliability evaluation by thermal cycling for CGA packages with 1752, 1517, 1509, and 1272 inputs/outputs (I/Os) and 1-mm pitch. It presented the thermal cycling (-55C either 100C or 125C) test results for up to 200 cycles. This report presents up to 500 thermal cycles with quality assurance and failure analysis evaluation represented by optical photomicrographs, 2D real time X-ray images, dye-and-pry photomicrographs, and optical/scanning electron Microscopy (SEM) cross-sectional images. The report also presents assembly challenge using reflowing by either vapor phase or rework station of CGA and land grid array (LGA) versions of three high I/O packages both ceramic and plastic configuration. A new test vehicle was designed having high density interconnect (HDI) printed circuit board (PCB) with microvia-in-pad to accommodate both LGA packages as well as a large number of fine pitch ball grid arrays (BGAs). The LGAs either were assembled onto HDI PCB as an LGA or were solder paste print and reflow first to form solder dome on pads before assembly. Both plastic BGAs with 1156 I/O and ceramic LGAs were assembled. It also presented the X-ray inspection results as well as failures due to 200 thermal cycles. Lessons learned on assembly of ceramic LGAs are also presented.

Thermal Protection Materials and Systems: Past, Present, and Future

NASA Technical Reports Server (NTRS)

Johnson, Sylvia M.

2013-01-01

Thermal protection materials and systems (TPS) protect vehicles from the heat generated when entering a planetary atmosphere. NASA has developed many TPS systems over the years for vehicle ranging from planetary probes to crewed vehicles. The goal for all TPS is efficient and reliable performance. Efficient means using the right material for the environment and minimizing the mass of the heat shield without compromising safety. Efficiency is critical if the payload such as science experiments is to be maximized on a particular vehicle. Reliable means that we understand and can predict performance of the material. Although much characterization and testing of materials is performed to qualify and certify them for flight, it is not possible to completely recreate the reentry conditions in test facilities, and flight-testing

Investigation of reliability attributes and accelerated stress factors on terrestrial solar cells

NASA Technical Reports Server (NTRS)

Lathrop, J. W.; Prince, J. L.

1980-01-01

Three tasks were undertaken to investigate reliability attributes of terrestrial solar cells: (1) a study of the electrical behavior of cells in the second (reverse) quadrant; (2) the accelerated stress testing of three new state-of-the-art cells; and (3) the continued bias-temperature testing of four block 2 type silicon cells at 78 C and 135 C. Electrical characteristics measured in the second quadrant were determined to be a function of the cell's thermal behavior with breakdown depending on the initiation of localized heating. This implied that high breakdown cells may be more fault tolerant when forced to operate in the second quadrant, a result contrary to conventional thinking. The accelerated stress tests used in the first (power) quadrant were bias-temperature, bias-temperature-humidity, temperature-humidity, thermal shock, and thermal cycle. The new type cells measured included an EFG cell, a polycrystalline cell, and a Czochralski cell. Significant differences in the response to the various tests were observed between cell types. A microprocessed controlled, short interval solar cell tester was designed and construction initiated on a prototype.

Assembly reliability of CSPs with various chiip sizes by accelerated thermal and mechanical cycling test

NASA Technical Reports Server (NTRS)

Ghaffarian, R.

2000-01-01

A JPL-led chip scale package (CSP) Consortium, composed of team members representing government agencies and private companies, recently joined together to pool in-kind resources for developing the quality and reliability of chip scale packages (CSPs) for a variety of projects.

Effect of thermal cycling ramp rate on CSP assembly reliability

NASA Technical Reports Server (NTRS)

Ghaffarian, R.

2001-01-01

A JPL-led chip scale package consortium of enterprises recently joined together to pool in-kind resources for developing the quality and reliability of chip scale packages for a variety of projects. The experience of the consortium in building more than 150 test vehicle assemblies, single and double sided multilayer PWBs, and the environmental test results has now been published as a chip scale package guidelines document.

A Study on a Novel Phase Change Material Panel Based on Tetradecanol/Lauric Acid/Expanded Perlite/Aluminium Powder for Building Heat Storage

PubMed Central

Wang, Enyu; Kong, Xiangfei; Rong, Xian; Yao, Chengqiang; Yang, Hua; Qi, Chengying

2016-01-01

Phase change material (PCM) used in buildings can reduce the building energy consumption and indoor temperature fluctuation. A composite PCM has been fabricated by the binary eutectic mixture of tetradecanol (TD) and lauric acid (LA) absorbed into the expanded perlite (EP) using vacuum impregnation method, and its thermal conductivity was promoted by aluminium powder (AP) additive. Besides, the styrene-acrylic emulsion has been mixed with the composite PCM particles to form the protective film, so as to solve the problem of leakage. Thus, a novel PCM panel (PCMP) has been prepared using compression moulding forming method. The thermal property, microstructure characteristic, mechanical property, thermal conductivity, thermal reliability and leakage of the composite PCM have been investigated and analysed. Meanwhile, the thermal performance of the prepared PCMP was tested through PCMPs installed on the inside wall of a cell under outdoor climatic conditions. The composite PCM has a melting temperature of 24.9 °C, a freezing temperature of 25.2 °C, a melting latent heat of 78.2 J/g and a freezing latent heat of 81.3 J/g. The thermal conductivity test exposed that the thermal conductivity has been enhanced with the addition of AP and the latent heat has been decreased, but it still remains in a high level. The leakage test result has proven that liquid PCM leaking has been avoided by the surface film method. The thermal performance experiment has shown the significant function of PCMP about adjusting the indoor temperature and reducing the heats transferring between the wall inside and outside. In view of the thermal performance, mechanical property and thermal reliability results, it can be concluded that the prepared PCMP has a promising building application potential. PMID:28774020

Insulation commonality assessment (phase 1). Volume 2: Section 7.0 through 16.0. [evaluation of materials used for spacecraft thermal insulation

NASA Technical Reports Server (NTRS)

1973-01-01

The heat transfer characteristics of various materials used for the thermal insulation of spacecraft are discussed. Techniques for conducting thermal performance analysis, structural performance analysis, and dynamic analysis are described. Processes for producing and finishing the materials are explained. The methods for determining reliability, system safety, materials tests, and design effectiveness are explained.

Reliability of emerging bonded interface materials for large-area attachments

DOE PAGES

Paret, Paul P.; DeVoto, Douglas J.; Narumanchi, Sreekant

2015-12-30

In this study, conventional thermal interface materials (TIMs), such as greases, gels, and phase change materials, pose bottlenecks to heat removal and have long caused reliability issues in automotive power electronics packages. Bonded interface materials (BIMs) with superior thermal performance have the potential to be a replacement to the conventional TIMs. However, due to coefficient of thermal expansion mismatches between different components in a package and resultant thermomechanical stresses, fractures or delamination could occur, causing serious reliability concerns. These defects manifest themselves in increased thermal resistance in the package. In this paper, the results of reliability evaluation of emerging BIMsmore » for large-area attachments in power electronics packaging are reported. Thermoplastic (polyamide) adhesive with embedded near-vertical-aligned carbon fibers, sintered silver, and conventional lead solder (Sn 63Pb 37) materials were bonded between 50.8 mm x 50.8 mm cross-sectional footprint silicon nitride substrates and copper base plate samples, and were subjected to accelerated thermal cycling until failure or 2500 cycles. Damage in the BIMs was monitored every 100 cycles by scanning acoustic microscopy. Thermoplastic with embedded carbon fibers performed the best with no defects, whereas sintered silver and lead solder failed at 2300 and 1400 thermal cycles, respectively. Besides thermal cycling, additional lead solder samples were subjected to thermal shock and thermal cycling with extended dwell periods. A finite element method (FEM)-based model was developed to simulate the behavior of lead solder under thermomechanical loading. Strain energy density per cycle results were calculated from the FEM simulations. A predictive lifetime model was formulated for lead solder by correlating strain energy density results extracted from modeling with cycles-to-failure obtained from experimental accelerated tests. A power-law-based approach was used to formulate the - redictive lifetime model.« less

DC to DC Converter Testing for Space Applications: Use of EMI Filters and Thermal Range of Operation

NASA Technical Reports Server (NTRS)

Leon, Rosa

2008-01-01

Several tests were performed on Interpoint and International Rectifier (IR) direct current (DC) to DC converters to evaluate potential performance and reliability issues in space use of DC to DC converters and to determine if the use of electromagnetic interference (EMI) filters mitigates concerns observed during previous tests. Test findings reported here include those done up until September - October 2008. Tests performed include efficiency, regulation, cross-regulation, power consumption with inhibit on, load transient response, synchronization, and turn-on tests. Some of the test results presented here span the thermal range -55 C to 125 C. Lower range was extended to -120 C in some tested converters. Determination of failure root cause in DC/DC converters that failed at thermal extremes is also included.

Power Cycle Testing of Power Switches: A Literature Survey

DOE Office of Scientific and Technical Information (OSTI.GOV)

GopiReddy, Lakshmi Reddy; Tolbert, Leon M.; Ozpineci, Burak

Reliability of power converters and lifetime prediction has been a major topic of research in the last few decades, especially for traction applications. The main failures in high power semiconductors are caused by thermomechanical fatigue. Power cycling and temperature cycling are the two most common thermal acceleration tests used in assessing reliability. The objective of this paper is to study the various power cycling tests found in the literature and to develop generalized steps in planning application specific power cycling tests. A comparison of different tests based on the failures, duration, test circuits, and monitored electrical parameters is presented.

Power Cycle Testing of Power Switches: A Literature Survey

DOE PAGES

GopiReddy, Lakshmi Reddy; Tolbert, Leon M.; Ozpineci, Burak

2014-09-18

Reliability of power converters and lifetime prediction has been a major topic of research in the last few decades, especially for traction applications. The main failures in high power semiconductors are caused by thermomechanical fatigue. Power cycling and temperature cycling are the two most common thermal acceleration tests used in assessing reliability. The objective of this paper is to study the various power cycling tests found in the literature and to develop generalized steps in planning application specific power cycling tests. A comparison of different tests based on the failures, duration, test circuits, and monitored electrical parameters is presented.

Thermal Vacuum Testing of a Multi-Evaporator Miniature Loop Heat Pipe

NASA Technical Reports Server (NTRS)

Ku, Jentung; Ottenstein, Laura; Nagano, Hosei

2008-01-01

Under NASA's New Millennium Program Space Technology 8 Project, four experiments are being developed for future small system applications requiring low mass, low power, and compactness. GSFC is responsible for developing the Thermal Loop experiment, which is an advanced thermal control system consisting of a miniature loop heat pipe (MLHP) with multiple evaporators and condensers. The objective is to validate the operation of an MLHP, including reliable start-ups, steady operation, heat load sharing, and tight temperature control over the range of 273K to 308K. An MLHP Breadboard has been built and tested for 1200 hours under the laboratory environment and 500 hours in a thermal vacuum chamber. Results of the TV tests are presented here.

Investigation of low glass transition temperature on COTS PEMs reliability

NASA Technical Reports Server (NTRS)

Sandor, M.; Agarwal, S.

2002-01-01

Many factors influence PEM component reliability.One of the factors that can affect PEM performance and reliability is the glass transition temperature (Tg) and the coefficient of thermal expansion (CTE) of the encapsulant or underfill. JPL/NASA is investigating how the Tg and CTE for PEMs affect device reliability under different temperature and aging conditions. Other issues with Tg are also being investigated. Some preliminary data will be presented on glass transition temperature test results conducted at JPL.

A thermal vacuum-UV solar simulator test system for assessing microbiological viability

NASA Technical Reports Server (NTRS)

Ross, D. S.; Wardle, M. D.; Taylor, D. M.

1975-01-01

Microorganisms were exposed to a simulated space environment in order to assess the photobiological effect of broad spectrum, nonionizing solar electromagnetic radiation in terms of viability. A thermal vacuum chamber capable of maintaining a vacuum of 0.000133n/sq m and an ultraviolet rich solar simulator were the main ingredients of the test system. Results to date indicate the system to be capable of providing reliable microbiological data.

The FLIR ONE thermal imager for the assessment of burn wounds: Reliability and validity study.

PubMed

Jaspers, M E H; Carrière, M E; Meij-de Vries, A; Klaessens, J H G M; van Zuijlen, P P M

2017-11-01

Objective measurement tools may be of great value to provide early and reliable burn wound assessment. Thermal imaging is an easy, accessible and objective technique, which measures skin temperature as an indicator of tissue perfusion. These thermal images might be helpful in the assessment of burn wounds. However, before implementation of a novel measurement tool into clinical practice is considered, it is appropriate to test its clinimetric properties (i.e. reliability and validity). The objective of this study was to assess the reliability and validity of the recently introduced FLIR ONE thermal imager. Two observers obtained thermal images of burn wounds in adult patients at day 1-3, 4-7 and 8-10 after burn. Subsequently, temperature differences between the burn wound and healthy skin (ΔT) were calculated on an iPad mini containing the FLIR Tools app. To assess reliability, ΔT values of both observers were compared by calculating the intraclass correlation coefficient (ICC) and measurement error parameters. To assess validity, the ΔT values of the first observer were compared to the registered healing time of the burn wounds, which was specified into three categories: (I) ≤14 days, (II) 15-21 days and (III) >21 days. The ability of the FLIR ONE to discriminate between healing ≤21 days and >21 days was evaluated by means of a receiver operating characteristic curve and an optimal ΔT cut-off value. Reliability: ICCs were 0.99 for each time point, indicating excellent reliability up to 10 days after burn. The standard error of measurement varied between 0.17-0.22°C. the area under the curve was calculated at 0.69 (95% CI 0.54-0.84). A cut-off value of -1.15°C shows a moderate discrimination between burn wound healing ≤21 days and >21 days (46% sensitivity; 82% specificity). Our results show that the FLIR ONE thermal imager is highly reliable, but the moderate validity calls for additional research. However, the FLIR ONE is pre-eminently feasible, allowing easy and fast measurements in clinical burn practice. Copyright © 2017 Elsevier Ltd and ISBI. All rights reserved.

Development and thermal management of 10 kW CW, direct diode laser source

NASA Astrophysics Data System (ADS)

Zhu, Hongbo; Hao, Mingming; Zhang, Jianwei; Ji, Wenyu; Lin, Xingchen; Zhang, Jinsheng; Ning, Yongqiang

2016-01-01

We report on the development of direct diode laser source with high-power and high reliability. The laser source was realized by the polarization and wavelength combination of four diode laser stacks. When at the operating current of 122 A, the source was capable of producing 10,120 W output while maintaining 46% electro-optical conversion efficiency. The maximum temperature on the lens was decreased from 442.2 K to 320 K by utilizing an efficient thermal dissipation structure, and the corresponding maximum von Mises stress was reduced from 75.4 MPa to 14 MPa. In addition, a reliability test demonstrated that our laser source was reliable and potential in the applications of laser cladding and heat treatment.

Reliability of COTS MEMS accelerometer under shock and thermomechanical cycling

NASA Technical Reports Server (NTRS)

Teverovsky, A.; Ghaffarian, R.; Sutton, D. G.; Chaffee, P.; Marquez, N.; Sharma, A. K.

2001-01-01

A comparison of the data from microaccelerometers of the same type and between several types will be presented. Self-test output signals and X-ray evaluation test data after completion of 182 thermal cycles will also be presented.

Test-retest reliability of neurophysiological tests of hand-arm vibration syndrome in vibration exposed workers and unexposed referents.

PubMed

Gerhardsson, Lars; Gillström, Lennart; Hagberg, Mats

2014-01-01

Exposure to hand-held vibrating tools may cause the hand-arm vibration syndrome (HAVS). The aim was to study the test-retest reliability of hand and muscle strength tests, and tests for the determination of thermal and vibration perception thresholds, which are used when investigating signs of neuropathy in vibration exposed workers. In this study, 47 vibration exposed workers who had been investigated at the department of Occupational and Environmental Medicine in Gothenburg were compared with a randomized sample of 18 unexposed subjects from the general population of the city of Gothenburg. All participants passed a structured interview, answered several questionnaires and had a physical examination including hand and finger muscle strength tests, determination of vibrotactile (VPT) and thermal perception thresholds (TPT). Two weeks later, 23 workers and referents, selected in a randomized manner, were called back for the same test-procedures for the evaluation of test-retest reliability. The test-retest reliability after a two week interval expressed as limits of agreement (LOA; Bland-Altman), intra-class correlation coefficients (ICC) and Pearson correlation coefficients was excellent for tests with the Baseline hand grip, Pinch-grip and 3-Chuck grip among the exposed workers and referents (N = 23: percentage of differences within LOA 91 - 100%; ICC-values ≥0.93; Pearson r ≥0.93). The test-retest reliability was also excellent (percentage of differences within LOA 96-100 %) for the determination of vibration perception thresholds in digits 2 and 5 bilaterally as well as for temperature perception thresholds in digits 2 and 5, bilaterally (percentage of differences within LOA 91 - 96%). For ICC and Pearson r the results for vibration perception thresholds were good for digit 2, left hand and for digit 5, bilaterally (ICC ≥ 0.84; r ≥0.85), and lower (ICC = 0.59; r = 0.59) for digit 2, right hand. For the latter two indices the test-retest reliability for the determination of temperature thresholds was lower and showed more varying results. The strong test-retest reliability for hand and muscle strength tests as well as for the determination of VPTs makes these procedures useful for diagnostic purposes and follow-up studies in vibration exposed workers.

Impact of Total Ionizing Dose Radiation Testing and Long-Term Thermal Cycling on the Operation of CMF20120D Silicon Carbide Power MOSFET

NASA Technical Reports Server (NTRS)

Patterson, Richard L.; Scheidegger, Robert J.; Lauenstein, Jean-Marie; Casey, Megan; Scheick, Leif; Hammoud, Ahmad

2013-01-01

Power systems designed for use in NASA space missions are required to work reliably under harsh conditions including radiation, thermal cycling, and extreme temperature exposures. Silicon carbide devices show great promise for use in future power electronics systems, but information pertaining to performance of the devices in the space environment is very scarce. A silicon carbide N-channel enhancement-mode power MOSFET called the CMF20120 is of interest for use in space environments. Samples of the device were exposed to radiation followed by long-term thermal cycling to address their reliability for use in space applications. The results of the experimental work are presentd and discussed.

Materials selection for long life in low earth orbit - A critical evaluation of atomic oxygen testing with thermal atom systems

NASA Technical Reports Server (NTRS)

Koontz, S. L.; Albyn, K.; Leger, L.

1990-01-01

The use of thermal atom test methods as a materials selection and screening technique for low-earth orbit (LEO) spacecraft is critically evaluated. The chemistry and physics of thermal atom environments are compared with the LEO environment. The relative reactivities of a number of materials determined in thermal atom environments are compared with those observed in LEO and in high-quality LEO simulations. Reaction efficiencies (cu cm/atom) measured in a new type of thermal atom apparatus are one-thousandth to one ten-thousandth those observed in LEO, and many materials showing nearly identical reactivities in LEO show relative reactivities differing by as much as a factor of eight in thermal atom systems. A simple phenomenological kinetic model for the reaction of oxygen atoms with organic materials can be used to explain the differences in reactivity in different environments. Certain speciic thermal atom test environments can be used as reliable materials screening tools.

Fabrication of capsule assemblies, phase 3

NASA Technical Reports Server (NTRS)

Keeton, A. R.; Stemann, L. G.

1973-01-01

Thirteen capsule assemblies were fabricated for evaluation of fuel pin design concepts for a fast spectrum lithium cooled compact space power reactor. These instrumented assemblies were designed for real time test of prototype fuel pins. Uranium mononitride fuel pins were encased in AISI 304L stainless steel capsules. Fabrication procedures were fully qualified by process development and assembly qualification tests. Instrumentation reliability was achieved utilizing specially processed and closely controlled thermocouple hot zone fabrication and by thermal screening tests. Overall capsule reliability was achieved with an all electron beam welded assembly.

A Bayesian Framework for Reliability Analysis of Spacecraft Deployments

NASA Technical Reports Server (NTRS)

Evans, John W.; Gallo, Luis; Kaminsky, Mark

2012-01-01

Deployable subsystems are essential to mission success of most spacecraft. These subsystems enable critical functions including power, communications and thermal control. The loss of any of these functions will generally result in loss of the mission. These subsystems and their components often consist of unique designs and applications for which various standardized data sources are not applicable for estimating reliability and for assessing risks. In this study, a two stage sequential Bayesian framework for reliability estimation of spacecraft deployment was developed for this purpose. This process was then applied to the James Webb Space Telescope (JWST) Sunshield subsystem, a unique design intended for thermal control of the Optical Telescope Element. Initially, detailed studies of NASA deployment history, "heritage information", were conducted, extending over 45 years of spacecraft launches. This information was then coupled to a non-informative prior and a binomial likelihood function to create a posterior distribution for deployments of various subsystems uSing Monte Carlo Markov Chain sampling. Select distributions were then coupled to a subsequent analysis, using test data and anomaly occurrences on successive ground test deployments of scale model test articles of JWST hardware, to update the NASA heritage data. This allowed for a realistic prediction for the reliability of the complex Sunshield deployment, with credibility limits, within this two stage Bayesian framework.

Reliability of the method of levels for determining cutaneous temperature sensitivity

NASA Astrophysics Data System (ADS)

Jakovljević, Miroljub; Mekjavić, Igor B.

2012-09-01

Determination of the thermal thresholds is used clinically for evaluation of peripheral nervous system function. The aim of this study was to evaluate reliability of the method of levels performed with a new, low cost device for determining cutaneous temperature sensitivity. Nineteen male subjects were included in the study. Thermal thresholds were tested on the right side at the volar surface of mid-forearm, lateral surface of mid-upper arm and front area of mid-thigh. Thermal testing was carried out by the method of levels with an initial temperature step of 2°C. Variability of thermal thresholds was expressed by means of the ratio between the second and the first testing, coefficient of variation (CV), coefficient of repeatability (CR), intraclass correlation coefficient (ICC), mean difference between sessions (S1-S2diff), standard error of measurement (SEM) and minimally detectable change (MDC). There were no statistically significant changes between sessions for warm or cold thresholds, or between warm and cold thresholds. Within-subject CVs were acceptable. The CR estimates for warm thresholds ranged from 0.74°C to 1.06°C and from 0.67°C to 1.07°C for cold thresholds. The ICC values for intra-rater reliability ranged from 0.41 to 0.72 for warm thresholds and from 0.67 to 0.84 for cold thresholds. S1-S2diff ranged from -0.15°C to 0.07°C for warm thresholds, and from -0.08°C to 0.07°C for cold thresholds. SEM ranged from 0.26°C to 0.38°C for warm thresholds, and from 0.23°C to 0.38°C for cold thresholds. Estimated MDC values were between 0.60°C and 0.88°C for warm thresholds, and 0.53°C and 0.88°C for cold thresholds. The method of levels for determining cutaneous temperature sensitivity has acceptable reliability.

Investigation of reliability attributes and accelerated stress factors on terrestrial solar cells

NASA Technical Reports Server (NTRS)

Prince, J. L.; Lathrop, J. W.

1979-01-01

The results of accelerated stress testing of four different types of silicon terrestrial solar cells are discussed. The accelerated stress tests used included bias-temperature tests, bias-temperature-humidity tests, thermal cycle and thermal shock tests, and power cycle tests. Characterization of the cells was performed before stress testing and at periodic down-times, using electrical measurement, visual inspection, and metal adherence pull tests. Electrical parameters measured included short-circuit current, open circuit voltage, and output power, voltage, and current at the maximum power point. Incorporated in the report are the distributions of the prestress electrical data for all cell types. Data were also obtained on cell series and shunt resistance.

Reliability of Sn/Pb and Lead-Free (SnAgCu) Solders of Surface Mounted Miniaturized Passive Components for Extreme Temperature (-185 C to +125 C) Space Missions

NASA Technical Reports Server (NTRS)

Ramesham, Rajeshuni

2011-01-01

Surface mount electronic package test boards have been assembled using tin/lead (Sn/Pb) and lead-free (Pb-free or SnAgCu or SAC305) solders. The soldered surface mount packages include ball grid arrays (BGA), flat packs, various sizes of passive chip components, etc. They have been optically inspected after assembly and subsequently subjected to extreme temperature thermal cycling to assess their reliability or future deep space, long-term, extreme temperature environmental missions. In this study, the employed temperature range (-185oC to +125oC) covers military specifications (-55oC to +100oC), extreme old Martian (-120oC to +115oC), asteroid Nereus (-180oC to +25oC) and JUNO (-150oC to +120oC) environments. The boards were inspected at room temperature and at various intervals as a function of extreme temperature thermal cycling and bake duration. Electrical resistance measurements made at room temperature are reported and the tests to date have shown some change in resistance as a function of extreme temperature thermal cycling and some showed increase in resistance. However, the change in interconnect resistance becomes more noticeable with increasing number of thermal cycles. Further research work will be carried out to understand the reliability of packages under extreme temperature applications (-185oC to +125oC) via continuously monitoring the daisy chain resistance for BGA, Flat-packs, lead less chip packages, etc. This paper will describe the experimental reliability results of miniaturized passive components (01005, 0201, 0402, 0603, 0805, and 1206) assembled using surface mounting processes with tin-lead and lead-free solder alloys under extreme temperature environments.

Reliability of Sn/Pb and lead-free (SnAgCu) solders of surface mounted miniaturized passive components for extreme temperature (-185°C to +125°C) space missions

NASA Astrophysics Data System (ADS)

Ramesham, Rajeshuni

2011-02-01

Surface mount electronic package test boards have been assembled using tin/lead (Sn/Pb) and lead-free (Pb-free or SnAgCu or SAC305) solders. The soldered surface mount packages include ball grid arrays (BGA), flat packs, various sizes of passive chip components, etc. They have been optically inspected after assembly and subsequently subjected to extreme temperature thermal cycling to assess their reliability for future deep space, long-term, extreme temperature environmental missions. In this study, the employed temperature range (-185°C to +125°C) covers military specifications (-55°C to +100°C), extreme cold Martian (-120°C to +115°C), asteroid Nereus (-180°C to +25°C) and JUNO (-150°C to +120°C) environments. The boards were inspected at room temperature and at various intervals as a function of extreme temperature thermal cycling and bake duration. Electrical resistance measurements made at room temperature are reported and the tests to date have shown some change in resistance as a function of extreme temperature thermal cycling and some showed increase in resistance. However, the change in interconnect resistance becomes more noticeable with increasing number of thermal cycles. Further research work will be carried out to understand the reliability of packages under extreme temperature applications (-185°C to +125°C) via continuously monitoring the daisy chain resistance for BGA, Flat-packs, lead less chip packages, etc. This paper will describe the experimental reliability results of miniaturized passive components (01005, 0201, 0402, 0603, 0805, and 1206) assembled using surface mounting processes with tin-lead and lead-free solder alloys under extreme temperature environments.

Thermal Expert System (TEXSYS): Systems automony demonstration project, volume 1. Overview

NASA Technical Reports Server (NTRS)

Glass, B. J. (Editor)

1992-01-01

The Systems Autonomy Demonstration Project (SADP) produced a knowledge-based real-time control system for control and fault detection, isolation, and recovery (FDIR) of a prototype two-phase Space Station Freedom external active thermal control system (EATCS). The Thermal Expert System (TEXSYS) was demonstrated in recent tests to be capable of reliable fault anticipation and detection, as well as ordinary control of the thermal bus. Performance requirements were addressed by adopting a hierarchical symbolic control approach-layering model-based expert system software on a conventional, numerical data acquisition and control system. The model-based reasoning capabilities of TEXSYS were shown to be advantageous over typical rule-based expert systems, particularly for detection of unforeseen faults and sensor failures. Volume 1 gives a project overview and testing highlights. Volume 2 provides detail on the EATCS test bed, test operations, and online test results. Appendix A is a test archive, while Appendix B is a compendium of design and user manuals for the TEXSYS software.

Test-retest agreement and reliability of quantitative sensory testing 1 year after breast cancer surgery.

PubMed

Andersen, Kenneth Geving; Kehlet, Henrik; Aasvang, Eske Kvanner

2015-05-01

Quantitative sensory testing (QST) is used to assess sensory dysfunction and nerve damage by examining psychophysical responses to controlled, graded stimuli such as mechanical and thermal detection and pain thresholds. In the breast cancer population, 4 studies have used QST to examine persistent pain after breast cancer treatment, suggesting neuropathic pain being a prominent pain mechanism. However, the agreement and reliability of QST has not been described in the postsurgical breast cancer population, hindering exact interpretation of QST studies in this population. The aim of the present study was to assess test-retest properties of QST after breast cancer surgery. A total of 32 patients recruited from a larger ongoing prospective trial were examined with QST 12 months after breast cancer surgery and reexamined a week later. A standardized QST protocol was used, including sensory mapping for mechanical, warmth and cold areas of sensory dysfunction, mechanical thresholds using monofilaments and pin-prick, thermal thresholds including warmth and cold detection thresholds and heat pain threshold, with bilateral examination. Agreement and reliability were assessed by Bland-Altman plots, descriptive statistics, coefficients of variance, and intraclass correlation. Bland-Altman plots showed high variation on the surgical side. Intraclass coefficients ranged from 0.356 to 0.847 (moderate to substantial reliability). Between-patient variation was generally higher (0.9 to 14.5 SD) than within-patient variation (0.23 to 3.55 SD). There were no significant differences between pain and pain-free patients. The individual test-retest variability was higher on the operated side compared with the nonoperated side. The QST protocol reliability allows for group-to-group comparison of sensory function, but less so for individual follow-up after breast cancer surgery.

Materials selection for long life in LEO: A critical evaluation of atomic oxygen testing with thermal atom systems

NASA Technical Reports Server (NTRS)

Koontz, S. L.; Kuminecz, J.; Leger, L.; Nordine, P.

1988-01-01

The use of thermal atom test methods as a materials selection and screening technique for low-Earth orbit (LEO) spacecraft is critically evaluated. The chemistry and physics of thermal atom environments are compared with the LEO environment. The relative reactivities of a number of materials determined to be in thermal atom environments are compared to those observed in LEO and in high quality LEO simulations. Reaction efficiencies measured in a new type of thermal atom apparatus are one-hundredth to one-thousandth those observed in LEO, and many materials showing nearly identical reactivities in LEO show relative reactivities differing by as much as a factor of 8 in thermal atom systems. A simple phenomenological kinetic model for the reaction of oxygen atoms with organic materials can be used to explain the differences in reactivity in different environments. Certain specific thermal test environments can be used as reliable materials screening tools. Using thermal atom methods to predict material lifetime in LEO requires direct calibration of the method against LEO data or high quality simulation data for each material.

A Multi-Environment Thermal Control System With Freeze-Tolerant Radiator

NASA Technical Reports Server (NTRS)

Chen, Weibo; Fogg, David; Mancini, Nick; Steele, John; Quinn, Gregory; Bue, Grant; Littibridge, Sean

2013-01-01

Future space exploration missions require advanced thermal control systems (TCS) to dissipate heat from spacecraft, rovers, or habitats operating in environments that can vary from extremely hot to extremely cold. A lightweight, reliable TCS is being developed to effectively control cabin and equipment temperatures under widely varying heat loads and ambient temperatures. The system uses freeze-tolerant radiators, which eliminate the need for a secondary circulation loop or heat pipe systems. Each radiator has a self-regulating variable thermal conductance to its ambient environment. The TCS uses a nontoxic, water-based working fluid that is compatible with existing lightweight aluminum heat exchangers. The TCS is lightweight, compact, and requires very little pumping power. The critical characteristics of the core enabling technologies were demonstrated. Functional testing with condenser tubes demonstrated the key operating characteristics required for a reliable, freeze-tolerant TCS, namely (1) self-regulating thermal conductance with short transient responses to varying thermal loads, (2) repeatable performance through freeze-thaw cycles, and (3) fast start-up from a fully frozen state. Preliminary coolant tests demonstrated that the corrosion inhibitor in the water-based coolant can reduce the corrosion rate on aluminum by an order of magnitude. Performance comparison with state-of-the-art designs shows significant mass and power saving benefits of this technology.

A combined application of thermal desorber and gas chromatography to the analysis of gaseous carbonyls with the aid of two internal standards.

PubMed

Kim, Ki-Hyun; Anthwal, A; Pandey, Sudhir Kumar; Kabir, Ehsanul; Sohn, Jong Ryeul

2010-11-01

In this study, a series of GC calibration experiments were conducted to examine the feasibility of the thermal desorption approach for the quantification of five carbonyl compounds (acetaldehyde, propionaldehyde, butyraldehyde, isovaleraldehyde, and valeraldehyde) in conjunction with two internal standard compounds. The gaseous working standards of carbonyls were calibrated with the aid of thermal desorption as a function of standard concentration and of loading volume. The detection properties were then compared against two types of external calibration data sets derived by fixed standard volume and fixed standard concentration approach. According to this comparison, the fixed standard volume-based calibration of carbonyls should be more sensitive and reliable than its fixed standard concentration counterpart. Moreover, the use of internal standard can improve the analytical reliability of aromatics and some carbonyls to a considerable extent. Our preliminary test on real samples, however, indicates that the performance of internal calibration, when tested using samples of varying dilution ranges, can be moderately different from that derivable from standard gases. It thus suggests that the reliability of calibration approaches should be examined carefully with the considerations on the interactive relationships between the compound-specific properties and the operation conditions of the instrumental setups.

High-temperature deformation field measurement by combining transient aerodynamic heating simulation system and reliability-guided digital image correlation

NASA Astrophysics Data System (ADS)

Pan, Bing; Wu, Dafang; Xia, Yong

2010-09-01

To determine the full-field high-temperature thermal deformation of the structural materials used in high-speed aerospace flight vehicles, a novel non-contact high-temperature deformation measurement system is established by combining transient aerodynamic heating simulation device with the reliability-guided digital image correlation (RG-DIC). The test planar sample with size varying from several mm 2 to several hundreds mm 2 can be heated from room temperature to 1100 °C rapidly and accurately using the infrared radiator of the transient aerodynamic heating simulation system. The digital images of the test sample surface at various temperatures are recorded using an ordinary optical imaging system. To cope with the possible local decorrelated regions caused by black-body radiation within the deformed images at the temperatures over 450 °C, the RG-DIC technique is used to extract full-field in-plane thermal deformation from the recorded images. In validation test, the thermal deformation fields and the values of coefficient of thermal expansion (CTEs) of a chromiumnickel austenite stainless steel sample from room temperature to 550 °C is measured and compared with the well-established handbook value, confirming the effectiveness and accuracy of the proposed technique. The experimental results reveal that the present system using an ordinary optical imaging system, is able to accurately measure full-field thermal deformation of metals and alloys at temperatures not exceeding 600 °C.

Quantitative Accelerated Life Testing of MEMS Accelerometers

PubMed Central

Bâzu, Marius; Gălăţeanu, Lucian; Ilian, Virgil Emil; Loicq, Jerome; Habraken, Serge; Collette, Jean-Paul

2007-01-01

Quantitative Accelerated Life Testing (QALT) is a solution for assessing the reliability of Micro Electro Mechanical Systems (MEMS). A procedure for QALT is shown in this paper and an attempt to assess the reliability level for a batch of MEMS accelerometers is reported. The testing plan is application-driven and contains combined tests: thermal (high temperature) and mechanical stress. Two variants of mechanical stress are used: vibration (at a fixed frequency) and tilting. Original equipment for testing at tilting and high temperature is used. Tilting is appropriate as application-driven stress, because the tilt movement is a natural environment for devices used for automotive and aerospace applications. Also, tilting is used by MEMS accelerometers for anti-theft systems. The test results demonstrated the excellent reliability of the studied devices, the failure rate in the “worst case” being smaller than 10-7h-1. PMID:28903265

Die Attachment for -120 C to +20 C Thermal Cycling of Microelectronics for Future Mars Rovers: An Overview

NASA Technical Reports Server (NTRS)

Kirschman, Randall K.; Sokolowski, Witold M.; Kolawa, Elizabeth A.

1999-01-01

Active thermal control for electronics on Mars Rovers imposes a serious penalty in weight, volume, power consumption, and reliability. Thus, we propose that thermal control be eliminated for future Rovers. From a functional standpoint there is no reason that the electronics could not operate over the entire temperature range of the Martian environment, which can vary from a low of approximately equal -90 C to a high of approximately equal +20 C during the Martian night and day. The upper end of this range is well within that for conventional electronics. Although the lower end is considerably below that for which conventional--even high-reliability electronics is designed or tested, it is well established that electronic devices can operate to such low temperatures. The primary concern is reliability of the overall electronic system, especially in regard to the numerous daily temperature cycles that it would experience over the duration of a mission on Mars. Accordingly, key reliability issues have been identified for elimination of thermal control on future Mars Rovers. One of these is attachment of semiconductor die onto substrates and into packages. Die attachment is critical since it forms a mechanical, thermal and electrical interface between the electronic device and the substrate or package. This paper summarizes our initial investigation of existing information related to this issue, in order to form an opinion whether die attachment techniques exist, or could be developed with reasonable effort, to withstand the Mars thermal environment for a mission duration of approximately I year. Our conclusion, from a review of literature and personal contacts. is that die attachment can be made sufficiently reliable to satisfy the requirements of future Mars Rovers. Moreover, it appears that there are several possible techniques from which to choose and that the requirements could be met by judicious selection from existing methods using hard solders, soft solders, or organic adhesives. Thus from the standpoint of die attachment. it appears feasible to eliminate thermal control for Rover electronics. We recommend that this be further investigated and verified for the specific hardware and thermal conditions appropriate to Mars Rovers.

Thermal Cycling Life Prediction of Sn-3.0Ag-0.5Cu Solder Joint Using Type-I Censored Data

PubMed Central

Mi, Jinhua; Yang, Yuan-Jian; Huang, Hong-Zhong

2014-01-01

Because solder joint interconnections are the weaknesses of microelectronic packaging, their reliability has great influence on the reliability of the entire packaging structure. Based on an accelerated life test the reliability assessment and life prediction of lead-free solder joints using Weibull distribution are investigated. The type-I interval censored lifetime data were collected from a thermal cycling test, which was implemented on microelectronic packaging with lead-free ball grid array (BGA) and fine-pitch ball grid array (FBGA) interconnection structures. The number of cycles to failure of lead-free solder joints is predicted by using a modified Engelmaier fatigue life model and a type-I censored data processing method. Then, the Pan model is employed to calculate the acceleration factor of this test. A comparison of life predictions between the proposed method and the ones calculated directly by Matlab and Minitab is conducted to demonstrate the practicability and effectiveness of the proposed method. At last, failure analysis and microstructure evolution of lead-free solders are carried out to provide useful guidance for the regular maintenance, replacement of substructure, and subsequent processing of electronic products. PMID:25121138

Assessing Reliability of Cold Spray Sputter Targets in Photovoltaic Manufacturing

NASA Astrophysics Data System (ADS)

Hardikar, Kedar; Vlcek, Johannes; Bheemreddy, Venkata; Juliano, Daniel

2017-10-01

Cold spray has been used to manufacture more than 800 Cu-In-Ga (CIG) sputter targets for deposition of high-efficiency photovoltaic thin films. It is a preferred technique since it enables high deposit purity and transfer of non-equilibrium alloy states to the target material. In this work, an integrated approach to reliability assessment of such targets with deposit weight in excess of 50 lb. is undertaken, involving thermal-mechanical characterization of the material in as-deposited condition, characterization of the interface adhesion on cylindrical substrate in as-deposited condition, and developing means to assess target integrity under thermal-mechanical loads during the physical vapor deposition (PVD) sputtering process. Mechanical characterization of cold spray deposited CIG alloy is accomplished through the use of indentation testing and adaptation of Brazilian disk test. A custom lever test was developed to characterize adhesion along the cylindrical interface between the CIG deposit and cylindrical substrate, overcoming limitations of current standards. A cohesive zone model for crack initiation and propagation at the deposit interface is developed and validated using the lever test and later used to simulate the potential catastrophic target failure in the PVD process. It is shown that this approach enables reliability assessment of sputter targets and improves robustness.

Thermal Expert System (TEXSYS): Systems autonomy demonstration project, volume 2. Results

NASA Technical Reports Server (NTRS)

Glass, B. J. (Editor)

1992-01-01

The Systems Autonomy Demonstration Project (SADP) produced a knowledge-based real-time control system for control and fault detection, isolation, and recovery (FDIR) of a prototype two-phase Space Station Freedom external active thermal control system (EATCS). The Thermal Expert System (TEXSYS) was demonstrated in recent tests to be capable of reliable fault anticipation and detection, as well as ordinary control of the thermal bus. Performance requirements were addressed by adopting a hierarchical symbolic control approach-layering model-based expert system software on a conventional, numerical data acquisition and control system. The model-based reasoning capabilities of TEXSYS were shown to be advantageous over typical rule-based expert systems, particularly for detection of unforeseen faults and sensor failures. Volume 1 gives a project overview and testing highlights. Volume 2 provides detail on the EATCS testbed, test operations, and online test results. Appendix A is a test archive, while Appendix B is a compendium of design and user manuals for the TEXSYS software.

Thermal Expert System (TEXSYS): Systems autonomy demonstration project, volume 2. Results

NASA Astrophysics Data System (ADS)

Glass, B. J.

1992-10-01

The Systems Autonomy Demonstration Project (SADP) produced a knowledge-based real-time control system for control and fault detection, isolation, and recovery (FDIR) of a prototype two-phase Space Station Freedom external active thermal control system (EATCS). The Thermal Expert System (TEXSYS) was demonstrated in recent tests to be capable of reliable fault anticipation and detection, as well as ordinary control of the thermal bus. Performance requirements were addressed by adopting a hierarchical symbolic control approach-layering model-based expert system software on a conventional, numerical data acquisition and control system. The model-based reasoning capabilities of TEXSYS were shown to be advantageous over typical rule-based expert systems, particularly for detection of unforeseen faults and sensor failures. Volume 1 gives a project overview and testing highlights. Volume 2 provides detail on the EATCS testbed, test operations, and online test results. Appendix A is a test archive, while Appendix B is a compendium of design and user manuals for the TEXSYS software.

Temperature Control with Two Parallel Small Loop Heat Pipes for GLM Program

NASA Technical Reports Server (NTRS)

Khrustalev, Dmitry; Stouffer, Chuck; Ku, Jentung; Hamilton, Jon; Anderson, Mark

2014-01-01

The concept of temperature control of an electronic component using a single Loop Heat Pipe (LHP) is well established for Aerospace applications. Using two LHPs is often desirable for redundancy/reliability reasons or for increasing the overall heat source-sink thermal conductance. This effort elaborates on temperature controlling operation of a thermal system that includes two small ammonia LHPs thermally coupled together at the evaporator end as well as at the condenser end and operating "in parallel". A transient model of the LHP system was developed on the Thermal Desktop (TradeMark) platform to understand some fundamental details of such parallel operation of the two LHPs. Extensive thermal-vacuum testing was conducted with two thermally coupled LHPs operating simultaneously as well as with only one LHP operating at a time. This paper outlines the temperature control procedures for two LHPs operating simultaneously with widely varying sink temperatures. The test data obtained during the thermal-vacuum testing, with both LHPs running simultaneously in comparison with only one LHP operating at a time, are presented with detailed explanations.

Scientific Research Program for Power, Energy, and Thermal Technologies. Task Order 0002: Power, Thermal and Control Technologies and Processes Experimental Research. Subtask: Laboratory Test Set-up to Evaluate Electromechanical Actuation Systems for Aircraft Flight Control

DTIC Science & Technology

2015-08-01

faults are incorporated into the system in order to better understand the EMA reliability, and to aid in designing fault detection software for real...to a fixed angle repeatedly and accurately [16]. The motor in the EHA is used to drive a reversible pump tied to a hydraulic cylinder which moves...24] [25] [26]. These test stands are used for the prognostic testing of EMAS that have had mechanical or electrical faults injected into them. The

[Test of thermal deformation for electronic devices of high thermal reliability].

PubMed

Li, Hai-yuan; Li, Bao-ming

2002-06-01

Thermal deformation can be caused by high partial heat flux and greatly reduce thermal reliability of electronic devices. In this paper, an attempt is made to measure the thermal deformation of high power electronic devices under working condition using laser holographic interferometry with double exposure. Laser holographic interferometry is an untouched measurement with measurement precision up to micron dimension. The electronic device chosen for measurement is a type of solid state relay which is used for ignition of rockets. The output circuit of the solid state relay is made up of a MOSFET chip and the power density of the chip can reach high value. In particular situations thermal deformation and stress may significantly influence working performance of the solid state relay. The bulk deformation of the chip and its mount is estimated by number of interferential stripes on chip surface. While thermal stress and deformation can be estimated by curvature of interferential stripes on chip surface. Experimental results indicate that there are more interferential stripes on chip surface and greater flexural degree of stripes under high power. Therefore, these results reflect large out-of-plain displacement and deformed size of the chip with the increase of load current.

A Novel Test Method for Fuel Thermal Stability

DTIC Science & Technology

1993-02-01

1 1.1. The Problem ................................................. . 1 1.2. The Innovations ...OPPORTUNITY ....................... 4 2.1. The Problem .................................................... 4 2.2. The Innovations and Opportunity for Sol...reliable instrument and test method to evaluate these fuels. 1.2. The Innovations The first innovation is the application of Fourier-Transform Infrared

Evaluation of accuracy, reliability, and repeatability of five dental pulp tests.

PubMed

Chen, Eugene; Abbott, Paul V

2011-12-01

The aim of this study was to compare the clinical accuracy, reliability, and repeatability of laser Doppler flowmetry (LDF), an electric pulp test (EPT), and various thermal pulp sensibility tests. Pulp tests were done on 121 teeth in 20 subjects by using LDF, EPT, and thermal pulp testing (CO(2), Endo Frost [EF], Ice) during 2 or 3 test sessions with at least 1-week intervals. The order of testing was reversed on the second visit. A laser Doppler flowmeter was used to measure mean pulp blood flow (Flux) calibrated against a brownian motion medium and zeroed against a static reflector. The laser source was 780 nm, with 0.5-mm fiber separation in the probe, 3.1 kHz as the primary bandwidth for filter set to 0.1-second time output constant. Customized polyvinylsiloxane splints were fabricated for each participant, and a minimum of 90-second recording time was used for each tooth. Raw data were analyzed by using repeated measure analysis of variance, pairwise comparisons, and interclass correlations (ICC). The accuracy of EPT, CO(2), and LDF tests was 97.7%, 97.0%, and 96.3%, respectively, without significant differences (P > .3). Accuracy of EF and Ice was 90.7% and 84.8%, respectively. EPT (P = .015) and CO(2) (P = .022) were significantly more accurate than EF. LDF was more accurate than EF, but this was not statistically significant (P = .063). Ice was significantly less accurate than EPT (P = .004), CO(2) (P = .005), LDF (P = .006), and EF (P = .019). With the exception of Ice (effect of visit: F(2,38) = 5.67, mean squared error = 0.01, P = .007, η(2)(p) = 0.23), all tests were reliable. Ice (ICC = 0.677) and LDF (ICC = 0.654) were the most repeatable of the tests, whereas EPT (ICC = 0.434) and CO(2) (ICC = 0.432) were less repeatable. CO(2), EPT, and LDF were reliable and the most accurate tests, but CO(2) and EPT were less repeatable yet less time-consuming than LDF. EF was reliable but not as accurate as EPT and CO(2) and less repeatable than Ice and LDF. Ice was the most repeatable but the least accurate and least reliable test. Copyright © 2011 American Association of Endodontists. Published by Elsevier Inc. All rights reserved.

Instrumentation for accelerated life tests of concentrator solar cells.

PubMed

Núñez, N; Vázquez, M; González, J R; Jiménez, F J; Bautista, J

2011-02-01

Concentrator photovoltaic is an emergent technology that may be a good economical and efficient alternative for the generation of electricity at a competitive cost. However, the reliability of these new solar cells and systems is still an open issue due to the high-irradiation level they are subjected to as well as the electrical and thermal stresses that they are expected to endure. To evaluate the reliability in a short period of time, accelerated aging tests are essential. Thermal aging tests for concentrator photovoltaic solar cells and systems under illumination are not available because no technical solution to the problem of reaching the working concentration inside a climatic chamber has been available. This work presents an automatic instrumentation system that overcomes the aforementioned limitation. Working conditions have been simulated by forward biasing the solar cells to the current they would handle at the working concentration (in this case, 700 and 1050 times the irradiance at one standard sun). The instrumentation system has been deployed for more than 10 000 h in a thermal aging test for III-V concentrator solar cells, in which the generated power evolution at different temperatures has been monitored. As a result of this test, the acceleration factor has been calculated, thus allowing for the degradation evolution at any temperature in addition to normal working conditions to be obtained.

Thermal Performance Testing of EMU and CSAFE Liquid Cooling Garments

NASA Technical Reports Server (NTRS)

Rhodes, Richard; Bue, Grant; Hakam, Mark; Radford, Tamara

2013-01-01

Future exploration missions require the development of a new liquid cooling garment (LCG) that offers greater system reliability, is more comfortable, and maximizes thermal performance. To inform the development of a future LCG a thermal performance test was conducted to evaluate three factors: (1) the effect of the thermal comfort undergarment (TCU) on tactile and thermal comfort, (2) the comparable thermal performance of an CSAFE developed engineering evaluation unit (EEU) LCG, which uses a commercial-off-the-shelf (COTS) wicking garment as the base, and (3) the performance of a torso or upper body only LCG configuration to evaluate a proposed auxiliary loop configuration. To evaluate the thermal performance of each configuration a metabolic suit test was conducted, utilizing suited subjects to generate metabolic heat by walking on a treadmill at various speeds. Three (3) test subjects of similar height and weight produced a metabolic load for five tests by either resting (300-600 BTU/hr), walking at a slow pace (1200 BTU/hr), and walking at a brisk pace (2200 BTU/hr). During the test, data was collected that would allow us to track the heat transfer to the LCG and ventilation system to determine the thermal performance of the LCG configurations. Four different test configurations were tested, with one configuration tested twice. The test results show that the CSAFE EEU LCG and EMU LCG had comparable performance. The testing also showed that an auxiliary loop LCG, sized similarly to the shirt-only configuration, should provide adequate cooling for contingency scenarios. Finally, the testing showed the previous analysis that assumed a UA deterioration from the TCU was too conservative and the TCU may prove to be acceptable for future development with additional analysis and testing.

Thermal interface material characterization for cryogenic electronic packaging solutions

NASA Astrophysics Data System (ADS)

Dillon, A.; McCusker, K.; Van Dyke, J.; Isler, B.; Christiansen, M.

2017-12-01

As applications of superconducting logic technologies continue to grow, the need for efficient and reliable cryogenic packaging becomes crucial to development and testing. A trade study of materials was done to develop a practical understanding of the properties of interface materials around 4 K. While literature exists for varying interface tests, discrepancies are found in the reported performance of different materials and in the ranges of applied force in which they are optimal. In considering applications extending from top cooling a silicon chip to clamping a heat sink, a range of forces from approximately 44 N to approximately 445 N was chosen for testing different interface materials. For each range of forces a single material was identified to optimize the thermal conductance of the joint. Of the tested interfaces, indium foil clamped at approximately 445 N showed the highest thermal conductance. Results are presented from these characterizations and useful methodologies for efficient testing are defined.

Phase 1 of the First Small Power System Experiment (engineering Experiment No. 1). Volume 3: Experimental System Descriptions. [development and testing of a solar thermal power plant

NASA Technical Reports Server (NTRS)

Holl, R. J.

1979-01-01

The design and development of a modular solar thermal power system for application in the 1 to 10 MWe range is described. The system consists of five subsystems: the collector, power conversion, energy transport, energy storage, and the plant control subsystem. The collector subsystem consists of concentrator, receiver, and tower assemblies. The energy transport subsystem uses a mixture of salts with a low melting temperature to transport thermal energy. A steam generator drives a steam Rankine cycle turbine which drives an electrical generator to produce electricity. Thermal and stress analysis tests are performed on each subsystem in order to determine the operational reliability, the minimum risk of failure, and the maintenance and repair characteristics.

Low thermal flux glass-fiber tubing for cryogenic service

NASA Technical Reports Server (NTRS)

Hall, C. A.; Spond, D. E.

1977-01-01

This paper describes analytical techniques, fabrication development, and test results for composite tubing that has many applications in aerospace and commercial cryogenic installations. Metal liner fabrication is discussed in detail with attention given to resistance-welded liners, fusion-welded liners, chem-milled tubing liners, joining tube liners and end fittings, heat treatment and leak checks. Composite overwrapping, a second method of tubing fabrication, is also discussed. Test programs and analytical correlation are considered along with composite tubing advantages such as minimum weight, thermal efficiency and safety and reliability.

A New Metre for Cheap, Quick, Reliable and Simple Thermal Transmittance (U-Value) Measurements in Buildings.

PubMed

Andújar Márquez, José Manuel; Martínez Bohórquez, Miguel Ángel; Gómez Melgar, Sergio

2017-09-03

This paper deals with the thermal transmittance measurement focused on buildings and specifically in building energy retrofitting. Today, if many thermal transmittance measurements in a short time are needed, the current devices, based on the measurement of the heat flow through the wall, cannot carry out them, except if a great amount of devices are used at once along with intensive and tedious post-processing and analysis work. In this paper, from well-known physical laws, authors develop a methodology based on three temperatures measurements, which is implemented by a novel thermal transmittance metre. The paper shows its development step by step. As a result the developed device is modular, scalable, and fully wireless; it is capable of taking as many measurements at once as user needs. The developed system is compared working together on a same test to the currently used one based on heat flow. The results show that the developed metre allows carrying out thermal transmittance measurements in buildings in a cheap, quick, reliable and simple way.

Failure Mechanisms of SAC/Fe-Ni Solder Joints During Thermal Cycling

NASA Astrophysics Data System (ADS)

Gao, Li-Yin; Liu, Zhi-Quan; Li, Cai-Fu

2017-08-01

Thermal cycling tests have been conducted on Sn-Ag-Cu/Fe- xNi ( x = 73 wt.% or 45 wt.%) and Sn-Ag-Cu/Cu solder joints according to the Joint Electron Device Engineering Council industrial standard to study their interfacial reliability under thermal stress. The interfacial intermetallic compounds formed for solder joints on Cu, Fe-73Ni, and Fe-45Ni were 4.5 μm, 1.7 μm, and 1.4 μm thick, respectively, after 3000 cycles, demonstrating excellent diffusion barrier effect of Fe-Ni under bump metallization (UBM). Also, two deformation modes, viz. solder extrusion and fatigue crack formation, were observed by scanning electron microscopy and three-dimensional x-ray microscopy. Solder extrusion dominated for solder joints on Cu, while fatigue cracks dominated for solder joints on Fe-45Ni and both modes were detected for those on Fe-73Ni. Solder joints on Fe-Ni presented inferior reliability during thermal cycling compared with those on Cu, with characteristic lifetime of 3441 h, 3190 h, and 1247 h for Cu, Fe-73Ni, and Fe-45Ni UBM, respectively. This degradation of the interfacial reliability for solder joints on Fe-Ni is attributed to the mismatch in coefficient of thermal expansion (CTE) at interconnection level. The CTE mismatch at microstructure level was also analyzed by electron backscatter diffraction for clearer identification of recrystallization-related deformation mechanisms.

Performance and Reliability of Bonded Interfaces for High-Temperature Packaging

DOE Office of Scientific and Technical Information (OSTI.GOV)

Paret, Paul P

2017-08-02

Sintered silver has proven to be a promising candidate for use as a die-attach and substrate-attach material in automotive power electronics components. It holds promise of greater reliability than lead-based and lead-free solders, especially at higher temperatures (>200 degrees C). Accurate predictive lifetime models of sintered silver need to be developed and its failure mechanisms thoroughly characterized before it can be deployed as a die-attach or substrate-attach material in wide-bandgap device-based packages. Mechanical characterization tests that result in stress-strain curves and accelerated tests that produce cycles-to-failure result will be conducted. Also, we present a finite element method (FEM) modeling methodologymore » that can offer greater accuracy in predicting the failure of sintered silver under accelerated thermal cycling. A fracture mechanics-based approach is adopted in the FEM model, and J-integral/thermal cycle values are computed.« less

Overview of RICOR tactical cryogenic refrigerators for space missions

NASA Astrophysics Data System (ADS)

Riabzev, Sergey; Filis, Avishai; Livni, Dorit; Regev, Itai; Segal, Victor; Gover, Dan

2016-05-01

Cryogenic refrigerators represent a significant enabling technology for Earth and Space science enterprises. Many of the space instruments require cryogenic refrigeration to enable the use of advanced detectors to explore a wide range of phenomena from space. RICOR refrigerators involved in various space missions are overviewed in this paper, starting in 1994 with "Clementine" Moon mission, till the latest ExoMars mission launched in 2016. RICOR tactical rotary refrigerators have been incorporated in many space instruments, after passing qualification, life time, thermal management testing and flight acceptance. The tactical to space customization framework includes an extensive characterization and qualification test program to validate reliability, the design of thermal interfacing with a detector, vibration export control, efficient heat dissipation in a vacuum environment, robustness, mounting design, compliance with outgassing requirements and strict performance screening. Current RICOR development is focused on dedicated ultra-long-life, highly reliable, space cryogenic refrigerator based on a Pulse Tube design

Development of Passive Fuel Cell Thermal Management Heat Exchanger

NASA Technical Reports Server (NTRS)

Burke, Kenneth A.; Jakupca, Ian J.; Colozza, Anthony J.

2010-01-01

The NASA Glenn Research Center is developing advanced passive thermal management technology to reduce the mass and improve the reliability of space fuel cell systems for the NASA Exploration program. The passive thermal management system relies on heat conduction within highly thermally conductive cooling plates to move the heat from the central portion of the cell stack out to the edges of the fuel cell stack. Using the passive approach eliminates the need for a coolant pump and other cooling loop components within the fuel cell system which reduces mass and improves overall system reliability. Previous development demonstrated the performance of suitable highly thermally conductive cooling plates that could conduct the heat, provide a sufficiently uniform temperature heat sink for each cell of the fuel cell stack, and be substantially lighter than the conventional thermal management approach. Tests were run with different materials to evaluate the design approach to a heat exchanger that could interface with the edges of the passive cooling plates. Measurements were made during fuel cell operation to determine the temperature of individual cooling plates and also to determine the temperature uniformity from one cooling plate to another.

Development of Passive Fuel Cell Thermal Management Technology

NASA Technical Reports Server (NTRS)

Burke, Kenneth A.; Jakupca, Ian; Colozza, Anthony

2011-01-01

The NASA Glenn Research Center is developing advanced passive thermal management technology to reduce the mass and improve the reliability of space fuel cell systems for the NASA exploration program. The passive thermal management system relies on heat conduction within the cooling plate to move the heat from the central portion of the cell stack out to the edges of the fuel cell stack rather than using a pumped loop cooling system to convectively remove the heat. Using the passive approach eliminates the need for a coolant pump and other cooling loop components which reduces fuel cell system mass and improves overall system reliability. Previous analysis had identified that low density, ultra-high thermal conductivity materials would be needed for the cooling plates in order to achieve the desired reductions in mass and the highly uniform thermal heat sink for each cell within a fuel cell stack. A pyrolytic graphite material was identified and fabricated into a thin plate using different methods. Also a development project with Thermacore, Inc. resulted in a planar heat pipe. Thermal conductivity tests were done using these materials. The results indicated that lightweight passive fuel cell cooling is feasible.

Thermal conductivity, bulk properties, and thermal stratigraphy of silicic tuffs from the upper portion of hole USW-G1, Yucca Mountain, Nye County, Nevada

DOE Office of Scientific and Technical Information (OSTI.GOV)

Lappin, A.R.; VanBuskirk, R.G.; Enniss, D.O.

1982-03-01

Thermal-conductivity and bulk-property measurements were made on welded and nonwelded silicic tuffs from the upper portion of Hole USW-G1, located near the southwestern margin of the Nevada Test Site. Bulk-property measurements were made by standard techniques. Thermal conductivities were measured at temperatures as high as 280{sup 0}C, confining pressures to 10 MPa, and pore pressures to 1.5 MPa. Extrapolation of measured saturated conductivities to zero porosity suggests that matrix conductivity of both zeolitized and devitrified tuffs is independent of stratigraphic position, depth, and probably location. This fact allows development of a thermal-conductivity stratigraphy for the upper portion of Hole G1.more » Estimates of saturated conductivities of zeolitized nonwelded tuffs and devitrified tuffs below the water table appear most reliable. Estimated conductivities of saturated densely welded devitrified tuffs above the water table are less reliable, due to both internal complexity and limited data presently available. Estimation of conductivity of dewatered tuffs requires use of different air thermal conductivities in devitrified and zeolitized samples. Estimated effects of in-situ fracturing generally appear negligible.« less

Thermal stability, adhesion and electrical studies on (Ti,Zr)N x thin films as low resistive diffusion barriers between Cu and Si

NASA Astrophysics Data System (ADS)

Huang, Cheng-Lin; Lai, Chih-Huang; Tsai, Po-Hao; Kuo, Yu-Lin; Lin, Jing-Cheng; Lee, Chiapyng

2014-05-01

In this study, we investigated the thermal stability, wettability, adhesion and reliability of (Ti,Zr)N x films used as the diffusion barrier between Cu and Si. (Ti,Zr)N x films were prepared by DC reactive magnetron sputtering from a Ti-5 at. % Zr alloy target in N2/Ar gas mixtures. A minimum film resistivity of 59.3 µω cm was obtained at an N2/Ar flow ratio of 2.75, which corresponds to the near stoichiometric composition (N/(Ti,Zr) ratio ˜0.95). The sheet resistance of Cu/(Ti,Zr)N0.95/Si was not significantly increased until annealing above 750°C, indicating good thermal stability. On the other hand, the adhesion energy between Cu and the (Ti,Zr)Nx film was reduced as the N/Ti ratio was increased. To obtain reliable performance on stress-induced-voiding (SIV) and electromigration (EM) tests, we proposed to use (Ti,Zr)/(Ti,Zr)N x /(Ti,Zr) tri-layers. We suggest that the interfacial adhesion between barrier and Cu plays an important role in reliability. The proposed tri-layer structure may be a promising candidate for a barrier, as it exhibits excellent reliability without increasing resistance.

A Thermal Runaway Failure Model for Low-Voltage BME Ceramic Capacitors with Defects

NASA Technical Reports Server (NTRS)

Teverovsky, Alexander

2017-01-01

Reliability of base metal electrode (BME) multilayer ceramic capacitors (MLCCs) that until recently were used mostly in commercial applications, have been improved substantially by using new materials and processes. Currently, the inception of intrinsic wear-out failures in high quality capacitors became much greater than the mission duration in most high-reliability applications. However, in capacitors with defects degradation processes might accelerate substantially and cause infant mortality failures. In this work, a physical model that relates the presence of defects to reduction of breakdown voltages and decreasing times to failure has been suggested. The effect of the defect size has been analyzed using a thermal runaway model of failures. Adequacy of highly accelerated life testing (HALT) to predict reliability at normal operating conditions and limitations of voltage acceleration are considered. The applicability of the model to BME capacitors with cracks is discussed and validated experimentally.

Mechanical Reliability of the Epoxy Sn-58wt.%Bi Solder Joints with Different Surface Finishes Under Thermal Shock

NASA Astrophysics Data System (ADS)

Sung, Yong-Gue; Myung, Woo-Ram; Jeong, Haksan; Ko, Min-Kwan; Moon, Jeonghoon; Jung, Seung-Boo

2018-04-01

The effect of thermal shock on the mechanical reliability of epoxy Sn-58wt.%Bi composite (epoxy Sn-58wt.%Bi) solder joints was investigated with different surface-finished substrates. Sn-58wt.%Bi-based solder has been considered as a promising candidate for low-temperature solder among various lead-free solders. However, Sn-58wt.%Bi solder joints can be easily broken under impact conditions such as mechanical shock, drop tests, and bending tests because of their poor ductility. Therefore, previous researchers have tried to improve the mechanical property of Sn-58wt.%Bi solder by additional elements and mixtures of metal powder and epoxy resin. Epoxy Sn-58wt.%Bi solder paste was fabricated by mixing epoxy resin and Sn-58wt.%Bi solder powder to enhance the mechanical reliability of Sn-58wt.%Bi solder joints. The epoxy Sn-58wt.%Bi solder paste was screen-printed onto various printed circuit board surfaces finished with organic solder preservatives (OSP), electroless nickel immersion gold (ENIG), and electroless nickel electroless palladium immersion gold (ENEPIG). The test components were prepared by a reflow process at a peak temperature of 190°C. The thermal shock test was carried out under the temperature range of - 40 to 125°C to evaluate the reliability of Sn-58wt.%Bi and epoxy Sn-58wt.%Bi solder joints. The OSP-finished sample showed a relatively higher mechanical property than those of ENIG and ENEPIG after thermal shock. The average number of cycles for epoxy Sn-58wt.%Bi solder with the OSP surface finish were 6 times higher than that for Sn-58wt.%Bi solder with the same finish. The microstructures of the solder joints were investigated by scanning electron microscopy, and the composition of the intermetallic compound (IMC) layer was analyzed by using energy dispersive spectrometry. Cu6Sn5 IMC was formed by the reaction between Sn-58wt.%Bi solder and a OSP surface-finished Cu after the reflow process. Ni3Sn4 IMC and (Ni, Pd)3Sn4 IMC were formed at the solder joints between the ENIG and solder, and between ENEPIG surface finish and solders, respectively.

Mechanical Reliability of the Epoxy Sn-58wt.%Bi Solder Joints with Different Surface Finishes Under Thermal Shock

NASA Astrophysics Data System (ADS)

Sung, Yong-Gue; Myung, Woo-Ram; Jeong, Haksan; Ko, Min-Kwan; Moon, Jeonghoon; Jung, Seung-Boo

2018-07-01

The effect of thermal shock on the mechanical reliability of epoxy Sn-58wt.%Bi composite (epoxy Sn-58wt.%Bi) solder joints was investigated with different surface-finished substrates. Sn-58wt.%Bi-based solder has been considered as a promising candidate for low-temperature solder among various lead-free solders. However, Sn-58wt.%Bi solder joints can be easily broken under impact conditions such as mechanical shock, drop tests, and bending tests because of their poor ductility. Therefore, previous researchers have tried to improve the mechanical property of Sn-58wt.%Bi solder by additional elements and mixtures of metal powder and epoxy resin. Epoxy Sn-58wt.%Bi solder paste was fabricated by mixing epoxy resin and Sn-58wt.%Bi solder powder to enhance the mechanical reliability of Sn-58wt.%Bi solder joints. The epoxy Sn-58wt.%Bi solder paste was screen-printed onto various printed circuit board surfaces finished with organic solder preservatives (OSP), electroless nickel immersion gold (ENIG), and electroless nickel electroless palladium immersion gold (ENEPIG). The test components were prepared by a reflow process at a peak temperature of 190°C. The thermal shock test was carried out under the temperature range of - 40 to 125°C to evaluate the reliability of Sn-58wt.%Bi and epoxy Sn-58wt.%Bi solder joints. The OSP-finished sample showed a relatively higher mechanical property than those of ENIG and ENEPIG after thermal shock. The average number of cycles for epoxy Sn-58wt.%Bi solder with the OSP surface finish were 6 times higher than that for Sn-58wt.%Bi solder with the same finish. The microstructures of the solder joints were investigated by scanning electron microscopy, and the composition of the intermetallic compound (IMC) layer was analyzed by using energy dispersive spectrometry. Cu6Sn5 IMC was formed by the reaction between Sn-58wt.%Bi solder and a OSP surface-finished Cu after the reflow process. Ni3Sn4 IMC and (Ni, Pd)3Sn4 IMC were formed at the solder joints between the ENIG and solder, and between ENEPIG surface finish and solders, respectively.

Estimates Of The Orbiter RSI Thermal Protection System Thermal Reliability

NASA Technical Reports Server (NTRS)

Kolodziej, P.; Rasky, D. J.

2002-01-01

In support of the Space Shuttle Orbiter post-flight inspection, structure temperatures are recorded at selected positions on the windward, leeward, starboard and port surfaces. Statistical analysis of this flight data and a non-dimensional load interference (NDLI) method are used to estimate the thermal reliability at positions were reusable surface insulation (RSI) is installed. In this analysis, structure temperatures that exceed the design limit define the critical failure mode. At thirty-three positions the RSI thermal reliability is greater than 0.999999 for the missions studied. This is not the overall system level reliability of the thermal protection system installed on an Orbiter. The results from two Orbiters, OV-102 and OV-105, are in good agreement. The original RSI designs on the OV-102 Orbital Maneuvering System pods, which had low reliability, were significantly improved on OV-105. The NDLI method was also used to estimate thermal reliability from an assessment of TPS uncertainties that was completed shortly before the first Orbiter flight. Results fiom the flight data analysis and the pre-flight assessment agree at several positions near each other. The NDLI method is also effective for optimizing RSI designs to provide uniform thermal reliability on the acreage surface of reusable launch vehicles.

Lumen degradation and chromaticity shift in glass and silicone based high-power phosphor-converted white-emitting diodes under thermal tests

NASA Astrophysics Data System (ADS)

Cheng, Wood-Hi; Tsai, Chun-Chin; Wang, Jimmy

2011-10-01

The lumen degradation and chromaticity shift in glass and silicone based high-power phosphor-converted white-emitting diodes (PC-WLEDs) under accelerated thermal tests at 150°C, 200°C, and 250°C are presented and compared. The glass based PC-WLEDs exhibited better thermal stability than the silicone by 4.8 time reductions in lumen loss 6.8 time reductions in chromaticity shift at 250°C, respectively. The mean-time-to-failure (MTTF) evaluation of glass and silicone based high-power PC-WLEDs in accelerated thermal tests is also presented and compared. The results showed that the glass based PC-WLEDs exhibited higher MTTF than the silicone by 7.53 times in lumen loss and 14.4 times in chromaticity shift at 250°C, respectively. The thermal performance of lumen, chromaticity, and MTTF investigations demonstrated that the thermal stability of the glass based PC-WLEDs were better than the silicone. A better thermal stability phosphor layer of glass as encapsulation material may be beneficial to the many applications where the LED modules with high power and high reliability are demanded.

Thermal-Structural Analysis of PICA Tiles for Solar Tower Test

NASA Technical Reports Server (NTRS)

Agrawal, Parul; Empey, Daniel M.; Squire, Thomas H.

2009-01-01

Thermal protection materials used in spacecraft heatshields are subjected to severe thermal and mechanical loading environments during re-entry into earth atmosphere. In order to investigate the reliability of PICA tiles in the presence of high thermal gradients as well as mechanical loads, the authors designed and conducted solar-tower tests. This paper presents the design and analysis work for this tests series. Coupled non-linear thermal-mechanical finite element analyses was conducted to estimate in-depth temperature distribution and stress contours for various cases. The first set of analyses performed on isolated PICA tile showed that stresses generated during the tests were below the PICA allowable limit and should not lead to any catastrophic failure during the test. The tests results were consistent with analytical predictions. The temperature distribution and magnitude of the measured strains were also consistent with predicted values. The second test series is designed to test the arrayed PICA tiles with various gap-filler materials. A nonlinear contact method is used to model the complex geometry with various tiles. The analyses for these coupons predict the stress contours in PICA and inside gap fillers. Suitable mechanical loads for this architecture will be predicted, which can be applied during the test to exceed the allowable limits and demonstrate failure modes. Thermocouple and strain-gauge data obtained from the solar tower tests will be used for subsequent analyses and validation of FEM models.

A nuclear method to measure spallation by thermal cycling of protective surface layers

NASA Astrophysics Data System (ADS)

Stroosnijder, M. F.; Macchi, G.

1995-05-01

After a general introduction on spallation by thermal cycling, the principle of Thin Layer Activation (TLA) is outlined. A practical setup to measure spallation of protective surface layers by thermal cycling using TLA is discussed. Its use is illustrated with the study of the spallation behaviour of an advanced thermal barrier coating. It is shown that among the various benefits, TLA has a direct relation to material loss and shows a significant increase in sensitivity over other test methods. Due to its intrinsic properties, TLA can contribute to a greater scientific understanding of material degradation by thermal cycling and it can provide a more reliable assessment of the service lives of technical components.

Advanced Nanoindentation Testing for Studying Strain-Rate Sensitivity and Activation Volume

NASA Astrophysics Data System (ADS)

Maier-Kiener, Verena; Durst, Karsten

2017-11-01

Nanoindentation became a versatile tool for testing local mechanical properties beyond hardness and modulus. By adapting standard nanoindentation test methods, simple protocols capable of probing thermally activated deformation processes can be accomplished. Abrupt strain-rate changes within one indentation allow determining the strain-rate dependency of hardness at various indentation depths. For probing lower strain-rates and excluding thermal drift influences, long-term creep experiments can be performed by using the dynamic contact stiffness for determining the true contact area. From both procedures hardness and strain-rate, and consequently strain-rate sensitivity and activation volume can be reliably deducted within one indentation, permitting information on the locally acting thermally activated deformation mechanism. This review will first discuss various testing protocols including possible challenges and improvements. Second, it will focus on different examples showing the direct influence of crystal structure and/or microstructure on the underlying deformation behavior in pure and highly alloyed material systems.

Acoustic testing of high temperature panels

NASA Technical Reports Server (NTRS)

Leatherwood, Jack D.; Clevenson, Sherman A.; Powell, Clemans A.; Daniels, Edward F.

1990-01-01

Results are presented of a series of thermal-acoustic tests conducted on the NASA Langley Research Center Thermal-Acoustic Test Apparatus to (1) investigate techniques for obtaining strain measurements on metallic and carbon-carbon materials at elevated temperature; (2) document the dynamic strain response characteristics of several superalloy honeycomb thermal protection system panels at elevated temperatures of up to 1200 F; and (3) determine the strain response and sonic fatigue behavior of four carbon-carbon panels at both ambient and elevated temperatures. A second study tested four carbon-carbon panels to document panel dynamic response characteristics at ambient and elevated temperature, determine time to failure and faliure modes, and collect continuous strain data up to panel failure. Strain data are presented from both types of panels, and problems encountered in obtaining reliable strain data on the carbon-carbon panels are described. The failure modes of the carbon-carbon panels are examined.

Microstructural characterization of ultra thin copper interconnects

NASA Astrophysics Data System (ADS)

Yang, Hee-Dong

The present study investigates the defects related to reliability issues, such as physical failures developed during processing and end use. In the first part of this study, kinetic analysis using the Johnson-Mehl-Avrami (JMA) model demonstrates that a self-annealing mechanism in electroplated Cu films depends on the film properties, such as thickness and the amount of crystal defects in an as-deposited state. In order to obtain the evidence of such defects, the microstructural characterization of defects in ultra thin copper interconnects using transmission electron microscopy (TEM) is presented. Examination of the defects using TEM reveals that voids filled with gas form as a lens shape along the {110} habit planes of the copper matrix. In the second part of this study, methodology and results of an electro-thermal-fatigue (ETF) testing, designed for early detection of process defects, are presented. Such ETF testing combines high-density current electrical stressing and thermal cycling to accelerate the evolution of defects in Cu interconnects. In ETF testing, the evolution of defects provides the nucleation sites for voids which open or close during thermal cycling. Then, the accumulation of voids creates the change in resistance when they reach a critical size. As a result of voids evolution, the high current density and high joule heating create a transient resistance increase. ETF testing reveals two failure modes, and the mode-I failure has the importance in detecting defects. The number of cycles to failure in ETF testing decreases with higher current density, but the rate of thermal cycling has no effect. Results from this investigation suggest that impurities in the copper electrodeposition process must be carefully controlled to achieve reliable ultra thin copper interconnects.

Pulse compression favourable aperiodic infrared imaging approach for non-destructive testing and evaluation of bio-materials

NASA Astrophysics Data System (ADS)

Mulaveesala, Ravibabu; Dua, Geetika; Arora, Vanita; Siddiqui, Juned A.; Muniyappa, Amarnath

2017-05-01

In recent years, aperiodic, transient pulse compression favourable infrared imaging methodologies demonstrated as reliable, quantitative, remote characterization and evaluation techniques for testing and evaluation of various biomaterials. This present work demonstrates a pulse compression favourable aperiodic thermal wave imaging technique, frequency modulated thermal wave imaging technique for bone diagnostics, especially by considering the bone with tissue, skin and muscle over layers. In order to find the capabilities of the proposed frequency modulated thermal wave imaging technique to detect the density variations in a multi layered skin-fat-muscle-bone structure, finite element modeling and simulation studies have been carried out. Further, frequency and time domain post processing approaches have been adopted on the temporal temperature data in order to improve the detection capabilities of frequency modulated thermal wave imaging.

Effect of reflective p-type ohmic contact on thermal reliability of vertical InGaN/GaN LEDs

NASA Astrophysics Data System (ADS)

Son, Jun Ho; Song, Yang Hee; Kim, Buem Joon; Lee, Jong-Lam

2014-11-01

We report on the enhanced thermal reliability of vertical-LEDs (VLEDs) using novel reflective p-type ohmic contacts with good thermal stability. The reflective p-type ohmic contacts with Ni/Ag-Cu alloy multi-layer structure shows low contact resistivity, as low as 9.3 × 10-6 Ωcm2, and high reflectance of 86% after annealing at 450°C. The V-LEDs with Ni/Ag-Cu alloy multi-layer structure show good thermal reliability with stress time at 300°C in air ambient. The improved thermal stability of the reflective ohmic contacts to p-type GaN is believed to play a critical role in the thermal reliability of V-LEDs. [Figure not available: see fulltext.

Carbon-Nanotube-Based Epoxy Matrix Thermal Interface Materials for Thermal Management in Load Bearing Aerospace Structures

DTIC Science & Technology

2012-01-12

fabrication of the composite indicate physical deformities and defects, including entanglement of carbon nanotubes and fused contacts, that are understood...working distance, and spot size, 2.5) of MWCNT array batch of which the composite was made and tested: (a) Entanglements of Individual Nanotubes...electron, photon and phonon) in these materials is critical to their reliable and robust performance, thus accommodating denser circuits 2 and higher

Thermal-Structural Optimization of Integrated Cryogenic Propellant Tank Concepts for a Reusable Launch Vehicle

NASA Technical Reports Server (NTRS)

Johnson, Theodore F.; Waters, W. Allen; Singer, Thomas N.; Haftka, Raphael T.

2004-01-01

A next generation reusable launch vehicle (RLV) will require thermally efficient and light-weight cryogenic propellant tank structures. Since these tanks will be weight-critical, analytical tools must be developed to aid in sizing the thickness of insulation layers and structural geometry for optimal performance. Finite element method (FEM) models of the tank and insulation layers were created to analyze the thermal performance of the cryogenic insulation layer and thermal protection system (TPS) of the tanks. The thermal conditions of ground-hold and re-entry/soak-through for a typical RLV mission were used in the thermal sizing study. A general-purpose nonlinear FEM analysis code, capable of using temperature and pressure dependent material properties, was used as the thermal analysis code. Mechanical loads from ground handling and proof-pressure testing were used to size the structural geometry of an aluminum cryogenic tank wall. Nonlinear deterministic optimization and reliability optimization techniques were the analytical tools used to size the geometry of the isogrid stiffeners and thickness of the skin. The results from the sizing study indicate that a commercial FEM code can be used for thermal analyses to size the insulation thicknesses where the temperature and pressure were varied. The results from the structural sizing study show that using combined deterministic and reliability optimization techniques can obtain alternate and lighter designs than the designs obtained from deterministic optimization methods alone.

Thermal System Upgrade of the Space Environment Simulation Test Chamber

NASA Technical Reports Server (NTRS)

Desai, Ashok B.

1997-01-01

The paper deals with the refurbishing and upgrade of the thermal system for the existing thermal vacuum test facility, the Space Environment Simulator, at NASA's Goddard Space Flight Center. The chamber is the largest such facility at the center. This upgrade is the third phase of the long range upgrade of the chamber that has been underway for last few years. The first phase dealt with its vacuum system, the second phase involved the GHe subsystem. The paper describes the considerations of design philosophy options for the thermal system; approaches taken and methodology applied, in the evaluation of the remaining "life" in the chamber shrouds and related equipment by conducting special tests and studies; feasibility and extent of automation, using computer interfaces and Programmable Logic Controllers in the control system and finally, matching the old components to the new ones into an integrated, highly reliable and cost effective thermal system for the facility. This is a multi-year project just started and the paper deals mainly with the plans and approaches to implement the project successfully within schedule and costs.

Lightweight thermally efficient composite feedlines for the space tug cryogenic propulsion system

NASA Technical Reports Server (NTRS)

Spond, D. E.

1975-01-01

Six liquid hydrogen feedline design concepts were developed for the cryogenic space tug. The feedlines include composite and all-metal vacuum jacketed and nonvacuum jacketed concepts, and incorporate the latest technological developments in the areas of thermally efficient vacuum jacket end closures and standoffs, radiation shields in the vacuum annulus, thermal coatings, and lightweight dissimilar metal flanged joints. The feedline design concepts are evaluated on the basis of thermal performance, weight, cost, reliability, and reusability. Design concepts were proved in a subscale test program. Detail design was completed on the most promising composite feedline concept and an all-metal feedline. Three full scale curved composite feedlines and one all-metal feedline assembly were fabricated and subjected to a test program representative of flight hardware qualification. The test results show that composite feedline technology is fully developed. Composite feedlines are ready for space vehicle application and offer significant reduction in weights over the conventional all-metal feedlines presently used.

Detection of impact damage on thermal protection systems using thin-film piezoelectric sensors for integrated structural health monitoring

NASA Astrophysics Data System (ADS)

Na, Jeong K.; Kuhr, Samuel J.; Jata, Kumar V.

2008-03-01

Thermal Protection Systems (TPS) can be subjected to impact damage during flight and/or during ground maintenance and/or repair. AFRL/RXLP is developing a reliable and robust on-board sensing/monitoring capability for next generation thermal protection systems to detect and assess impact damage. This study was focused on two classes of metallic thermal protection tiles to determine threshold for impact damage and develop sensing capability of the impacts. Sensors made of PVDF piezoelectric film were employed and tested to evaluate the detectability of impact signals and assess the onset or threshold of impact damage. Testing was performed over a range of impact energy levels, where the sensors were adhered to the back of the specimens. The PVDF signal levels were analyzed and compared to assess damage, where digital microscopy, visual inspection, and white light interferometry were used for damage verification. Based on the impact test results, an assessment of the impact damage thresholds for each type of metallic TPS system was made.

Thickness measurement by two-sided step-heating thermal imaging

NASA Astrophysics Data System (ADS)

Li, Xiaoli; Tao, Ning; Sun, J. G.; Zhang, Cunlin; Zhao, Yuejin

2018-01-01

Infrared thermal imaging is a promising nondestructive technique for thickness prediction. However, it is usually thought to be only appropriate for testing the thickness of thin objects or near-surface structures. In this study, we present a new two-sided step-heating thermal imaging method which employed a low-cost portable halogen lamp as the heating source and verified it with two stainless steel step wedges with thicknesses ranging from 5 mm to 24 mm. We first derived the one-dimensional step-heating thermography theory with the consideration of warm-up time of the lamp, and then applied the nonlinear regression method to fit the experimental data by the derived function to determine the thickness. After evaluating the reliability and accuracy of the experimental results, we concluded that this method is capable of testing thick objects. In addition, we provided the criterions for both the required data length and the applicable thickness range of the testing material. It is evident that this method will broaden the thermal imaging application for thickness measurement.

26th Space Simulation Conference Proceedings. Environmental Testing: The Path Forward

NASA Technical Reports Server (NTRS)

Packard, Edward A.

2010-01-01

Topics covered include: A Multifunctional Space Environment Simulation Facility for Accelerated Spacecraft Materials Testing; Exposure of Spacecraft Surface Coatings in a Simulated GEO Radiation Environment; Gravity-Offloading System for Large-Displacement Ground Testing of Spacecraft Mechanisms; Microscopic Shutters Controlled by cRIO in Sounding Rocket; Application of a Physics-Based Stabilization Criterion to Flight System Thermal Testing; Upgrade of a Thermal Vacuum Chamber for 20 Kelvin Operations; A New Approach to Improve the Uniformity of Solar Simulator; A Perfect Space Simulation Storm; A Planetary Environmental Simulator/Test Facility; Collimation Mirror Segment Refurbishment inside ESA s Large Space; Space Simulation of the CBERS 3 and 4 Satellite Thermal Model in the New Brazilian 6x8m Thermal Vacuum Chamber; The Certification of Environmental Chambers for Testing Flight Hardware; Space Systems Environmental Test Facility Database (SSETFD), Website Development Status; Wallops Flight Facility: Current and Future Test Capabilities for Suborbital and Orbital Projects; Force Limited Vibration Testing of JWST NIRSpec Instrument Using Strain Gages; Investigation of Acoustic Field Uniformity in Direct Field Acoustic Testing; Recent Developments in Direct Field Acoustic Testing; Assembly, Integration and Test Centre in Malaysia: Integration between Building Construction Works and Equipment Installation; Complex Ground Support Equipment for Satellite Thermal Vacuum Test; Effect of Charging Electron Exposure on 1064nm Transmission through Bare Sapphire Optics and SiO2 over HfO2 AR-Coated Sapphire Optics; Environmental Testing Activities and Capabilities for Turkish Space Industry; Integrated Circuit Reliability Simulation in Space Environments; Micrometeoroid Impacts and Optical Scatter in Space Environment; Overcoming Unintended Consequences of Ambient Pressure Thermal Cycling Environmental Tests; Performance and Functionality Improvements to Next Generation Thermal Vacuum Control System; Robotic Lunar Lander Development Project: Three-Dimensional Dynamic Stability Testing and Analysis; Thermal Physical Properties of Thermal Coatings for Spacecraft in Wide Range of Environmental Conditions: Experimental and Theoretical Study; Molecular Contamination Generated in Thermal Vacuum Chambers; Preventing Cross Contamination of Hardware in Thermal Vacuum Chambers; Towards Validation of Particulate Transport Code; Updated Trends in Materials' Outgassing Technology; Electrical Power and Data Acquisition Setup for the CBER 3 and 4 Satellite TBT; Method of Obtaining High Resolution Intrinsic Wire Boom Damping Parameters for Multi-Body Dynamics Simulations; and Thermal Vacuum Testing with Scalable Software Developed In-House.

Thermal Mechanical Stability of Single-Crystal-Oxide Refractive Concentrators Evaluated for High-Temperature Solar-Thermal Propulsion

NASA Technical Reports Server (NTRS)

Jacobson, Nathan S.; Jacobson, Nathan S.; Miller, Robert A.

1999-01-01

Recently, refractive secondary solar concentrator systems were developed for solar thermal power and propulsion (ref. 1). Single-crystal oxides-such as yttria-stabilized zirconia (Y2O3-ZrO2), yttrium aluminum garnet (Y3Al5O12, or YAG), magnesium oxide (MgO), and sapphire (Al2O3)-are candidate refractive secondary concentrator materials. However, the refractive concentrator system will experience high-temperature thermal cycling in the solar thermal engine during the sun/shade transition of a space mission. The thermal mechanical reliability of these components in severe thermal environments is of great concern. Simulated mission tests are important for evaluating these candidate oxide materials under a variety of transient and steady-state heat flux conditions. In this research at the NASA Lewis Research Center, a controlled heat flux test approach was developed for investigating the thermal mechanical stability of the candidate oxide. This approach used a 3.0-kW continuous-wave (wavelength, 10.6 mm) carbon dioxide (CO2) laser (ref. 2). The CO2 laser is especially well-suited for single-crystal thermal shock tests because it can directly deliver well-characterized heat energy to the oxide surfaces. Since the oxides are opaque at the 10.6-mm wavelength of the laser beam, the light energy is absorbed at the surfaces rather than transmitting into the crystals, and thus generates the required temperature gradients within the specimens. The following figure is a schematic diagram of the test rig.

Thermal cycling test results of CSP and RF assemblies

NASA Technical Reports Server (NTRS)

Ghaffarian, R.; Nelson, G.; Cooper, M.; Lam, D.; Strudler, S.; Umdekar, A.; Selk, K.; Bjorndahl, B.; Duprey, R.

2000-01-01

A JPL-led chip scale package (CSP) Consortium of enterprises, composed of representing agencies and private companies, recently joined together to pool in-kind resources for developing the quality and reliability of chip scale packages (CSPs) for a variety of projects.

Reliability testing of the Hughes temperature controlled 1/4 watt split cycle cryogenic cooler (HD-1045 (V)/UA)

NASA Astrophysics Data System (ADS)

Shaffer, James; Dunmire, Howard; Samuels, Raemon; Trively, Martin

1989-12-01

The U.S. Army CECOM Center for Night Vision and Electro-Optics (C2NVEO) is responsible for developing cryogenic coolers for all infrared imaging systems for the Army. C2NVEO also maintains configuration management control of the forward-looking infrared (FLIR) Common Module coolers used in thermal imagers in fielded Army weapon systems such as: M60A3 and M1 Tanks, Bradley Fighting Vehicle (BFV) System, tube-launched, optically tracked, wire-guided (TOW) Missile System, and Army Attack Helicopters. Currently, there are over 30,000 coolers in fielded systems and several thousand more are added each year. C2NVEO conducts development programs and monitors contractor internal research and development efforts to improve cooler performance such as reliability, audio noise, power consumption, and output vibration. The HD-1045 1/4-Watt Split Stirling Cooler was originally designed and developed by the C2NVEO in the early 1970s as a replacement for the gas bottle/cryostat used on the Manportable Common Thermal Night Sights. To date, however, the HD-1045 cooler has been used in the field in the Integrated Sight Unit (ISU) of the BFV System and is currently being used in the Driver Thermal Viewer (DTV) full scale development program. This document describes and reports the results of reliability testing done on Hughes Temperature Controlled 1/4 Watt split Cycle Cryogenic Coolers (HD-1045 (V)/UA), referred to herein as the coolers.

Hollow cathode heater development for the Space Station plasma contactor

NASA Technical Reports Server (NTRS)

Soulas, George C.

1993-01-01

A hollow cathode-based plasma contactor has been selected for use on the Space Station. During the operation of the plasma contactor, the hollow cathode heater will endure approximately 12000 thermal cycles. Since a hollow cathode heater failure would result in a plasma contactor failure, a hollow cathode heater development program was established to produce a reliable heater design. The development program includes the heater design, process documents for both heater fabrication and assembly, and heater testing. The heater design was a modification of a sheathed ion thruster cathode heater. Three heaters have been tested to date using direct current power supplies. Performance testing was conducted to determine input current and power requirements for achieving activation and ignition temperatures, single unit operational repeatability, and unit-to-unit operational repeatability. Comparisons of performance testing data at the ignition input current level for the three heaters show the unit-to-unit repeatability of input power and tube temperature near the cathode tip to be within 3.5 W and 44 degrees C, respectively. Cyclic testing was then conducted to evaluate reliability under thermal cycling. The first heater, although damaged during assembly, completed 5985 ignition cycles before failing. Two additional heaters were subsequently fabricated and have completed 3178 cycles to date in an on-going test.

Thick thermal barrier coatings for diesel engines

NASA Technical Reports Server (NTRS)

Beardsley, M. Brad

1995-01-01

Caterpillar's approach to applying thick thermal barrier coatings (TTBC's) to diesel engine combustion chambers has been to use advanced modeling techniques to predict engine conditions and combine this information with fundamental property evaluation of TTBC systems to predict engine performance and TTBC stress states. Engine testing has been used to verify the predicted performance of the TTBC systems and provide information on failure mechanisms. The objective Caterpillar's program to date has been to advance the fundamental understanding of thick thermal barrier coating systems. Previous reviews of thermal barrier coating technology concluded that the current level of understanding of coating system behavior is inadequate and the lack of fundamental understanding may impeded the application of TTBC's to diesel engines. Areas of TTBC technology being examined in this program include powder characteristics and chemistry; bond coat composition; coating design, microstructure, and thickness as they affect properties, durability, and reliability; and TTBC 'aging' effects (microstructural and property changes) under diesel engine operating conditions. Methods to evaluate the reliability and durability of TTBC's have been developed that attempt to understand the fundamental strength of TTBC's for particular stress states.

Thick thermal barrier coatings for diesel engines

NASA Technical Reports Server (NTRS)

Beardsley, M. B.

1995-01-01

Caterpillar's approach to applying Thick Thermal Barrier Coatings (TTBC's) to diesel engine combustion chambers has been to use advanced modeling techniques to predict engine conditions and combine this information with fundamental property evaluation of TTBC systems to predict engine performance and TTBC stress states. Engine testing has been used to verify the predicted performance of the TTBC systems and provide information on failure mechanisms. The objective of Caterpillar's subcontract with ORNL is to advance the fundamental understanding of thick thermal barrier coating systems. Previous reviews of thermal barrier coating technology concluded that the current level of understanding of coating system behavior is inadequate and the lack of fundamental understanding may impede the application of TTBC's to diesel engines. Areas of TTBC technology being examined in this program include powder characteristics and chemistry; bond coat composition; coating design, microstructure, and thickness as they affect properties, durability, and reliability; and TTBC 'aging' effects (microstructural and property changes) under diesel engine operating conditions. Methods to evaluate the reliability and durability of TTBC's have been developed that attempt to understand the fundamental strength of TTBC's for particular stress states.

Application of Thermo-Mechanical Measurements of Plastic Packages for Reliability Evaluation of PEMS

NASA Technical Reports Server (NTRS)

Sharma, Ashok K.; Teverovsky, Alexander

2004-01-01

Thermo-mechanical analysis (TMA) is typically employed for measurements of the glass transition temperature (Tg) and coefficients of thermal expansion (CTE) in molding compounds used in plastic encapsulated microcircuits (PEMs). Application of TMA measurements directly to PEMs allows anomalies to be revealed in deformation of packages with temperature, and thus indicates possible reliability concerns related to thermo-mechanical integrity and stability of the devices. In this work, temperature dependencies of package deformation were measured in several types of PEMs that failed environmental stress testing including temperature cycling, highly accelerated stress testing (HAST) in humid environments, and bum-in (BI) testing. Comparison of thermo-mechanical characteristics of packages and molding compounds in the failed parts allowed for explanation of the observed failures. The results indicate that TMA of plastic packages might be used for quality evaluation of PEMs intended for high-reliability applications.

Ceramic Technology for Advanced Heat Engines Project. Semiannual progress report, October 1984-March 1985

DOE Office of Scientific and Technical Information (OSTI.GOV)

Not Available

1985-09-01

A five-year project plan was developed with extensive input from private industry. The objective of the project is to develop the industrial technology base required for reliable ceramics for application in advanced automotive heat engines. The project approach includes determining the mechanisms controlling reliability, improving processes for fabricating existing ceramics, developing new materials with increased reliability, and testing these materials in simulated engine environments to confirm reliability. Although this is a generic materials project, the focus is on structural ceramics for advanced gas turbine and diesel engines, ceramic bearings and attachments, and ceramic coatings for thermal barrier and wear applicationsmore » in these engines.« less

Ceramic technology for advanced heat engines project: Semiannual progress report for April through September 1986

DOE Office of Scientific and Technical Information (OSTI.GOV)

Not Available

1987-03-01

An assessment of needs was completed, and a five-year project plan was developed with extensive input from private industry. Objective is to develop the industrial technology base required for reliable ceramics for application in advanced automotive heat engines. The project approach includes determining the mechanisms controlling reliability, improving processes for fabricating existing ceramics, developing new materials with increased reliability, and testing these materials in simulated engine environments to confirm reliability. Although this is a generic materials project, the focus is on structural ceramics for advanced gas turbine and diesel engines, ceramic bearings and attachments, and ceramic coatings for thermal barriermore » and wear applications in these engines.« less

Superconducting magnet and cryostat for a space application

NASA Technical Reports Server (NTRS)

Pope, W. L.; Smoot, G. F.; Smith, L. H.; Taylor, C. E.

1975-01-01

The paper describes the design concepts, development, and testing of a superconducting coil and cryostat for an orbiting superconducting magnetic spectrometer. Several coils were subject to overall thermal performance and coil charging tests. The coils have low but persistent currents and have proven themselves to be rugged and reliable for mobile balloon flights. Satellite experiments will be conducted on a new, similar design.

DOE Office of Scientific and Technical Information (OSTI.GOV)

West, W.S.

Progress during the period includes completion of the SNAP 7C system tests, completion of safety analysis for the SNAP 7A and C systems, assembly and initial testing of SNAP 7A, assembly of a modified reliability model, and assembly of a 10-W generator. Other activities include completion of thermal and safety analyses for SNAP 7B and D generators and fuel processing for these generators. (J.R.D.)

Explosives for Lunar Seismic Profiling Experiment (LSPE)

NASA Technical Reports Server (NTRS)

1973-01-01

Explosive charges of various sizes were investigated for use in lunar seismic studies. Program logistics, and the specifications for procurement of bulk explosives are described. The differential analysis, thermal properties, and detonation velocity measurements on HNS/Teflon 7C 90/10 are reported along with the field tests of the hardware. It is concluded that nearly all large explosive charges crack after fabrication, from aging or thermal shock. The cracks do not affect the safety, or reliability of the explosives.

Accelerated stress testing of terrestrial solar cells

NASA Technical Reports Server (NTRS)

Lathrop, J. W.; Hawkins, D. C.; Prince, J. L.; Walker, H. A.

1982-01-01

The development of an accelerated test schedule for terrestrial solar cells is described. This schedule, based on anticipated failure modes deduced from a consideration of IC failure mechanisms, involves bias-temperature testing, humidity testing (including both 85-85 and pressure cooker stress), and thermal-cycle thermal-shock testing. Results are described for 12 different unencapsulated cell types. Both gradual electrical degradation and sudden catastrophic mechanical change were observed. These effects can be used to discriminate between cell types and technologies relative to their reliability attributes. Consideration is given to identifying laboratory failure modes which might lead to severe degradation in the field through second quadrant operation. Test results indicate that the ability of most cell types to withstand accelerated stress testing depends more on the manufacturer's design, processing, and worksmanship than on the particular metallization system. Preliminary tests comparing accelerated test results on encapsulated and unencapsulated cells are described.

Status of Hollow Cathode Heater Development for the Space Station Plasma Contactor

NASA Technical Reports Server (NTRS)

Soulas, George C.

1994-01-01

A hollow cathode-based plasma contactor has been selected for use on the Space Station. During the operation of the plasma contactor, the hollow cathode heater will endure approximately 12000 thermal cycles. Since a hollow cathode heater failure would result in a plasma contactor failure, a hollow cathode heater development program was established to produce a reliable heater. The development program includes the heater design, process documents for both heater fabrication and assembly, and heater testing. The heater design was a modification of a sheathed ion thruster cathode heater. Heater tests included testing of the heater unit alone and plasma contactor and ion thruster testing. To date, eight heaters have been or are being processed through heater unit testing, two through plasma contactor testing and three through ion thruster testing, all using direct current power supplies. Comparisons of data from heater unit performance tests before cyclic testing, plasma contactor tests, and ion thruster tests at the ignition input current level show the average deviation of input power and tube temperature near the cathode tip to be +/-0.9 W and +/- 21 C, respectively. Heater unit testing included cyclic testing to evaluate reliability under thermal cycling. The first heater, although damaged during assembly, completed 5985 ignition cycles before failing. Four additional heaters successfully completed 6300, 6300, 700, and 700 cycles. Heater unit testing is currently ongoing for three heaters which have to date accumulated greater than 7250, greater than 5500, and greater than 5500 cycles, respectively.

Simulation and test of the thermal behavior of pressure switch

NASA Astrophysics Data System (ADS)

Liu, Yifang; Chen, Daner; Zhang, Yao; Dai, Tingting

2018-04-01

Little, lightweight, low-power microelectromechanical system (MEMS) pressure switches offer a good development prospect for small, ultra-long, simple atmosphere environments. In order to realize MEMS pressure switch, it is necessary to solve one of the key technologies such as thermal robust optimization. The finite element simulation software is used to analyze the thermal behavior of the pressure switch and the deformation law of the pressure switch film under different temperature. The thermal stress releasing schemes are studied by changing the structure of fixed form and changing the thickness of the substrate, respectively. Finally, the design of the glass substrate thickness of 2.5 mm is used to ensure that the maximum equivalent stress is reduced to a quarter of the original value, only 154 MPa when the structure is in extreme temperature (80∘C). The test results show that after the pressure switch is thermally optimized, the upper and lower electrodes can be reliably contacted to accommodate different operating temperature environments.

Thermal Performance Testing of EMU and CSAFE Liquid Cooling Gannents

NASA Technical Reports Server (NTRS)

Rhodes, Richard; Bue, Grant; Meginnis, Ian; Hakam, Mary; Radford, Tamara

2013-01-01

Future exploration missions require the development of a new liquid cooling garment (LCG) to support the next generation extravehicular activity (EVA) suit system. The new LCG must offer greater system reliability, optimal thermal performance as required by mission directive, and meet other design requirements including improved tactile comfort. To advance the development of a future LCG, a thermal performance test was conducted to evaluate: (1) the comparable thermal performance of the EMU LCG and the CSAFE developed engineering evaluation unit (EEU) LCG, (2) the effect of the thermal comfort undergarment (TCU) on the EMU LCG tactile and thermal comfort, and (3) the performance of a torso or upper body only LCG shirt to evaluate a proposed auxiliary loop. To evaluate the thermal performance of each configuration, a metabolic test was conducted using the Demonstrator Spacesuit to create a relevant test environment. Three (3) male test subjects of similar height and weight walked on a treadmill at various speeds to produce three different metabolic loads - resting (300-600 BTU/hr), walking at a slow pace (1200 BTU/hr), and walking at a brisk pace (2200 BTU/hr). Each subject participated in five tests - two wearing the CSAFE full LCG, one wearing the EMU LCG without TCUs, one wearing the EMU LCG with TCUs, and one with the CSAFE shirt-only. During the test, performance data for the breathing air and cooling water systems and subject specific data was collected to define the thermal performance of the configurations. The test results show that the CSAFE EEU LCG and EMU LCG with TCU had comparable performance. The testing also showed that an auxiliary loop LCG, sized similarly to the shirt-only configuration, should provide adequate cooling for contingency scenarios. Finally, the testing showed that the TCU did not significantly hinder LCG heat transfer, and may prove to be acceptable for future suit use with additional analysis and testing.

Multi-Evaporator Miniature Loop Heat Pipe for Small Spacecraft Thermal Control. Part 2; Validation Results

NASA Technical Reports Server (NTRS)

Ku, Jentung; Ottenstein, Laura; Douglas, Donya; Hoang, Triem

2010-01-01

Under NASA s New Millennium Program Space Technology 8 (ST 8) Project, Goddard Space Fight Center has conducted a Thermal Loop experiment to advance the maturity of the Thermal Loop technology from proof of concept to prototype demonstration in a relevant environment , i.e. from a technology readiness level (TRL) of 3 to a level of 6. The thermal Loop is an advanced thermal control system consisting of a miniature loop heat pipe (MLHP) with multiple evaporators and multiple condensers designed for future small system applications requiring low mass, low power, and compactness. The MLHP retains all features of state-of-the-art loop heat pipes (LHPs) and offers additional advantages to enhance the functionality, performance, versatility, and reliability of the system. An MLHP breadboard was built and tested in the laboratory and thermal vacuum environments for the TRL 4 and TRL 5 validations, respectively, and an MLHP proto-flight unit was built and tested in a thermal vacuum chamber for the TRL 6 validation. In addition, an analytical model was developed to simulate the steady state and transient behaviors of the MLHP during various validation tests. The MLHP demonstrated excellent performance during experimental tests and the analytical model predictions agreed very well with experimental data. All success criteria at various TRLs were met. Hence, the Thermal Loop technology has reached a TRL of 6. This paper presents the validation results, both experimental and analytical, of such a technology development effort.

Microcoil Spring Interconnects for Ceramic Grid Array Integrated Circuits

NASA Technical Reports Server (NTRS)

Strickland, S. M.; Hester, J. D.; Gowan, A. K.; Montgomery, R. K.; Geist, D. L.; Blanche, J. F.; McGuire, G. D.; Nash, T. S.

2011-01-01

As integrated circuit miniaturization trends continue, they drive the need for smaller higher input/output (I/O) packages. Hermetically sealed ceramic area array parts are the package of choice by the space community for high reliability space flight electronic hardware. Unfortunately, the coefficient of thermal expansion mismatch between the ceramic area array package and the epoxy glass printed wiring board limits the life of the interconnecting solder joint. This work presents the results of an investigation by Marshall Space Flight Center into a method to increase the life of this second level interconnection by the use of compliant microcoil springs. The design of the spring and its attachment process are presented along with thermal cycling results of microcoil springs (MCS) compared with state-of-the-art ball and column interconnections. Vibration testing has been conducted on MCS and high lead column parts. Radio frequency simulation and measurements have been made and the MCS has been modeled and a stress analysis performed. Thermal cycling and vibration testing have shown MCS interconnects to be significantly more reliable than solder columns. Also, MCS interconnects are less prone to handling damage than solder columns. Future work that includes shock testing, incorporation into a digital signal processor board, and process evaluation of expansion from a 400 I/O device to a device with over 1,100 I/O is identified.

Cryogenic insulation standard data and methodologies

NASA Astrophysics Data System (ADS)

Demko, J. A.; Fesmire, J. E.; Johnson, W. L.; Swanger, A. M.

2014-01-01

Although some standards exist for thermal insulation, few address the sub-ambient temperature range and cold-side temperatures below 100 K. Standards for cryogenic insulation systems require cryostat testing and data analysis that will allow the development of the tools needed by design engineers and thermal analysts for the design of practical cryogenic systems. Thus, this critically important information can provide reliable data and methodologies for industrial efficiency and energy conservation. Two Task Groups have been established in the area of cryogenic insulation systems Under ASTM International's Committee C16 on Thermal Insulation. These are WK29609 - New Standard for Thermal Performance Testing of Cryogenic Insulation Systems and WK29608 - Standard Practice for Multilayer Insulation in Cryogenic Service. The Cryogenics Test Laboratory of NASA Kennedy Space Center and the Thermal Energy Laboratory of LeTourneau University are conducting Inter-Laboratory Study (ILS) of selected insulation materials. Each lab carries out the measurements of thermal properties of these materials using identical flat-plate boil-off calorimeter instruments. Parallel testing will provide the comparisons necessary to validate the measurements and methodologies. Here we discuss test methods, some initial data in relation to the experimental approach, and the manner reporting the thermal performance data. This initial study of insulation materials for sub-ambient temperature applications is aimed at paving the way for further ILS comparative efforts that will produce standard data sets for several commercial materials. Discrepancies found between measurements will be used to improve the testing and data reduction techniques being developed as part of the future ASTM International standards.

An accurate and reliable method of thermal data analysis in thermal imaging of the anterior knee for use in cryotherapy research.

PubMed

Selfe, James; Hardaker, Natalie; Thewlis, Dominic; Karki, Anna

2006-12-01

To develop an anatomic marker system (AMS) as an accurate, reliable method of thermal imaging data analysis, for use in cryotherapy research. Investigation of the accuracy of new thermal imaging technique. Hospital orthopedic outpatient department in England. Consecutive sample of 9 patients referred to anterior knee pain clinic. Not applicable. Thermally inert markers were placed at specific anatomic locations, defining an area over the anterior knee of patients with anterior knee pain. A baseline thermal image was taken. Patients underwent a 3-minute thermal washout of the affected knee. Thermal images were collected at a rate of 1 image per minute for a 20-minute re-warming period. A Matlab (version 7.0) program was written to digitize the marker positions and subsequently calculate the mean of the area over the anterior knee. Virtual markers were then defined as 15% distal from the proximal marker, 30% proximal from the distal markers, 15% lateral from the medial marker, and 15% medial from the lateral marker. The virtual markers formed an ellipse, which defined an area representative of the patella shape. Within the ellipse, the mean value of the full pixels determined the mean temperature of this region. Ten raters were recruited to use the program and interrater reliability was investigated. The intraclass correlation coefficient produced coefficients within acceptable bounds, ranging from .82 to .97, indicating adequate interrater reliability. The AMS provides an accurate, reliable method for thermal imaging data analysis and is a reliable tool with which to advance cryotherapy research.

Reliability of CCGA 1152 and CCGA 1272 Interconnect Packages for Extreme Thermal Environments

NASA Technical Reports Server (NTRS)

Ramesham, Rajeshuni

2013-01-01

Ceramic column grid array (CCGA) packages have been increasing in use based on their advantages of high interconnect density, very good thermal and electrical performance, and compatibility with standard surface-mount packaging assembly processes. CCGA packages are used in space applications such as in logics and microprocessor functions, telecommunications, flight avionics, and payload electronics. As these packages tend to have less solder joint strain relief than leaded packages, the reliability of CCGA packages is very important for short- and long-term space missions. Certain planetary satellites require operations of thermally uncontrolled hardware under extremely cold and hot temperatures with large diurnal temperature change from day to night. The planetary protection requires the hardware to be baked at +125 C for 72 hours to kill microbugs to avoid any biological contamination, especially for sample return missions. Therefore, the present CCGA package reliability research study has encompassed the temperature range of 185 to +125 C to cover various NASA deep space missions. Advanced 1152 and 1272 CCGA packaging interconnects technology test hardware objects have been subjected to ex treme temperature thermal cycles from 185 to +125 C. X-ray inspections of CCGA packages have been made before thermal cycling. No anomalous behavior and process problems were observed in the x-ray images. The change in resistance of the daisy-chained CCGA interconnects was measured as a function of increasing number of thermal cycles. Electrical continuity measurements of daisy chains have shown no anomalies, even until 596 thermal cycles. Optical inspections of hardware have shown a significant fatigue for CCGA 1152 packages over CCGA 1272 packages. No catastrophic failures have been observed yet in the results. Process qualification and assembly are required to optimize the CCGA assembly processes. Optical inspections of CCGA boards have been made after 258 and 596 thermal cycles. Corner columns have started showing significant fatigue per optical inspection results.

Quantitative Accelerated Life Testing of MEMS Accelerometers.

PubMed

Bâzu, Marius; Gălăţeanu, Lucian; Ilian, Virgil Emil; Loicq, Jerome; Habraken, Serge; Collette, Jean-Paul

2007-11-20

Quantitative Accelerated Life Testing (QALT) is a solution for assessing thereliability of Micro Electro Mechanical Systems (MEMS). A procedure for QALT is shownin this paper and an attempt to assess the reliability level for a batch of MEMSaccelerometers is reported. The testing plan is application-driven and contains combinedtests: thermal (high temperature) and mechanical stress. Two variants of mechanical stressare used: vibration (at a fixed frequency) and tilting. Original equipment for testing at tiltingand high temperature is used. Tilting is appropriate as application-driven stress, because thetilt movement is a natural environment for devices used for automotive and aerospaceapplications. Also, tilting is used by MEMS accelerometers for anti-theft systems. The testresults demonstrated the excellent reliability of the studied devices, the failure rate in the"worst case" being smaller than 10 -7 h -1 .

Multi-Evaporator Miniature Loop Heat Pipe for Small Spacecraft Thermal Control

NASA Technical Reports Server (NTRS)

Ku, Jentung; Ottenstein, Laura; Douglas, Donya

2008-01-01

This paper presents the development of the Thermal Loop experiment under NASA's New Millennium Program Space Technology 8 (ST8) Project. The Thermal Loop experiment was originally planned for validating in space an advanced heat transport system consisting of a miniature loop heat pipe (MLHP) with multiple evaporators and multiple condensers. Details of the thermal loop concept, technical advances and benefits, Level 1 requirements and the technology validation approach are described. An MLHP breadboard has been built and tested in the laboratory and thermal vacuum environments, and has demonstrated excellent performance that met or exceeded the design requirements. The MLHP retains all features of state-of-the-art loop heat pipes and offers additional advantages to enhance the functionality, performance, versatility, and reliability of the system. In addition, an analytical model has been developed to simulate the steady state and transient operation of the MHLP, and the model predictions agreed very well with experimental results. A protoflight MLHP has been built and is being tested in a thermal vacuum chamber to validate its performance and technical readiness for a flight experiment.

Thermophysical and Thermomechanical Properties of Thermal Barrier Coating Systems

NASA Technical Reports Server (NTRS)

Zhu, Dongming; Miller, Robert A.

2000-01-01

Thermal barrier coatings have been developed for advanced gas turbine and diesel engine applications to improve engine reliability and fuel efficiency. However, the issue of coating durability under high temperature cyclic conditions is still of major concern. The coating failure is closely related to thermal stresses and oxidation in the coating systems. Coating shrinkage cracking resulting from ceramic sintering and creep at high temperatures can further accelerate the coating failure process. The purpose of this paper is to address critical issues such as ceramic sintering and creep, thermal fatigue and their relevance to coating life prediction. Novel test approaches have been established to obtain critical thermophysical and thermomechanical properties of the coating systems under near-realistic temperature and stress gradients encountered in advanced engine systems. Emphasis is placed on the dynamic changes of the coating thermal conductivity and elastic modulus, fatigue and creep interactions, and resulting failure mechanisms during the simulated engine tests. Detailed experimental and modeling results describing processes occurring in the thermal barrier coating systems provide a framework for developing strategies to manage ceramic coating architecture, microstructure and properties.

Development of a prototype two-phase thermal bus system for Space Station

NASA Technical Reports Server (NTRS)

Myron, D. L.; Parish, R. C.

1987-01-01

This paper describes the basic elements of a pumped two-phase ammonia thermal control system designed for microgravity environments, the development of the concept into a Space Station flight design, and design details of the prototype to be ground-tested in the Johnson Space Center (JSC) Thermal Test Bed. The basic system concept is one of forced-flow heat transport through interface heat exchangers with anhydrous ammonia being pumped by a device expressly designed for two-phase fluid management in reduced gravity. Control of saturation conditions, and thus system interface temperatures, is accomplished with a single central pressure regulating valve. Flow control and liquid inventory are controlled by passive, nonelectromechanical devices. Use of these simple control elements results in minimal computer controls and high system reliability. Building on the basic system concept, a brief overview of a potential Space Station flight design is given. Primary verification of the system concept will involve testing at JSC of a 25-kW ground test article currently in fabrication.

Reliability Quantification of Advanced Stirling Convertor (ASC) Components

NASA Technical Reports Server (NTRS)

Shah, Ashwin R.; Korovaichuk, Igor; Zampino, Edward

2010-01-01

The Advanced Stirling Convertor, is intended to provide power for an unmanned planetary spacecraft and has an operational life requirement of 17 years. Over this 17 year mission, the ASC must provide power with desired performance and efficiency and require no corrective maintenance. Reliability demonstration testing for the ASC was found to be very limited due to schedule and resource constraints. Reliability demonstration must involve the application of analysis, system and component level testing, and simulation models, taken collectively. Therefore, computer simulation with limited test data verification is a viable approach to assess the reliability of ASC components. This approach is based on physics-of-failure mechanisms and involves the relationship among the design variables based on physics, mechanics, material behavior models, interaction of different components and their respective disciplines such as structures, materials, fluid, thermal, mechanical, electrical, etc. In addition, these models are based on the available test data, which can be updated, and analysis refined as more data and information becomes available. The failure mechanisms and causes of failure are included in the analysis, especially in light of the new information, in order to develop guidelines to improve design reliability and better operating controls to reduce the probability of failure. Quantified reliability assessment based on fundamental physical behavior of components and their relationship with other components has demonstrated itself to be a superior technique to conventional reliability approaches based on utilizing failure rates derived from similar equipment or simply expert judgment.

Phase 1 of the First Small Power System Experiment (engineering Experiment No. 1). Volume 4: Commercial System Definition. [development and testing of a solar thermal power plant

NASA Technical Reports Server (NTRS)

Holl, R. J.

1979-01-01

The development and design of a modular solar thermal power system for application in the 1 to 10 MWe range is described. The system is used in remote utility applications, small communities, rural areas, and for industrial uses. The operational reliability, the minimum risk of failure, and the maintenance and repair characteristics are determined and the commercial system design is defined.

20V, 40 Ah Lithium Ion Polymer Battery for the Spacesuit

NASA Technical Reports Server (NTRS)

Darcy, Eric; Wilburn, Monique; Hall, Dan; Roth, Peter; Das Gupta, Sankar; Jacobs, Jim; Bhola, Rakesh; Milicic, Gordan; Vandemeer, Dave

2006-01-01

Objective: Consider a new battery design for EMU. Results: a) Electrovaya s aerospace cell production line is improving, but must further improve to achieve acceptable reliability; b) Completed functional, vibration, and thermal cycling of LIB; c) So far, electrical safety tests have produced good results; d) Completed functional, vibration, thermal cycling, power quality and EMI of LIB Charger; e) Completed CDR on 9/23/04; and f) Manufacturing Readiness Review for flight cell/battery production scheduled for Dec 04.

Orbit Transfer Vehicle (OTV) engine, phase A study. Volume 2: Study

NASA Technical Reports Server (NTRS)

Mellish, J. A.

1979-01-01

The hydrogen oxygen engine used in the orbiter transfer vehicle is described. The engine design is analyzed and minimum engine performance and man rating requirements are discussed. Reliability and safety analysis test results are presented and payload, risk and cost, and engine installation parameters are defined. Engine tests were performed including performance analysis, structural analysis, thermal analysis, turbomachinery analysis, controls analysis, and cycle analysis.

A Risk-Based Approach for Aerothermal/TPS Analysis and Testing

DTIC Science & Technology

2007-07-01

RTO-EN-AVT-142 17 - 1 A Risk-Based Approach for Aerothermal/ TPS Analysis and Testing Michael J. Wright∗ and Jay H. Grinstead† NASA Ames...of the thermal protection system ( TPS ) is to protect the payload (crew, cargo, or science) from this entry heating environment. The performance of...the TPS is determined by the efficiency and reliability of this system, typically measured

Hydrocarbon Fuel Thermal Performance Modeling based on Systematic Measurement and Comprehensive Chromatographic Analysis

DTIC Science & Technology

2016-07-27

is a common requirement for aircraft, rockets , and hypersonic vehicles. The Aerospace Fuels Quality Test and Model Development (AFQTMoDev) project...was initiated to mature fuel quality assurance practices for rocket grade kerosene, thereby ensuring operational readiness of conventional and...and reliability, is a common requirement for aircraft, rockets , and hypersonic vehicles. The Aerospace Fuels Quality Test and Model Development

Power processor for a 30cm ion thruster

NASA Technical Reports Server (NTRS)

Biess, J. J.; Inouye, L. Y.

1974-01-01

A thermal vacuum power processor for the NASA Lewis 30cm Mercury Ion Engine was designed, fabricated and tested to determine compliance with electrical specifications. The power processor breadboard used the silicon controlled rectifier (SCR) series resonant inverter as the basic power stage to process all the power to an ion engine. The power processor includes a digital interface unit to process all input commands and internal telemetry signals so that operation is compatible with a central computer system. The breadboard was tested in a thermal vacuum environment. Integration tests were performed with the ion engine and demonstrate operational compatibility and reliable operation without any component failures. Electromagnetic interference data were also recorded on the design to provide information on the interaction with total spacecraft.

Capacitor Test, Evaluation. and Modeling Within NASA Electronic Parts and Packaging (NEPP) Program. "Why Ceramic Capacitors Fracture During Manual Soldering and How to Avoid Failures"

NASA Technical Reports Server (NTRS)

Teverovsky, Alexander

2011-01-01

Presentation discusses: (1) Why Multi-Layer Ceramic Capacitors(MLCCs) crack during manual soldering? Workmanship and parts issues. (2) Do existing qualification requirements assure crack-free soldering? MIL-spec Thermal Shock (TS) testing. MIL-spec Resistance to Soldering Heat (RSH) test. (3) What test can assure reliable soldering? Mechanical characteristics of ceramics. Comparison of three TS techniques: LND, TSD, and IWT. (4) Simulation of TS conditions.

A new approach for data acquisition at the JPL space simulators

NASA Technical Reports Server (NTRS)

Fisher, Terry C.

1992-01-01

In 1990, a personal computer based data acquisition system was put into service for the Space Simulators and Environmental Test Laboratory at the Jet Propulsion Laboratory (JPL) in Pasadena, California. The new system replaced an outdated minicomputer system which had been in use since 1980. This new data acquisition system was designed and built by JPL for the specific task of acquiring thermal test data in support of space simulation and thermal vacuum testing at JPL. The data acquisition system was designed using powerful personal computers and local-area-network (LAN) technology. Reliability, expandability, and maintainability were some of the most important criteria in the design of the data system and in the selection of hardware and software components. The data acquisition system is used to record both test chamber operational data and thermal data from the unit under test. Tests are conducted in numerous small thermal vacuum chambers and in the large solar simulator and range in size from individual components using only 2 or 3 thermocouples to entire planetary spacecraft requiring in excess of 1200 channels of test data. The system supports several of these tests running concurrently. The previous data system is described along with reasons for its replacement, the types of data acquired, the new data system, and the benefits obtained from the new system including information on tests performed to date.

Photometric and Colorimetric Assessment of LED Chip Scale Packages by Using a Step-Stress Accelerated Degradation Test (SSADT) Method.

PubMed

Qian, Cheng; Fan, Jiajie; Fang, Jiayi; Yu, Chaohua; Ren, Yi; Fan, Xuejun; Zhang, Guoqi

2017-10-16

By solving the problem of very long test time on reliability qualification for Light-emitting Diode (LED) products, the accelerated degradation test with a thermal overstress at a proper range is regarded as a promising and effective approach. For a comprehensive survey of the application of step-stress accelerated degradation test (SSADT) in LEDs, the thermal, photometric, and colorimetric properties of two types of LED chip scale packages (CSPs), i.e., 4000 °K and 5000 °K samples each of which was driven by two different levels of currents (i.e., 120 mA and 350 mA, respectively), were investigated under an increasing temperature from 55 °C to 150 °C and a systemic study of driving current effect on the SSADT results were also reported in this paper. During SSADT, junction temperatures of the test samples have a positive relationship with their driving currents. However, the temperature-voltage curve, which represents the thermal resistance property of the test samples, does not show significant variance as long as the driving current is no more than the sample's rated current. But when the test sample is tested under an overdrive current, its temperature-voltage curve is observed as obviously shifted to the left when compared to that before SSADT. Similar overdrive current affected the degradation scenario is also found in the attenuation of Spectral Power Distributions (SPDs) of the test samples. As used in the reliability qualification, SSADT provides explicit scenes on color shift and correlated color temperature (CCT) depreciation of the test samples, but not on lumen maintenance depreciation. It is also proved that the varying rates of the color shift and CCT depreciation failures can be effectively accelerated with an increase of the driving current, for instance, from 120 mA to 350 mA. For these reasons, SSADT is considered as a suitable accelerated test method for qualifying these two failure modes of LED CSPs.

Photometric and Colorimetric Assessment of LED Chip Scale Packages by Using a Step-Stress Accelerated Degradation Test (SSADT) Method

PubMed Central

Yu, Chaohua; Fan, Xuejun; Zhang, Guoqi

2017-01-01

By solving the problem of very long test time on reliability qualification for Light-emitting Diode (LED) products, the accelerated degradation test with a thermal overstress at a proper range is regarded as a promising and effective approach. For a comprehensive survey of the application of step-stress accelerated degradation test (SSADT) in LEDs, the thermal, photometric, and colorimetric properties of two types of LED chip scale packages (CSPs), i.e., 4000 °K and 5000 °K samples each of which was driven by two different levels of currents (i.e., 120 mA and 350 mA, respectively), were investigated under an increasing temperature from 55 °C to 150 °C and a systemic study of driving current effect on the SSADT results were also reported in this paper. During SSADT, junction temperatures of the test samples have a positive relationship with their driving currents. However, the temperature-voltage curve, which represents the thermal resistance property of the test samples, does not show significant variance as long as the driving current is no more than the sample’s rated current. But when the test sample is tested under an overdrive current, its temperature-voltage curve is observed as obviously shifted to the left when compared to that before SSADT. Similar overdrive current affected the degradation scenario is also found in the attenuation of Spectral Power Distributions (SPDs) of the test samples. As used in the reliability qualification, SSADT provides explicit scenes on color shift and correlated color temperature (CCT) depreciation of the test samples, but not on lumen maintenance depreciation. It is also proved that the varying rates of the color shift and CCT depreciation failures can be effectively accelerated with an increase of the driving current, for instance, from 120 mA to 350 mA. For these reasons, SSADT is considered as a suitable accelerated test method for qualifying these two failure modes of LED CSPs. PMID:29035300

A Risk-Based Approach for Aerothermal/TPS Analysis and Testing

NASA Technical Reports Server (NTRS)

Wright, Michael J.; Grinstead, Jay H.; Bose, Deepak

2007-01-01

The current status of aerothermal and thermal protection system modeling for civilian entry missions is reviewed. For most such missions, the accuracy of our simulations is limited not by the tools and processes currently employed, but rather by reducible deficiencies in the underlying physical models. Improving the accuracy of and reducing the uncertainties in these models will enable a greater understanding of the system level impacts of a particular thermal protection system and of the system operation and risk over the operational life of the system. A strategic plan will be laid out by which key modeling deficiencies can be identified via mission-specific gap analysis. Once these gaps have been identified, the driving component uncertainties are determined via sensitivity analyses. A Monte-Carlo based methodology is presented for physics-based probabilistic uncertainty analysis of aerothermodynamics and thermal protection system material response modeling. These data are then used to advocate for and plan focused testing aimed at reducing key uncertainties. The results of these tests are used to validate or modify existing physical models. Concurrently, a testing methodology is outlined for thermal protection materials. The proposed approach is based on using the results of uncertainty/sensitivity analyses discussed above to tailor ground testing so as to best identify and quantify system performance and risk drivers. A key component of this testing is understanding the relationship between the test and flight environments. No existing ground test facility can simultaneously replicate all aspects of the flight environment, and therefore good models for traceability to flight are critical to ensure a low risk, high reliability thermal protection system design. Finally, the role of flight testing in the overall thermal protection system development strategy is discussed.

Reliability evaluation of CMOS RAMs

NASA Astrophysics Data System (ADS)

Salvo, C. J.; Sasaki, A. T.

The results of an evaluation of the reliability of a 1K x 1 bit CMOS RAM and a 4K x 1 bit CMOS RAM for the USAF are reported. The tests consisted of temperature cycling, thermal shock, electrical overstress-static discharge and accelerated life test cells. The study indicates that the devices have high reliability potential for military applications. Use-temperature failure rates at 100 C were 0.54 x 10 to the -5th failures/hour for the 1K RAM and 0.21 x 10 to the -5th failures/hour for the 4K RAM. Only minimal electrostatic discharge damage was noted in the devices when they were subjected to multiple pulses at 1000 Vdc, and redesign of the 7 Vdc quiescent parameter of the 4K RAM is expected to raise its field threshold voltage.

Development and Testing of a USM High Altitude Balloon

NASA Astrophysics Data System (ADS)

Thaheer, A. S. Mohamed; Ismail, N. A.; Yusoff, S. H. Md.; Nasirudin, M. A.

2018-04-01

This paper discusses on tests conducted on the component and subsystem level during development of the USM High Altitude Balloon (HAB). The tests conducted by selecting initial components then tested individually based on several case studies such as reliability test, camera viewing, power consumption, thermal capability, and parachute performance. Then, the component is integrated into sub-system level for integration and functionality test. The preliminary result is utilized to tune the components and sub-systems and trial launch is conducted where the sample images are recorded and atmospheric data successfully collected.

Environmental testing of CIS based modules

DOE Office of Scientific and Technical Information (OSTI.GOV)

Willett, D.

1995-11-01

This report describes environmental testing of Siemen`s CIS modules. Charts and diagrams are presented on data concerning: temporary power loss of laminated mini-modules; the 50 thermal cycle test; the 10 humidity freeze cycle test; results after 1000 hours of exposure to damp heat; and interconnect test structures in damp heat testing. It is concluded that moisture ingress causes permanent increases in the series resistance of modules, and that improved packaging is needed for better high humidity reliability. Also, dry dark heat caused temporary power losses which were recovered in sunlight.

Properties Of Carbon/Carbon and Carbon/Phenolic Composites

NASA Technical Reports Server (NTRS)

Mathis, John R.; Canfield, A. R.

1993-01-01

Report presents data on physical properties of carbon-fiber-reinforced carbon-matrix and phenolic-matrix composite materials. Based on tests conducted on panels, cylinders, blocks, and formed parts. Data used by designers to analyze thermal-response and stress levels and develop structural systems ensuring high reliability at minimum weight.

Thermal fatigue testing of a diffusion-bonded beryllium divertor mock-up under ITER-relevant conditions

DOE Office of Scientific and Technical Information (OSTI.GOV)

Youchison, D.L.; Watson, R.D.; McDonald, J.M.

Thermal response and thermal fatigue tests of four 5-mm-thick beryllium tiles on a Russian Federation International Thermonuclear Experimental Reactor (ITER)-relevant divertor mock-up were completed on the electron beam test system at Sandia National Laboratories. Thermal response tests were performed on the tiles to an absorbed heat flux of 5 MW/m{sup 2} and surface temperatures near 300{degree}C using 1.4 MPa water at 5 m/s flow velocity and an inlet temperature of 8 to 15{degree}C. One tile was exposed to incrementally increasing heat fluxes up to 9.5 MW/m{sup 2} and surface temperatures up to 690{degree}C before debonding at 10MW/m{sup 2}. A secondmore » tile debonded in 25 to 30 cycles at <0.5 MW/m{sup 2}. However, a third tile debonded after 9200 thermal fatigue cycles at 5 MW/m{sup 2}, while another debonded after 6800 cycles. Posttest surface analysis indicated that fatigue failure occurred in the intermetallic layers between the beryllium and copper. No fatigue cracking of the bulk beryllium was observed. It appears that microcracks growing at the diffusion bond produced the observed gradual temperature increases during thermal cycling. These experiments indicate that diffusion-bonded beryllium tiles can survive several thousand thermal cycles under ITER-relevant conditions. However, the reliability of the diffusion-bonded joint remains a serious issue. 17 refs., 25 figs., 6 tabs.« less

Thermal-Mechanical Stability of Single Crystal Oxide Refractive Concentrators for High-Temperature Solar Thermal Propulsion

NASA Technical Reports Server (NTRS)

Zhu, Dongming; Jacobson, Nathan S.; Miller, Robert A.

1999-01-01

Single crystal oxides such as yttria-stabilized zirconia (Y2O3-ZrO2), yttrium aluminum garnet (Y3Al5O12, or YAG), magnesium oxide (MgO) and sapphire (Al2O3) are candidate refractive secondary concentrator materials for high temperature solar propulsion applications. However, thermo-mechanical reliability of these components in severe thermal environments during the space mission sun/shade transition is of great concern. Simulated mission tests are important for evaluating these candidate oxide materials under a variety of transient and steady-state heat flux conditions, and thus provide vital information for the component design. In this paper, a controlled heat flux thermal shock test approach is established for the single crystal oxide materials using a 3.0 kW continuous wave CO2 laser, with a wavelength 10.6 micron. Thermal fracture behavior and failure mechanisms of these oxide materials are investigated and critical temperature gradients are determined under various temperature and heating conditions. The test results show that single crystal sapphire is able to sustain the highest temperature gradient and heating-cooling rate, and thus exhibit the best thermal shock resistance, as compared to the yttria-stabilized zirconia, yttrium aluminum garnet and magnesium oxide.

Thermal-Mechanical Stability of Single Crystal Oxide Refractive Concentrators for High-Temperature Solar Thermal Propulsion

NASA Technical Reports Server (NTRS)

Zhu, Dongming; Jacobson, Nathan S.; Miller, Robert A.

1999-01-01

Single crystal oxides such as yttria-stabilized zirconia (Y2O3-ZrO2), yttrium aluminum garnet (Y3Al5O12, or YAG), magnesium oxide (MgO) and sapphire (Al2O3) are candidate refractive secondary concentrator materials for high temperature solar propulsion applications. However, thermo-mechanical reliability of these components in severe thermal environments during the space mission sun/shade transition is of great concern. Simulated mission tests are important for evaluating these candidate oxide materials under a variety of transient and steady-state heat flux conditions, and thus provide vital information for the component design. In this paper, a controlled heat flux thermal shock test approach is established for the single crystal oxide materials using a 3.0 kW continuous wave CO2 laser, with a wavelength 10.6 micron. Thermal fracture behavior and failure mechanisms of these oxide materials are investigated and critical temperature gradients are determined under various temperature and heating conditions. The test results show that single crystal sapphire is able to sustain the highest temperature gradient and heating-cooling rate, and thus exhibit the best thermal shock resistance, as compared to the yttria-stabilized zirconia, yttrium aluminum garnet, and magnesium oxide.

Thermal Performance Study of Composite Phase Change Material with Polyacrylicand Conformal Coating.

PubMed

Kee, Shin Yiing; Munusamy, Yamuna; Ong, Kok Seng; Cornelis Metselaar, Hendrik Simon; Chee, Swee Yong; Lai, Koon Chun

2017-07-28

The composite PCM was prepared by blending polymethyl methacrylate (PMMA) and myristic acid (MA) in different weight percentages. The MA and PMMA were selected as PCM and supporting material, respectively. As liquid MA may leak out during the phase transition, this study proposes the use of two coatings, namely a polyacrylic coating and a conformal coating to overcome the leakage problem. Both coatings were studied in terms of the leakage test, chemical compatibility, thermal stability, morphology, and reliability. No leakage was found in the PCMs with coatings compared to those without under the same proportions of MA/PMMA, thus justifying the use of coatings in the present study. The chemically compatibility was confirmed by FTIR spectra: the functional groups of PCMs were in accordance with those of coatings. DSC showed that the coatings did not significantly change the melting and freezing temperatures, however, they improved the thermal stability of composite PCMs as seen in TGA analysis. Furthermore, the composite PCMs demonstrated good thermal reliability after 1000 times thermal cycling. The latent heat of melting reduced by only 0.16% and 1.02% for the PCMs coated with conformal coating and polyacrylic coating, respectively. Therefore, the proposed coatings can be considered in preparing fatty acid/PMMA blends attributed to the good stability, compatibility and leakage prevention.

Long life high reliability thermal control systems study data handbook

NASA Technical Reports Server (NTRS)

Scollon, T. R., Jr.; Carpitella, M. J.

1971-01-01

The development of thermal control systems with high reliability and long service life is discussed. Various passive and semi-active thermal control systems which have been installed on space vehicles are described. The properties of the various coatings are presented in tabular form.

Film evaporation MEMS thruster array for micropropulsion

NASA Astrophysics Data System (ADS)

Cofer, Anthony G.

Current small sat propulsion systems require a substantial mass fraction of the vehicle involving tradeoffs between useful payload mass and maneuverability. This is also an issue with available attitude control systems which are either quickly saturated reaction wheels or movable high drag surfaces with long response times. What is needed is a low mass low power self-contained propulsion unit that can be easily installed and modeled. The proposed Film-Evaporation MEMS Tunable Array (FEMTA), exploits the small scale surface tension effect in conjunction with temperature dependent vapor pressure to realize a thermal valving system. The local vapor pressure is increased by resistive film heating until it exceeds meniscus strength in the nozzle inducing vacuum boiling which provides a stagnation pressure equal to vapor pressure at that point which is used for propulsion. The heat of vaporization is drawn from the bulk fluid and is replaced by either an integrated heater or waste heat from the vehicle. Proof of concept was initially achieved with a macroscale device made possible by using ethylene glycol, which has a low vapor pressure and high surface tension, as the working fluid. Both the thermal valving effect and cooling feature were demonstrated though at reduced performance than would be expected for water. Three generations of prototype FEMTA devices have been fabricated at Birck Nanotechnology Center on 200 and 500 micrometer thick silicon wafers. Preliminary testing on first generation models had tenuously demonstrated behavior consistent with the macroscale tests but there was not enough data for solid confirmation. Some reliability issues had arisen with the integrated heaters which were only partially alleviated in the second generation of FEMTAs. This led to a third generation and two changes in heater material until a chemically resilient material was found. The third generation of microthrusters were tested on the microNewton thrust stand at Purdue's High Vacuum Lab and confirmed the thermal valving concept. The microthrusters will also undergo thermal testing at the Goddard Space Flight Centers' ThermalVac environmental testing facility whenever device lifetime can be extended to the several week time frame needed to provide reliable data.

Miniature Loop Heat Pipe with Multiple Evaporators for Thermal Control of Small Spacecraft

NASA Technical Reports Server (NTRS)

Ku, Jentung; Ottenstein, Laura; Douglas, Denya; Pauken, Michael; Birur, Gajanana

2005-01-01

This paper presents an advanced miniature heat transport system for thermal control of small spacecraft. The thermal system consists of a loop heat pipe (LHP) with multiple evaporators and multiple deployable radiators for heat transfer, and variable emittance coatings on the radiators for performance enhancement. Thermoelectric coolers are used to control the loop operating temperature. The thermal system combines the functions of variable conductance heat pipes, thermal switches, thermal diodes, and the state-of-the-art LHPs into a single integrated thermal system. It retains all the performance characteristics of state-of-the-art LHPs and offers additional advantages to enhance the functionality, performance, versatility, and reliability of the system. Steady state and transient analytical models have been developed, and scaling criteria have also been established. A breadboard unit has been built for functional testing in laboratory and thermal vacuum environments. Experimental results show excellent performance of the thermal system and correlate very well with theoretical predictions.

A Probabilistic Approach to Predict Thermal Fatigue Life for Ball Grid Array Solder Joints

NASA Astrophysics Data System (ADS)

Wei, Helin; Wang, Kuisheng

2011-11-01

Numerous studies of the reliability of solder joints have been performed. Most life prediction models are limited to a deterministic approach. However, manufacturing induces uncertainty in the geometry parameters of solder joints, and the environmental temperature varies widely due to end-user diversity, creating uncertainties in the reliability of solder joints. In this study, a methodology for accounting for variation in the lifetime prediction for lead-free solder joints of ball grid array packages (PBGA) is demonstrated. The key aspects of the solder joint parameters and the cyclic temperature range related to reliability are involved. Probabilistic solutions of the inelastic strain range and thermal fatigue life based on the Engelmaier model are developed to determine the probability of solder joint failure. The results indicate that the standard deviation increases significantly when more random variations are involved. Using the probabilistic method, the influence of each variable on the thermal fatigue life is quantified. This information can be used to optimize product design and process validation acceptance criteria. The probabilistic approach creates the opportunity to identify the root causes of failed samples from product fatigue tests and field returns. The method can be applied to better understand how variation affects parameters of interest in an electronic package design with area array interconnections.

MECHANICAL PROPERTY CHARACTERIZATIONS AND PERFORMANCE MODELING OF SOFC SEALS

DOE Office of Scientific and Technical Information (OSTI.GOV)

Koeppel, Brian J.; Vetrano, John S.; Nguyen, Ba Nghiep

2008-03-26

This study provides modeling tools for the design of reliable seals for SOFC stacks. The work consists of 1) experimental testing to determine fundamental properties of SOFC sealing materials, and 2) numerical modeling of stacks and sealing systems. The material tests capture relevant temperature-dependent physical and mechanical data needed by the analytical models such as thermal expansion, strength, fracture toughness, and relaxation behavior for glass-ceramic seals and other materials. Testing has been performed on both homogenous specimens and multiple material assemblies to investigate the effect of interfacial reactions. A viscoelastic continuum damage model for a glass-ceramic seal was developed tomore » capture the nonlinear behavior of this material at high temperatures. This model was implemented in the MSC MARC finite element code and was used for a detailed analysis of a planar SOFC stack under thermal cycling conditions. Realistic thermal loads for the stack were obtained using PNNL’s in-house multiphysics solver. The accumulated seal damage and component stresses were evaluated for multiple thermal loading cycles, and regions of high seal damage susceptible to cracking were identified. Selected test results, numerical model development, and analysis results will be presented.« less

Fabrication and Testing of a Thin-Film Heat Flux Sensor for a Stirling Convertor

NASA Technical Reports Server (NTRS)

Wilson, Scott D.; Fralick, Gustave; Wrbanek, John; Sayir, Ali

2009-01-01

The NASA Glenn Research Center (GRC) has been testing high efficiency free-piston Stirling convertors for potential use in radioisotope power systems since 1999. Stirling convertors are being operated for many years to demonstrate a radioisotope power system capable of providing reliable power for potential multi-year missions. Techniques used to monitor the convertors for change in performance include measurements of temperature, pressure, energy addition, and energy rejection. Micro-porous bulk insulation is used in the Stirling convertor test set up to minimize the loss of thermal energy from the electric heat source to the environment. The insulation is characterized before extended operation, enabling correlation of the net thermal energy addition to the convertor. Aging microporous bulk insulation changes insulation efficiency, introducing errors in the correlation for net thermal energy addition. A thin-mm heat flux sensor was designed and fabricated to directly measure the net thermal energy addition to the Stirling convertor. The fabrication techniques include slip casting and using Physical Vapor Deposition (PVD). One micron thick noble metal thermocouples measure temperature on the surface of an Alumina ceramic disc and heat flux is calculated. Fabrication, integration, and test results of a thin film heat flux sensor are presented.

Fabrication and Testing of a Thin-Film Heat Flux Sensor for a Stirling Convertor

NASA Technical Reports Server (NTRS)

Wilson, Scott D.; Fralick, Gus c.; Wrbanek, John D.; Sayir, Ali

2010-01-01

The NASA Glenn Research Center (GRC) has been testing high-efficiency free-piston Stirling convertors for potential use in radioisotope power systems since 1999. Stirling convertors are being operated for many years to demonstrate a radioisotope power system capable of providing reliable power for potential multiyear missions. Techniques used to monitor the convertors for change in performance include measurements of temperature, pressure, energy addition, and energy rejection. Micro-porous bulk insulation is used in the Stirling convertor test setup to minimize the loss of thermal energy from the electric heat source to the environment. The insulation is characterized before extended operation, enabling correlation of the net thermal energy addition to the convertor. Aging micro-porous bulk insulation changes insulation efficiency, introducing errors in the correlation for net thermal energy addition. A thin-film heat flux sensor was designed and fabricated to directly measure the net thermal energy addition to the Stirling convertor. The fabrication techniques include slipcasting and using Physical Vapor Deposition (PVD). One-micron-thick noble metal thermocouples measure temperature on the surface of an alumina ceramic disk and heat flux is calculated. Fabrication, integration, and test results of a thin-film heat flux sensor are presented.

Multi-Evaporator Miniature Loop Heat Pipe for Small Spacecraft Thermal Control. Part 1; New Technologies and Validation Approach

NASA Technical Reports Server (NTRS)

Ku, Jentung; Ottenstein, Laura; Douglas, Donya; Hoang, Triem

2010-01-01

Under NASA s New Millennium Program Space Technology 8 (ST 8) Project, four experiments Thermal Loop, Dependable Microprocessor, SAILMAST, and UltraFlex - were conducted to advance the maturity of individual technologies from proof of concept to prototype demonstration in a relevant environment , i.e. from a technology readiness level (TRL) of 3 to a level of 6. This paper presents the new technologies and validation approach of the Thermal Loop experiment. The Thermal Loop is an advanced thermal control system consisting of a miniature loop heat pipe (MLHP) with multiple evaporators and multiple condensers designed for future small system applications requiring low mass, low power, and compactness. The MLHP retains all features of state-of-the-art loop heat pipes (LHPs) and offers additional advantages to enhance the functionality, performance, versatility, and reliability of the system. Details of the thermal loop concept, technical advances, benefits, objectives, level 1 requirements, and performance characteristics are described. Also included in the paper are descriptions of the test articles and mathematical modeling used for the technology validation. An MLHP breadboard was built and tested in the laboratory and thermal vacuum environments for TRL 4 and TRL 5 validations, and an MLHP proto-flight unit was built and tested in a thermal vacuum chamber for the TRL 6 validation. In addition, an analytical model was developed to simulate the steady state and transient behaviors of the MLHP during various validation tests. Capabilities and limitations of the analytical model are also addressed.

A reliability design method for a lithium-ion battery pack considering the thermal disequilibrium in electric vehicles

NASA Astrophysics Data System (ADS)

Xia, Quan; Wang, Zili; Ren, Yi; Sun, Bo; Yang, Dezhen; Feng, Qiang

2018-05-01

With the rapid development of lithium-ion battery technology in the electric vehicle (EV) industry, the lifetime of the battery cell increases substantially; however, the reliability of the battery pack is still inadequate. Because of the complexity of the battery pack, a reliability design method for a lithium-ion battery pack considering the thermal disequilibrium is proposed in this paper based on cell redundancy. Based on this method, a three-dimensional electric-thermal-flow-coupled model, a stochastic degradation model of cells under field dynamic conditions and a multi-state system reliability model of a battery pack are established. The relationships between the multi-physics coupling model, the degradation model and the system reliability model are first constructed to analyze the reliability of the battery pack and followed by analysis examples with different redundancy strategies. By comparing the reliability of battery packs of different redundant cell numbers and configurations, several conclusions for the redundancy strategy are obtained. More notably, the reliability does not monotonically increase with the number of redundant cells for the thermal disequilibrium effects. In this work, the reliability of a 6 × 5 parallel-series configuration is the optimal system structure. In addition, the effect of the cell arrangement and cooling conditions are investigated.

RADC Thermal Guide for Reliability Engineers.

DTIC Science & Technology

1982-06-01

sis in government procurements has been to tailor the (e.g., cockpit or crew area) environmental definition to the equipment’s intended use, thereby...AD- AIIB 839 HUGHES AIRCRAFT CO CULVER CITY CA F/G 20/13 ,RAUC THERMAL GUIDE FOR RELIABILITY ENSINEERS (U)’ JUN 82 6 N MORRISON. J N KALLIS. L A...Yet many a reliability engineer has little or no knowledge of thermal design and analysis. Moreover, texts and government handbooks published to

Reliability Study of Solder Paste Alloy for the Improvement of Solder Joint at Surface Mount Fine-Pitch Components.

PubMed

Rahman, Mohd Nizam Ab; Zubir, Noor Suhana Mohd; Leuveano, Raden Achmad Chairdino; Ghani, Jaharah A; Mahmood, Wan Mohd Faizal Wan

2014-12-02

The significant increase in metal costs has forced the electronics industry to provide new materials and methods to reduce costs, while maintaining customers' high-quality expectations. This paper considers the problem of most electronic industries in reducing costly materials, by introducing a solder paste with alloy composition tin 98.3%, silver 0.3%, and copper 0.7%, used for the construction of the surface mount fine-pitch component on a Printing Wiring Board (PWB). The reliability of the solder joint between electronic components and PWB is evaluated through the dynamic characteristic test, thermal shock test, and Taguchi method after the printing process. After experimenting with the dynamic characteristic test and thermal shock test with 20 boards, the solder paste was still able to provide a high-quality solder joint. In particular, the Taguchi method is used to determine the optimal control parameters and noise factors of the Solder Printer (SP) machine, that affects solder volume and solder height. The control parameters include table separation distance, squeegee speed, squeegee pressure, and table speed of the SP machine. The result shows that the most significant parameter for the solder volume is squeegee pressure (2.0 mm), and the solder height is the table speed of the SP machine (2.5 mm/s).

Reliability Study of Solder Paste Alloy for the Improvement of Solder Joint at Surface Mount Fine-Pitch Components

PubMed Central

Rahman, Mohd Nizam Ab.; Zubir, Noor Suhana Mohd; Leuveano, Raden Achmad Chairdino; Ghani, Jaharah A.; Mahmood, Wan Mohd Faizal Wan

2014-01-01

The significant increase in metal costs has forced the electronics industry to provide new materials and methods to reduce costs, while maintaining customers’ high-quality expectations. This paper considers the problem of most electronic industries in reducing costly materials, by introducing a solder paste with alloy composition tin 98.3%, silver 0.3%, and copper 0.7%, used for the construction of the surface mount fine-pitch component on a Printing Wiring Board (PWB). The reliability of the solder joint between electronic components and PWB is evaluated through the dynamic characteristic test, thermal shock test, and Taguchi method after the printing process. After experimenting with the dynamic characteristic test and thermal shock test with 20 boards, the solder paste was still able to provide a high-quality solder joint. In particular, the Taguchi method is used to determine the optimal control parameters and noise factors of the Solder Printer (SP) machine, that affects solder volume and solder height. The control parameters include table separation distance, squeegee speed, squeegee pressure, and table speed of the SP machine. The result shows that the most significant parameter for the solder volume is squeegee pressure (2.0 mm), and the solder height is the table speed of the SP machine (2.5 mm/s). PMID:28788270

Preliminary test of the prototype modular cryostat for a 10 MW offshore superconducting wind turbine

NASA Astrophysics Data System (ADS)

Sun, Jiuce; Ramalingam, R.; Sanz, Santiago; Neumann, Holger

2017-02-01

The SUPerconducting Reliable lightweight And more POWERful offshore wind turbine (SUPRAPOWER), an EU FP7 funded research project, are under development for an innovative superconducting 10 MW class offshore wind turbine. Due to the requirements of handling, maintenance, reliability of long term and offshore operation, the cryostats are divided in two major parts: the modular cryostat able to accommodate a single coil and a thermal collector that links all the modules. The prototype modular cryostat was designed, manufactured and assembled in Karlsruhe Institute of Technology (KIT). The paper reports preliminary test results of proto-type modular cryostat with a two-stage Gifford-McMahon (GM) cryocooler.

DOE Office of Scientific and Technical Information (OSTI.GOV)

Moreno, Gilberto; Bennion, Kevin; King, Charles

Thermal management strategies for automotive power electronic systems have evolved over time to reduce system cost and to improve reliability and thermal performance. In this study, we characterized the power electronic thermal management systems of two electric-drive vehicles--the 2012 Nissan LEAF and 2014 Honda Accord Hybrid. Tests were conducted to measure the insulated-gate bipolar transistor-to-coolant thermal resistances for both steady-state and transient conditions at various coolant flow rates. Water-ethylene glycol at a temperature of 65 degrees C was used as the coolant for these experiments. Computational fluid dynamics and finite element analysis models of the vehicle's power electronics thermal managementmore » system were then created and validated using experimentally obtained results. Results indicate that the Accord module provides lower steady-state thermal resistance as compared with the LEAF module. However, the LEAF design may provide improved performance in transient conditions and may have cost benefits.« less

Improvement and evaluation of thermal, electrical, sealing and mechanical contacts, and their interface materials

NASA Astrophysics Data System (ADS)

Luo, Xiangcheng

Material contacts, including thermal, electrical, seating (fluid sealing and electromagnetic sealing) and mechanical (pressure) contacts, together with their interface materials, were, evaluated, and in some cases, improved beyond the state of the art. The evaluation involved the use of thermal, electrical and mechanical methods. For thermal contacts, this work evaluated and improved the heat transfer efficiency between two contacting components by developing various thermal interface pastes. Sodium silicate based thermal pastes (with boron nitride particles as the thermally conductive filler) as well as polyethylene glycol (PEG) based thermal pastes were developed and evaluated. The optimum volume fractions of BN in sodium silicate based pastes and PEG based pastes were 16% and 18% respectively. The contribution of Li+ ions to the thermal contact conductance in the PEG-based paste was confirmed. For electrical contacts, the relationship between the mechanical reliability and electrical reliability of solder/copper and silver-epoxy/copper joints was addressed. Mechanical pull-out testing was conducted on solder/copper and silver-epoxy/copper joints, while the contact electrical resistivity was measured. Cleansing of the copper surface was more effective for the reliability of silver-epoxy/copper joint than that of solder/copper joint. For sealing contacts, this work evaluated flexible graphite as an electromagnetic shielding gasket material. Flexible graphite was found to be at least comparable to conductive filled silicone (the state of the art) in terms of the shielding effectiveness. The conformability of flexible graphite with its mating metal surface under repeated compression was characterized by monitoring the contact electrical resistance, as the conformability is important to both electromagnetic scaling and fluid waling using flexible graphite. For mechanical contacts, this work focused on the correlation of the interface structure (such as elastic/plastic deformation, oxidation, strain hardening, passive layer damage, fracture, etc.) with the electrical contact resistance, which was measured in real time for contacts under dynamic compression, thus allowing both reversible and irreversible changes to be observed. The materials studied included metals (carbon steel, stainless steel, aluminum and copper), carbon fiber reinforced polymer-matrix composite (nylon-6), ceramic (mortar) and graphite, due to their relevance to fastening, concrete structures, electric brushes and electrical pressure contacts.

Effect of Nickel Concentration on Bias Reliability and Thermal Stability of Thin-Film Transistors Fabricated by Ni-Metal-Induced Crystallization

NASA Astrophysics Data System (ADS)

Lai, Ming-Hui; Sermon Wu, YewChung; Huang, Jung-Jie

2012-01-01

Ni-metal-induced crystallization (MIC) of amorphous Si (α-Si) has been employed to fabricate low-temperature polycrystalline silicon (poly-Si) thin-film transistors (TFTs). Although the high leakage current is a major issue in the performance of conventional MIC-TFTs since Ni contamination induces deep-level state traps, it can be greatly improved by using well-known technologies to reduce Ni contamination. However, for active-matrix organic light-emitting diode (AMOLED) display applications, the bias reliability and thermal stability are major concerns especially when devices are operated under a hot carrier condition and in a high-temperature environment. It will be interesting to determine how the bias reliability and thermal stability are affected by the reduction of Ni concentration. In the study, the effect of Ni concentration on bias reliability and thermal stability was investigated. We found that a device exhibited high immunity against hot-carrier stress and elevated temperatures. These findings demonstrated that reducing the Ni concentration in MIC films was also beneficial for bias reliability and thermal stability.

Laser notching ceramics for reliable fracture toughness testing

DOE PAGES

Barth, Holly D.; Elmer, John W.; Freeman, Dennis C.; ...

2015-09-19

A new method for notching ceramics was developed using a picosecond laser for fracture toughness testing of alumina samples. The test geometry incorporated a single-edge-V-notch that was notched using picosecond laser micromachining. This method has been used in the past for cutting ceramics, and is known to remove material with little to no thermal effect on the surrounding material matrix. This study showed that laser-assisted-machining for fracture toughness testing of ceramics was reliable, quick, and cost effective. In order to assess the laser notched single-edge-V-notch beam method, fracture toughness results were compared to results from other more traditional methods, specificallymore » surface-crack in flexure and the chevron notch bend tests. Lastly, the results showed that picosecond laser notching produced precise notches in post-failure measurements, and that the measured fracture toughness results showed improved consistency compared to traditional fracture toughness methods.« less

Power Electronics and Electric Machines | Transportation Research | NREL

Science.gov Websites

-to resource for information from cutting-edge thermal management research, making wide-scale adoption battery, the motor, and other powertrain components. NREL's thermal management and reliability research is thermal management technologies to improve performance, cost, and reliability for power electronics and

Performance testing and module monitoring at the EC Necessary steps to develop cost-effective PV modules

NASA Astrophysics Data System (ADS)

Krebs, K.

Testing programs carried out by the European Communities to establish testing techniques and standards for verifying the reliability and integrity of solar cells intended for the marketplace are described. The efforts are being expended to assure quality control and certification for photovoltaic (PV) products manufactured in any of the member nations. The failure rate for PV modules was lowered to 0.5 pct/year by 1981, and single cell failures are projected to be lowered to 0.00001/yr, connectors to 0.001/yr, and batteries to 0.01/yr. Day/night thermal cycling causes the most dominant type of failures, i.e., cracked cells and interconnect defects. Tests have been standardized for inspection, verification, performance, mechanical loading, hail impact, damp heat, high temperature long exposure, hot-spot heating, thermal cycling, and humidity-freezing tolerance.

Application of airborne thermal imagery to surveys of Pacific walrus

USGS Publications Warehouse

Burn, D.M.; Webber, M.A.; Udevitz, M.S.

2006-01-01

We conducted tests of airborne thermal imagery of Pacific walrus to determine if this technology can be used to detect walrus groups on sea ice and estimate the number of walruses present in each group. In April 2002 we collected thermal imagery of 37 walrus groups in the Bering Sea at spatial resolutions ranging from 1-4 m. We also collected high-resolution digital aerial photographs of the same groups. Walruses were considerably warmer than the background environment of ice, snow, and seawater and were easily detected in thermal imagery. We found a significant linear relation between walrus group size and the amount of heat measured by the thermal sensor at all 4 spatial resolutions tested. This relation can be used in a double-sampling framework to estimate total walrus numbers from a thermal survey of a sample of units within an area and photographs from a subsample of the thermally detected groups. Previous methods used in visual aerial surveys of Pacific walrus have sampled only a small percentage of available habitat, resulting in population estimates with low precision. Results of this study indicate that an aerial survey using a thermal sensor can cover as much as 4 times the area per hour of flight time with greater reliability than visual observation.

Living Together in Space: The International Space Station Internal Active Thermal Control System Issues and Solutions-Sustaining Engineering Activities at the Marshall Space Flight Center From 1998 to 2005

NASA Technical Reports Server (NTRS)

Wieland, P. O.; Roman, M. C.; Miller, L.

2007-01-01

On board the International Space Station, heat generated by the crew and equipment is removed by the internal active thermal control system to maintain a comfortable working environment and prevent equipment overheating. Test facilities simulating the internal active thermal control system (IATCS) were constructed at the Marshall Space Flight Center as part of the sustaining engineering activities to address concerns related to operational issues, equipment capability, and reliability. A full-scale functional simulator of the Destiny lab module IATCS was constructed and activated prior to launch of Destiny in 2001. This facility simulates the flow and thermal characteristics of the flight system and has a similar control interface. A subscale simulator was built, and activated in 2000, with special attention to materials and proportions of wetted surfaces to address issues related to changes in fluid chemistry, material corrosion, and microbial activity. The flight issues that have arisen and the tests performed using the simulator facilities are discussed in detail. In addition, other test facilities at the MSFC have been used to perform specific tests related to IATCS issues. Future testing is discussed as well as potential modifications to the simulators to enhance their utility.

Furnace Cyclic Oxidation Behavior of Multi-Component Low Conductivity Thermal Barrier Coatings

NASA Technical Reports Server (NTRS)

Zhu, Dong-Ming; Nesbitt, James A.; Barrett, Charles A.; McCue, Terry R.; Miller, Robert A.

2004-01-01

Ceramic thermal barrier coatings will play an increasingly important role in advanced gas turbine engines because of their ability to further increase engine operating temperatures and reduce cooling, thus helping achieve future engine low emission, high efficiency and improved reliability goals. Advanced multi-component zirconia-based thermal barrier coatings are being developed using an oxide defect clustering design approach to achieve the required coating low thermal conductivity and high temperature stability. Although the new composition coatings were not yet optimized for cyclic durability, an initial durability screening of the candidate coating materials was conducted using conventional furnace cyclic oxidation tests. In this paper, furnace cyclic oxidation behavior of plasma-sprayed zirconia-based defect cluster thermal barrier coatings was investigated at 1163 C using 45 min hot cycles. The ceramic coating failure mechanisms were studied using scanning electron microscopy (SEM) combined with X-ray diffraction (XRD) phase analysis after the furnace tests. The coating cyclic lifetime is also discussed in relation to coating processing, phase structures, dopant concentration, and other thermo-physical properties.

Vibration and Thermal Cycling Effects on Bulk-fill Insulation Materials for Cryogenic Tanks

NASA Astrophysics Data System (ADS)

Fesmire, J. E.; Augustynowicz, S. D.; Nagy, Z. F.; Sojourner, S. J.; Morris, D. L.

2006-04-01

Large-scale (1,000,000 liters or more) cryogenic storage tanks are typically perlite-insulated double-walled vessels. Associated problems with perlite, such as mechanical compaction and settling, could be greatly reduced by using newer bulk-fill materials such as glass bubbles or aerogel beads. Using the newer materials should translate to lower life cycle costs and improved system reliability. NASA Kennedy Space Center is leveraging its experience in the areas of materials development, insulation testing, and cryogenic systems design to develop an insulation retrofit option that will meet both industry and NASA requirements. A custom 10-liter dewar test apparatus, developed by the KSC Cryogenics Test Laboratory, was used to determine the vibration and thermal cycling effects on different bulk-fill insulation materials for cryogenic tanks. The testing included liquid-nitrogen boiloff testing and thermal cycling (with vibration) of a number of test dewars. Test results show that glass bubbles have better thermal performance and less mechanical compaction compared to perlite powder. The higher cost of the bulk material should be offset by reduced commodity loss from boiloff and improvements in material handling, evacuation, and vacuum retention. The long-term problem with settling and compaction of perlite should also be eliminated. Aerogel beads are superior for the no-vacuum condition and can now be considered in some applications. Further studies on large-scale systems are presently being pursued.

Ocean Thermal Energy Conversion power system development. Phase I. Final report

DOE Office of Scientific and Technical Information (OSTI.GOV)

Not Available

1978-12-04

This report covers the conceptual and preliminary design of closed-cycle, ammonia, ocean thermal energy conversion power plants by Westinghouse Electric Corporation. Preliminary designs for evaporator and condenser test articles (0.13 MWe size) and a 10 MWe modular experiment power system are described. Conceptual designs for 50 MWe power systems, and 100 MWe power plants are also descirbed. Design and cost algorithms were developed, and an optimized power system design at the 50 MWe size was completed. This design was modeled very closely in the test articles and in the 10 MWe Modular Application. Major component and auxiliary system design, materials,more » biofouling, control response, availability, safety and cost aspects are developed with the greatest emphasis on the 10 MWe Modular Application Power System. It is concluded that all power plant subsystems are state-of-practice and require design verification only, rather than continued research. A complete test program, which verifies the mechanical reliability as well as thermal performance, is recommended and described.« less

Sublimator Driven Coldplate Engineering Development Unit Test Results

NASA Technical Reports Server (NTRS)

Sheth, Rubik B.; Stephan, Ryan A.; Leimkuehler, Thomas O.

2010-01-01

The Sublimator Driven Coldplate (SDC) is a unique piece of thermal control hardware that has several advantages over a traditional thermal control scheme. The principal advantage is the possible elimination of a pumped fluid loop, potentially increasing reliability and reducing complexity while saving both mass and power. Because the SDC requires a consumable feedwater, it can only be used for short mission durations. Additionally, the SDC is ideal for a vehicle with small transport distances and low heat rejection requirements. An SDC Engineering Development Unit was designed and fabricated. Performance tests were performed in a vacuum chamber to quantify and assess the performance of the SDC. The test data was then used to develop correlated thermal math models. Nonetheless, an Integrated Sublimator Driven Coldplate (ISDC) concept is being developed. The ISDC couples a coolant loop with the previously described SDC hardware. This combination allows the SDC to be used as a traditional coldplate during long mission phases and provides for dissimilar system redundancy

Propulsion system tests on a full scale Centaur vehicle to investigate 3-burn mission capability of the D-lT configuration

NASA Technical Reports Server (NTRS)

Groesbeck, W. A.; Baud, K. M.; Lacovic, R. F.; Tabata, W. K.; Szabo, S. V., Jr.

1974-01-01

Propulsion system tests were conducted on a full scale Centaur vehicle to investigate system capability of the proposed D-lT configuration for a three-burn mission. This particular mission profile requires that the engines be capable of restarting and firing for a final maneuver after a 5-1/2-hour coast to synchronous orbit. The thermal conditioning requirements of the engine and propellant feed system components for engine start under these conditions were investigated. Performance data were also obtained on the D-lT type computer controlled propellant tank pressurization system. The test results demonstrated that the RL-10 engines on the Centaur vehicle could be started and run reliably after being thermally conditioned to predicted engine start conditions for a one, two and three burn mission. Investigation of the thermal margins also indicated that engine starts could be accomplished at the maximum predicted component temperature conditions with prestart durations less than planned for flight.

Miniature sheathed thermocouples for turbine blade temperature measurement

NASA Technical Reports Server (NTRS)

Holanda, R.; Glawe, G. E.; Krause, L. N.

1974-01-01

An investigation was made of sheathed thermocouples for turbine blade temperature measurements. Tests were performed on the Chromel-Alumel sheathed thermocouples with both two-wire and single-wire configurations. Sheath diameters ranged from 0.25 to 0.76 mm, and temperatures ranged from 1080 to 1250 K. Both steady-state and thermal cycling tests were performed for times up to 450 hr. Special-order and commercial-grade thermocouples were tested. The tests showed that special-order single-wire sheathed thermocouples can be obtained that are reliable and accurate with diameters as small as 0.25 mm. However, all samples of 0.25-mm-diameter sheathed commercial-grade two-wire and single-wire thermocouples that were tested showed unacceptable drift rates for long-duration engine testing programs. The drift rates were about 1 percent in 10 hr. A thermocouple drift test is recommended in addition to the normal acceptance tests in order to select reliable miniature sheathed thermocouples for turbine blade applications.

Task 1, Design Analysis Report: Pulsed plasma solid propellant microthruster for the synchronous meteorological satellite

NASA Technical Reports Server (NTRS)

Guman, W. J. (Editor)

1971-01-01

Thermal vacuum design supporting thruster tests indicate no problems under the worst case conditions of sink temperature and spin rate. The reliability of the system was calculated to be 0.92 for a five-year mission. Minus the main energy storage capacitor it is 0.98.

Solar-cell interconnect design for terrestrial photovoltaic modules

NASA Technical Reports Server (NTRS)

Mon, G. R.; Moore, D. M.; Ross, R. G., Jr.

1984-01-01

Useful solar cell interconnect reliability design and life prediction algorithms are presented, together with experimental data indicating that the classical strain cycle (fatigue) curve for the interconnect material does not account for the statistical scatter that is required in reliability predictions. This shortcoming is presently addressed by fitting a functional form to experimental cumulative interconnect failure rate data, which thereby yields statistical fatigue curves enabling not only the prediction of cumulative interconnect failures during the design life of an array field, but also the quantitative interpretation of data from accelerated thermal cycling tests. Optimal interconnect cost reliability design algorithms are also derived which may allow the minimization of energy cost over the design life of the array field.

Solar-cell interconnect design for terrestrial photovoltaic modules

NASA Astrophysics Data System (ADS)

Mon, G. R.; Moore, D. M.; Ross, R. G., Jr.

1984-11-01

Useful solar cell interconnect reliability design and life prediction algorithms are presented, together with experimental data indicating that the classical strain cycle (fatigue) curve for the interconnect material does not account for the statistical scatter that is required in reliability predictions. This shortcoming is presently addressed by fitting a functional form to experimental cumulative interconnect failure rate data, which thereby yields statistical fatigue curves enabling not only the prediction of cumulative interconnect failures during the design life of an array field, but also the quantitative interpretation of data from accelerated thermal cycling tests. Optimal interconnect cost reliability design algorithms are also derived which may allow the minimization of energy cost over the design life of the array field.

Ocean properties

NASA Technical Reports Server (NTRS)

Korb, C. L.; Potter, J. F. (Principal Investigator)

1976-01-01

The author has identified the following significant results. Results of testing the CP program indicate that the best results can be obtained in the near infrared water bands. The absorption due to water vapor and carbon dioxide in the thermal infrared band appeared to be less reliable in comparison to spacecraft-acquired data and band models. Comparisons of laboratory carbon dioxide transmission in the thermal infrared band show good agreement except in regions where lines are known to be missing. The comparison of ozone transmission at a wavelength of 9.6 micrometers to laboratory data showed unexceptedly large differences.

Effect of Random Thermal Spikes on Stirling Convertor Heater Head Reliability

NASA Technical Reports Server (NTRS)

Shah, Ashwin R.; Korovaichuk, Igor; Halford, Gary R.

2004-01-01

Onboard radioisotope power systems being developed to support future NASA exploration missions require reliable design lifetimes of up to 14 yr and beyond. The structurally critical heater head of the high-efficiency developmental Stirling power convertor has undergone extensive computational analysis of operating temperatures (up to 650 C), stresses, and creep resistance of the thin-walled Inconel 718 bill of material. Additionally, assessment of the effect of uncertainties in the creep behavior of the thin-walled heater head, the variation in the manufactured thickness, variation in control temperature, and variation in pressure on the durability and reliability were performed. However, it is possible for the heater head to experience rare incidences of random temperature spikes (excursions) of short duration. These incidences could occur randomly with random magnitude and duration during the desired mission life. These rare incidences could affect the creep strain rate and therefore the life. The paper accounts for these uncertainties and includes the effect of such rare incidences, random in nature, on the reliability. The sensitivities of variables affecting the reliability are quantified and guidelines developed to improve the reliability are outlined. Furthermore, the quantified reliability is being verified with test data from the accelerated benchmark tests being conducted at the NASA Glenn Research Center.

Test Hardware Design for Flightlike Operation of Advanced Stirling Convertors (ASC-E3)

NASA Technical Reports Server (NTRS)

Oriti, Salvatore M.

2012-01-01

NASA Glenn Research Center (GRC) has been supporting development of the Advanced Stirling Radioisotope Generator (ASRG) since 2006. A key element of the ASRG project is providing life, reliability, and performance testing of the Advanced Stirling Convertor (ASC). For this purpose, the Thermal Energy Conversion branch at GRC has been conducting extended operation of a multitude of free-piston Stirling convertors. The goal of this effort is to generate long-term performance data (tens of thousands of hours) simultaneously on multiple units to build a life and reliability database. The test hardware for operation of these convertors was designed to permit in-air investigative testing, such as performance mapping over a range of environmental conditions. With this, there was no requirement to accurately emulate the flight hardware. For the upcoming ASC-E3 units, the decision has been made to assemble the convertors into a flight-like configuration. This means the convertors will be arranged in the dual-opposed configuration in a housing that represents the fit, form, and thermal function of the ASRG. The goal of this effort is to enable system level tests that could not be performed with the traditional test hardware at GRC. This offers the opportunity to perform these system-level tests much earlier in the ASRG flight development, as they would normally not be performed until fabrication of the qualification unit. This paper discusses the requirements, process, and results of this flight-like hardware design activity.

Test Hardware Design for Flight-Like Operation of Advanced Stirling Convertors

NASA Technical Reports Server (NTRS)

Oriti, Salvatore M.

2012-01-01

NASA Glenn Research Center (GRC) has been supporting development of the Advanced Stirling Radioisotope Generator (ASRG) since 2006. A key element of the ASRG project is providing life, reliability, and performance testing of the Advanced Stirling Convertor (ASC). For this purpose, the Thermal Energy Conversion branch at GRC has been conducting extended operation of a multitude of free-piston Stirling convertors. The goal of this effort is to generate long-term performance data (tens of thousands of hours) simultaneously on multiple units to build a life and reliability database. The test hardware for operation of these convertors was designed to permit in-air investigative testing, such as performance mapping over a range of environmental conditions. With this, there was no requirement to accurately emulate the flight hardware. For the upcoming ASC-E3 units, the decision has been made to assemble the convertors into a flight-like configuration. This means the convertors will be arranged in the dual-opposed configuration in a housing that represents the fit, form, and thermal function of the ASRG. The goal of this effort is to enable system level tests that could not be performed with the traditional test hardware at GRC. This offers the opportunity to perform these system-level tests much earlier in the ASRG flight development, as they would normally not be performed until fabrication of the qualification unit. This paper discusses the requirements, process, and results of this flight-like hardware design activity.

An Intelligent Strain Gauge with Debond Detection and Temperature Compensation

NASA Technical Reports Server (NTRS)

Jensen, Scott L.

2012-01-01

The harsh rocket propulsion test environment will expose any inadequacies associated with preexisting instrumentation technologies, and the criticality for collecting reliable test data justifies investigating any encountered data anomalies. Novel concepts for improved systems are often conceived during the high scrutiny investigations by individuals with an in-depth knowledge from maintaining critical test operations. The Intelligent Strain Gauge concept was conceived while performing these kinds of activities. However, the novel concepts are often unexplored even if it has the potential for advancing the current state of the art. Maturing these kinds of concepts is often considered to be a tangential development or a research project which are both normally abandoned within the propulsion-oriented environment. It is also difficult to justify these kinds of projects as a facility enhancement because facility developments are only accepted for mature and proven technologies. Fortunately, the CIF program has provided an avenue for bringing the Intelligent Strain Gauge to fruition. Two types of fully functional smart strain gauges capable of performing reliable and sensitive debond detection have been successfully produced. Ordinary gauges are designed to provide test article data and they lack the ability to supply information concerning the gauge itself. A gauge is considered to be a smart gauge when it provides supplementary data relating other relevant attributes for performing diagnostic function or producing enhanced data. The developed strain gauges provide supplementary signals by measuring strain and temperature through embedded Karma and nickel chromium (NiCr) alloy elements. Intelligently interpreting the supplementary data into valuable information can be performed manually, however, integrating this functionality into an automatic system is considered to be an intelligent gauge. This was achieved while maintaining a very low mass. The low mass enables debond detection and temperature compensation to be performed when the gauge is utilized on small test articles. It was also found that the element's mass must be relatively small to avoid overbearing the desired thermal dissipation characteristics. Detecting the degradation of a gauge s bond was reliably achieved by correlating thermal dissipation with the bond s integrity. This was accomplished by precisely coupling a NiCr element with a Karma element for accurately interjecting and quantifying thermal energy. A finite amount of thermal energy is consistently placed in the gauge by electrically powering the NiCr element. The energy will only be temporarily stored before it begins to dissipate into the surrounding structure through the gauge bond. The ability to transmit the energy into the structure becomes greatly inhibited by any discontinuity in the bond s substrate. Therefore, the way the thermal dissipation occurs will reveal even the slightest change in the integrity of the bond.

Composite materials for space applications

NASA Technical Reports Server (NTRS)

Rawal, Suraj P.; Misra, Mohan S.; Wendt, Robert G.

1990-01-01

The objectives of the program were to: generate mechanical, thermal, and physical property test data for as-fabricated advanced materials; design and fabricate an accelerated thermal cycling chamber; and determine the effect of thermal cycling on thermomechanical properties and dimensional stability of composites. In the current program, extensive mechanical and thermophysical property tests of various organic matrix, metal matrix, glass matrix, and carbon-carbon composites were conducted, and a reliable database was constructed for spacecraft material selection. Material property results for the majority of the as-fabricated composites were consistent with the predicted values, providing a measure of consolidation integrity attained during fabrication. To determine the effect of thermal cycling on mechanical properties, microcracking, and thermal expansion behavior, approximately 500 composite specimens were exposed to 10,000 cycles between -150 and +150 F. These specimens were placed in a large (18 cu ft work space) thermal cycling chamber that was specially designed and fabricated to simulate one year low earth orbital (LEO) thermal cycling in 20 days. With this rate of thermal cycling, this is the largest thermal cycling unit in the country. Material property measurements of the thermal cycled organic matrix composite laminate specimens exhibited less than 24 percent decrease in strength, whereas, the remaining materials exhibited less than 8 percent decrease in strength. The thermal expansion response of each of the thermal cycled specimens revealed significant reduction in hysteresis and residual strain, and the average CTE values were close to the predicted values.

Results from the Thermal Vacuum Tests of the Chinese-Brazilian Earth Resources Satellite - CBERS FM2

NASA Astrophysics Data System (ADS)

Almeida, J. S.; Garcia, E. C.; Santos, M. B.; Fu, P. Z.

2002-01-01

This paper details the approach adopted and applied on the thermal vacuum tests campaign of the CBERS Flight Model #2 spacecraft, successfully performed at the Integration and Tests Laboratory - LIT, National Institute for Space Research - INPE, in São José dos Campos, SP, from September 7th to 28th, 2001. Measuring approximately 1.8 x 2.0 x 2.2m, weighting 1,500kg and carrying three cameras as the main payload, this spacecraft is scheduled to be launched in China and it will be orbiting the Earth at 778km as part of its remote sensing mission profile. Exploring the capabilities of LIT's 3m x 3m thermal vacuum chamber in terms of appropriately selecting and adjusting its cold shroud temperatures and also some low cost heat input/sink techniques, the spacecraft was adequately disjoined at its service and payload model interface in such a way that each part could physically fit inside the T/V chamber one at a time. Assuring all the necessary functional and test cabling interconnection between the two models through the chamber walls for the proper spacecraft electrical operations as an integrated system, specific thermal test techniques were applied in order to obtain the required hot and cold acceptance levels of temperature at the spacecraft subsystems and structural surfaces, as a consequence of the simulated thermal conditioning from the distinct orbital configurations. These thermal simulation techniques consisted of a combination of skin-heaters, the thermal vacuum chamber main shrouds and dedicated LN2 cold plates, effectively leading to reliable and very satisfactory testing methodology results. Taking more than 350 hours and having 67 people directly involved, including teams from both Brazil and China, this test can be considered as a very important accomplishment in terms of distinct technique of spacecraft testing and also in terms of the satisfactory working relationship between two quite different cultures.

Thermal cycling fatigue of organic thermal interface materials using a thermal-displacement measurement technique

NASA Astrophysics Data System (ADS)

Steill, Jason Scott

The long term reliability of polymer-based thermal interface materials (TIM) is essential for modern electronic packages which require robust thermal management. The challenge for today's materials scientists and engineers is to maximize the heat flow from integrated circuits through a TIM and out the heat sink. Thermal cycling of the electronic package and non-uniformity in the heat flux with respect to the plan area can lead to void formation and delamination which re-introduces inefficient heat transfer. Measurement and understanding at the nano-scale is essential for TIM development. Finding and documenting the evolution of the defects is dependent upon a full understanding of the thermal probes response to changing environmental conditions and the effects of probe usage. The response of the thermal-displacement measurement technique was dominated by changes to the environment. Accurate measurement of the thermal performance was hindered by the inability to create a model system and control the operating conditions. This research highlights the need for continued study into the probe's thermal and mechanical response using tightly controlled test conditions.

Comparison of Hyperthermal Ground Laboratory Atomic Oxygen Erosion Yields With Those in Low Earth Orbit

NASA Technical Reports Server (NTRS)

Banks, Bruce A.; Dill, Grace C.; Loftus, Ryan J.; deGroh, Kim K.; Miller, Sharon K.

2013-01-01

The atomic oxygen erosion yields of 26 materials (all polymers except for pyrolytic graphite) were measured in two directed hyperthermal radio frequency (RF) plasma ashers operating at 30 or 35 kHz with air. The hyperthermal asher results were compared with thermal energy asher results and low Earth orbital (LEO) results from the Materials International Space Station Experiment 2 and 7 (MISSE 2 and 7) flight experiments. The hyperthermal testing was conducted to a significant portion of the atomic oxygen fluence similar polymers were exposed to during the MISSE 2 and 7 missions. Comparison of the hyperthermal asher prediction of LEO erosion yields with thermal energy asher erosion yields indicates that except for the fluorocarbon polymers of PTFE and FEP, the hyperthermal energy ashers are a much more reliable predictor of LEO erosion yield than thermal energy asher testing, by a factor of four.

Building Energy Storage Panel Based on Paraffin/Expanded Perlite: Preparation and Thermal Performance Study.

PubMed

Kong, Xiangfei; Zhong, Yuliang; Rong, Xian; Min, Chunhua; Qi, Chengying

2016-01-25

This study is focused on the preparation and performance of a building energy storage panel (BESP). The BESP was fabricated through a mold pressing method based on phase change material particle (PCMP), which was prepared in two steps: vacuum absorption and surface film coating. Firstly, phase change material (PCM) was incorporated into expanded perlite (EP) through a vacuum absorption method to obtain composite PCM; secondly, the composite PCM was immersed into the mixture of colloidal silica and organic acrylate, and then it was taken out and dried naturally. A series of experiments, including differential scanning calorimeter (DSC), scanning electron microscope (SEM), best matching test, and durability test, have been conducted to characterize and analyze the thermophysical property and reliability of PCMP. Additionally, the thermal performance of BESP was studied through a dynamic thermal property test. The results have showed that: (1) the surface film coating procedure can effectively solve the leakage problem of composite phase change material prepared by vacuum impregnation; (2) the optimum adsorption ratio for paraffin and EP was 52.5:47.5 in mass fraction, and the PCMP has good thermal properties, stability, and durability; and (3) in the process of dynamic thermal performance test, BESP have low temperature variation, significant temperature lagging, and large heat storage ability, which indicated the potential of BESP in the application of building energy efficiency.

Building Energy Storage Panel Based on Paraffin/Expanded Perlite: Preparation and Thermal Performance Study

PubMed Central

Kong, Xiangfei; Zhong, Yuliang; Rong, Xian; Min, Chunhua; Qi, Chengying

2016-01-01

This study is focused on the preparation and performance of a building energy storage panel (BESP). The BESP was fabricated through a mold pressing method based on phase change material particle (PCMP), which was prepared in two steps: vacuum absorption and surface film coating. Firstly, phase change material (PCM) was incorporated into expanded perlite (EP) through a vacuum absorption method to obtain composite PCM; secondly, the composite PCM was immersed into the mixture of colloidal silica and organic acrylate, and then it was taken out and dried naturally. A series of experiments, including differential scanning calorimeter (DSC), scanning electron microscope (SEM), best matching test, and durability test, have been conducted to characterize and analyze the thermophysical property and reliability of PCMP. Additionally, the thermal performance of BESP was studied through a dynamic thermal property test. The results have showed that: (1) the surface film coating procedure can effectively solve the leakage problem of composite phase change material prepared by vacuum impregnation; (2) the optimum adsorption ratio for paraffin and EP was 52.5:47.5 in mass fraction, and the PCMP has good thermal properties, stability, and durability; and (3) in the process of dynamic thermal performance test, BESP have low temperature variation, significant temperature lagging, and large heat storage ability, which indicated the potential of BESP in the application of building energy efficiency. PMID:28787870

Gas adsorption/absorption heat switch, phase 1

NASA Technical Reports Server (NTRS)

Chan, C. K.

1987-01-01

The service life and/or reliability of far-infrared sensors on surveillance satellites is presently limited by the cryocooler. The life and/or reliability, however, can be extended by using redundant cryocoolers. To reduce parasitic heat leak, each stage of the inactive redundant cryocooler must be thermally isolated from the optical system, while each stage of the active cryocooler must be thermally connected to the system. The thermal break or the thermal contact can be controlled by heat switches. Among different physical mechanisms for heat switching, mechanically activated heat switches tend to have low reliability and, furthermore, require a large contact force. Magnetoresistive heat switches are, except at very low temperatures, of very low efficiency. Heat switches operated by the heat pipe principle usually require a long response time. A sealed gas gap heat switch operated by an adsorption pump has no mechanical motion and should provide the reliability and long lifetime required in long-term space missions. Another potential application of a heat switch is the thermal isolation of the optical plane during decontamination.

A high reliability module with thermoelectric device by molding technology for M2M wireless sensor network

NASA Astrophysics Data System (ADS)

Nakagawa, K.; Tanaka, T.; Suzuki, T.

2015-10-01

This paper presents the fabrication of a new energy harvesting module that uses a thermoelectric device (TED) by using molding technology. Through molding technology, the TED and circuit board can be properly protected and a heat-radiating fin structure can be simultaneously constructed. The output voltage per heater temperature of the TED module at 20 °C ambient temperature is 8 mV K-1, similar to the result with the aluminum heat sink which is almost the same fin size as the TED module. The accelerated environmental tests are performed on a damp heat test, which is an aging test under high temperature and high humidity, highly accelerated temperature, and humidity stress test (HAST) for the purpose of evaluating the electrical reliability in harsh environments, cold test and thermal cycle test to evaluate degrading characteristics by cycling through two temperatures. All test results indicate that the TED and circuit board can be properly protected from harsh temperature and humidity by using molding technology because the output voltage of after-tested modules is reduced by less than 5%. This study presents a novel fabrication method for a high reliability TED-installed module appropriate for Machine to Machine wireless sensor networks.

Development of Composite PCMs by Incorporation of Paraffin into Various Building Materials

PubMed Central

Memon, Shazim Ali; Liao, Wenyu; Yang, Shuqing; Cui, Hongzhi; Shah, Syed Farasat Ali

2015-01-01

In this research, we focused on the development of composite phase-change materials (CPCMs) by incorporation of a paraffin through vacuum impregnation in widely used building materials (Kaolin and ground granulated blast-furnace slag (GGBS)). The composite PCMs were characterized using environmental scanning electron microscopy (ESEM), Fourier transform infrared spectroscopy (FT-IR), differential scanning calorimetry (DSC) and thermogravimetric analysis (TGA) techniques. Moreover, thermal performance of cement paste composite PCM panels was evaluated using a self-designed heating system. Test results showed that the maximum percentage of paraffin retained by Kaolin and GGBS was found to be 18% and 9%, respectively. FT-IR results show that CPCMs are chemically compatible. The phase-change temperatures of CPCMs were in the human comfort zone, and they possessed considerable latent-heat storage capacity. TGA results showed that CPCMs are thermally stable, and they did not show any sign of degradation below 150 °C. From thermal cycling tests, it was revealed that the CPCMs are thermally reliable. Thermal performance tests showed that in comparison to the control room model, the room models prepared with CPCMs reduced both the temperature fluctuations and maximum indoor center temperature. Therefore, the prepared CPCMs have some potential in reducing peak loads in buildings when applied to building facade. PMID:28787953

Practical Aspects of Suspension Plasma Spray for Thermal Barrier Coatings on Potential Gas Turbine Components

NASA Astrophysics Data System (ADS)

Ma, X.; Ruggiero, P.

2018-04-01

Suspension plasma spray (SPS) process has attracted extensive efforts and interests to produce fine-structured and functional coatings. In particular, thermal barrier coatings (TBCs) applied by SPS process gain increasing interest due to its potential for superior thermal protection of gas turbine hot sections as compared to conventional TBCs. Unique columnar architectures and nano- and submicrometric grains in the SPS-TBC demonstrated some advantages of thermal shock durability, low thermal conductivity, erosion resistance and strain-tolerant microstructure. This work aimed to look into some practical aspects of SPS processing for TBC applications before it becomes a reliable industry method. The spray capability and applicability of SPS process to achieve uniformity thickness and microstructure on curved substrates were emphasized in designed spray trials to simulate the coating fabrication onto industrial turbine parts with complex configurations. The performances of the SPS-TBCs were tested in erosion, falling ballistic impact and indentational loading tests as to evaluate SPS-TBC performances in simulated turbine service conditions. Finally, a turbine blade was coated and sectioned to verify SPS sprayability in multiple critical sections. The SPS trials and test results demonstrated that SPS process is promising for innovative TBCs, but some challenges need to be addressed and resolved before it becomes an economic and capable industrial process, especially for complex turbine components.

Scaled CMOS Reliability and Considerations for Spacecraft Systems: Bottom-Up and Top-Down Perspective

NASA Technical Reports Server (NTRS)

White, Mark

2012-01-01

New space missions will increasingly rely on more advanced technologies because of system requirements for higher performance, particularly in instruments and high-speed processing. Component-level reliability challenges with scaled CMOS in spacecraft systems from a bottom-up perspective have been presented. Fundamental Front-end and Back-end processing reliability issues with more aggressively scaled parts have been discussed. Effective thermal management from system-level to the componentlevel (top-down) is a key element in overall design of reliable systems. Thermal management in space systems must consider a wide range of issues, including thermal loading of many different components, and frequent temperature cycling of some systems. Both perspectives (top-down and bottom-up) play a large role in robust, reliable spacecraft system design.

Application of High-Temperature Extrinsic Fabry-Perot Interferometer Strain Sensor

NASA Technical Reports Server (NTRS)

Piazza, Anthony

2008-01-01

In this presentation to the NASA Aeronautics Sensor Working Group the application of a strain sensor is outlined. The high-temperature extrinsic Fabry-Perot interferometer (EFPI) strain sensor was developed due to a need for robust strain sensors that operate accurately and reliably beyond 1800 F. Specifically, the new strain sensor would provide data for validating finite element models and thermal-structural analyses. Sensor attachment techniques were also developed to improve methods of handling and protecting the fragile sensors during the harsh installation process. It was determined that thermal sprayed attachments are preferable even though cements are simpler to apply as cements are more prone to bond failure and are often corrosive. Previous thermal/mechanical cantilever beam testing of EFPI yielded very little change to 1200 F, with excellent correlation with SG to 550 F. Current combined thermal/mechanical loading for sensitivity testing is accomplished by a furnace/cantilever beam loading system. Dilatometer testing has can also be used in sensor characterization to evaluate bond integrity, evaluate sensitivity and accuracy and to evaluate sensor-to-sensor scatter, repeatability, hysteresis and drift. Future fiber optic testing will examine single-mode silica EFPIs in a combined thermal/mechanical load fixture on C-C and C-SiC substrates, develop a multi-mode Sapphire strain-sensor, test and evaluate high-temperature fiber Bragg Gratings for use as strain and temperature sensors and attach and evaluate a high-temperature heat flux gauge.

DOE Office of Scientific and Technical Information (OSTI.GOV)

Fu, Jiajia; Zhao, Lixia, E-mail: lxzhao@semi.ac.cn, E-mail: jmli@semi.ac.cn; Cao, Haicheng

The degradation behaviors of high power GaN-based vertical blue LEDs on Si substrates were measured using in-situ accelerated life test. The results show that the dominant failure mechanism would be different during the operation. Besides that, the corresponding associated failure mechanisms were investigated systematically by using different analysis technologies, such as Scan Electron Microscopy, Reflectivity spectroscopy, Transient Thermal Analysis, Raman Spectra, etc. It is shown that initially, the failure modes were mainly originated from the semiconductor die and interconnect, while afterwards, the following serious deterioration of the radiant fluxes was attributed to the package. The interface material and quality, suchmore » as die attach and frame, play an important role in determining the thermal performance and reliability. In addition, the heating effect during the operation will also release the compressive strain in the chip. These findings will help to improve the reliability of GaN-based LEDs, especially for the LEDs with vertical structure.« less

RADC thermal guide for reliability engineers

NASA Astrophysics Data System (ADS)

Morrison, G. N.; Kallis, J. M.; Strattan, L. A.; Jones, I. R.; Lena, A. L.

1982-06-01

This guide was developed to provide a reliability engineer, who is not proficient in thermal design and analysis techniques, with the tools for managing and evaluating the thermal design and production of electronic equipment. It defines the requirements and tasks that should be addressed in system equipment specifications and statements of work, and describes how to evaluate performance.

Qualification and Reliability for MEMS and IC Packages

NASA Technical Reports Server (NTRS)

Ghaffarian, Reza

2004-01-01

Advanced IC electronic packages are moving toward miniaturization from two key different approaches, front and back-end processes, each with their own challenges. Successful use of more of the back-end process front-end, e.g. microelectromechanical systems (MEMS) Wafer Level Package (WLP), enable reducing size and cost. Use of direct flip chip die is the most efficient approach if and when the issues of know good die and board/assembly are resolved. Wafer level package solve the issue of known good die by enabling package test, but it has its own limitation, e.g., the I/O limitation, additional cost, and reliability. From the back-end approach, system-in-a-package (SIAP/SIP) development is a response to an increasing demand for package and die integration of different functions into one unit to reduce size and cost and improve functionality. MEMS add another challenging dimension to electronic packaging since they include moving mechanical elements. Conventional qualification and reliability need to be modified and expanded in most cases in order to detect new unknown failures. This paper will review four standards that already released or being developed that specifically address the issues on qualification and reliability of assembled packages. Exposures to thermal cycles, monotonic bend test, mechanical shock and drop are covered in these specifications. Finally, mechanical and thermal cycle qualification data generated for MEMS accelerometer will be presented. The MEMS was an element of an inertial measurement unit (IMU) qualified for NASA Mars Exploration Rovers (MERs), Spirit and Opportunity that successfully is currently roaring the Martian surface

Reliability analysis of single crystal NiAl turbine blades

NASA Technical Reports Server (NTRS)

Salem, Jonathan; Noebe, Ronald; Wheeler, Donald R.; Holland, Fred; Palko, Joseph; Duffy, Stephen; Wright, P. Kennard

1995-01-01

As part of a co-operative agreement with General Electric Aircraft Engines (GEAE), NASA LeRC is modifying and validating the Ceramic Analysis and Reliability Evaluation of Structures algorithm for use in design of components made of high strength NiAl based intermetallic materials. NiAl single crystal alloys are being actively investigated by GEAE as a replacement for Ni-based single crystal superalloys for use in high pressure turbine blades and vanes. The driving force for this research lies in the numerous property advantages offered by NiAl alloys over their superalloy counterparts. These include a reduction of density by as much as a third without significantly sacrificing strength, higher melting point, greater thermal conductivity, better oxidation resistance, and a better response to thermal barrier coatings. The current drawback to high strength NiAl single crystals is their limited ductility. Consequently, significant efforts including the work agreement with GEAE are underway to develop testing and design methodologies for these materials. The approach to validation and component analysis involves the following steps: determination of the statistical nature and source of fracture in a high strength, NiAl single crystal turbine blade material; measurement of the failure strength envelope of the material; coding of statistically based reliability models; verification of the code and model; and modeling of turbine blades and vanes for rig testing.

A novel 3D deformation measurement method under optical microscope for micro-scale bulge-test

NASA Astrophysics Data System (ADS)

Wu, Dan; Xie, Huimin

2017-11-01

A micro-scale 3D deformation measurement method combined with optical microscope is proposed in this paper. The method is based on gratings and phase shifting algorithm. By recording the grating images before and after deformation from two symmetrical angles and calculating the phases of the grating patterns, the 3D deformation field of the specimen can be extracted from the phases of the grating patterns. The proposed method was applied to the micro-scale bulge test. A micro-scale thermal/mechanical coupling bulge-test apparatus matched with the super-depth microscope was exploited. With the gratings fabricated onto the film, the deformed morphology of the bulged film was measured reliably. The experimental results show that the proposed method and the exploited bulge-test apparatus can be used to characterize the thermal/mechanical properties of the films at micro-scale successfully.

Thermal Management and Reliability of Automotive Power Electronics and Electric Machines

DOE Office of Scientific and Technical Information (OSTI.GOV)

Narumanchi, Sreekant V; Bennion, Kevin S; Cousineau, Justine E

Low-cost, high-performance thermal management technologies are helping meet aggressive power density, specific power, cost, and reliability targets for power electronics and electric machines. The National Renewable Energy Laboratory is working closely with numerous industry and research partners to help influence development of components that meet aggressive performance and cost targets through development and characterization of cooling technologies, and thermal characterization and improvements of passive stack materials and interfaces. Thermomechanical reliability and lifetime estimation models are important enablers for industry in cost-and time-effective design.

Design and reliability of a MEMS thermal rotary actuator.

DOE Office of Scientific and Technical Information (OSTI.GOV)

Baker, Michael Sean; Corwin, Alex David

2007-09-01

A new rotary MEMS actuator has been developed and tested at Sandia National Laboratories that utilizes a linear thermal actuator as the drive mechanism. This actuator was designed to be a low-voltage, high-force alternative to the existing electrostatic torsional ratcheting actuator (TRA) [1]. The new actuator, called the Thermal Rotary Actuator (ThRA), is conceptually much simpler than the TRA and consists of a gear on a hub that is turned by a linear thermal actuator [2] positioned outside of the gear. As seen in Figure 1, the gear is turned through a ratcheting pawl, with anti-reverse pawls positioned around themore » gear for unidirectional motion (see Figure 1). A primary consideration in the design of the ThRA was the device reliability and in particular, the required one-to-one relationship between the ratcheting output motion and the electrical input signal. The electrostatic TRA design has been shown to both over-drive and under-drive relative to the number of input pulses [3]. Two different ThRA designs were cycle tested to measure the skip rate. This was done in an automated test setup by using pattern matching to measure the angle of rotation of the output gear after a defined number of actuation pulses. By measuring this gear angle over time, the number of skips can be determined. Figure 2 shows a picture of the ThRA during testing, with the pattern-matching features highlighted. In the first design tested, it was found that creep in the thermal actuator limited the number of skip-free cycles, as the rest position of the actuator would creep forward enough to prevent the counter-rotation pawls from fully engaging (Figure 3). Even with this limitation, devices were measured with up to 100 million cycles with no skipping. A design modification was made to reduce the operating temperature of the thermal actuator which has been shown in a previous study [2] to reduce the creep rate. In addition, changes were made to the drive ratchet design and actuation direction to increase the available output force. This new design was tested and shown to operate in one case out to greater than 360 million cycles without any skipping, after which the test was stopped without failure. The output force was also measured as a function of input voltage (Figure 4), and shown to be higher than the previous design. The maximum force shown in the figure is a limit of the gauge used, not the actuator itself. Continued work for this design will focus on understanding the actuator performance while driving a load, as all current tests were performed with no load on the output gear.« less

Lateral Load Testing of the Advanced Stirling Convertor (ASC-E2) Heater Head

NASA Technical Reports Server (NTRS)

Cornell, Peggy A.; Krause, David L.; Davis, Glen; Robbie, Malcolm G.; Gubics, David A.

2010-01-01

Free-piston Stirling convertors are fundamental to the development of NASA s next generation of radioisotope power system, the Advanced Stirling Radioisotope Generator (ASRG). The ASRG will use General Purpose Heat Source (GPHS) modules as the energy source and Advanced Stirling Convertors (ASCs) to convert heat into electrical energy, and is being developed by Lockheed Martin under contract to the Department of Energy. Achieving flight status mandates that the ASCs satisfy design as well as flight requirements to ensure reliable operation during launch. To meet these launch requirements, GRC performed a series of quasi-static mechanical tests simulating the pressure, thermal, and external loading conditions that will be experienced by an ASC-E2 heater head assembly. These mechanical tests were collectively referred to as "lateral load tests" since a primary external load lateral to the heater head longitudinal axis was applied in combination with the other loading conditions. The heater head was subjected to the operational pressure, axial mounting force, thermal conditions, and axial and lateral launch vehicle acceleration loadings. To permit reliable prediction of the heater head s structural performance, GRC completed Finite Element Analysis (FEA) computer modeling for the stress, strain, and deformation that will result during launch. The heater head lateral load test directly supported evaluation of the analysis and validation of the design to meet launch requirements. This paper provides an overview of each element within the test and presents assessment of the modeling as well as experimental results of this task.

Lateral Load Testing of the Advanced Stirling Convertor (ASC-E2) Heater Head

NASA Technical Reports Server (NTRS)

Cornell, Peggy A.; Krause, David L.; Davis, Glen; Robbie, Malcolm G.; Gubics, David A.

2011-01-01

Free-piston Stirling convertors are fundamental to the development of NASA s next generation of radioisotope power system, the Advanced Stirling Radioisotope Generator (ASRG). The ASRG will use General Purpose Heat Source (GPHS) modules as the energy source and Advanced Stirling Convertors (ASCs) to convert heat into electrical energy, and is being developed by Lockheed Martin under contract to the Department of Energy. Achieving flight status mandates that the ASCs satisfy design as well as flight requirements to ensure reliable operation during launch. To meet these launch requirements, GRC performed a series of quasi-static mechanical tests simulating the pressure, thermal, and external loading conditions that will be experienced by an ASC-E2 heater head assembly. These mechanical tests were collectively referred to as "lateral load tests" since a primary external load lateral to the heater head longitudinal axis was applied in combination with the other loading conditions. The heater head was subjected to the operational pressure, axial mounting force, thermal conditions, and axial and lateral launch vehicle acceleration loadings. To permit reliable prediction of the heater head s structural performance, GRC completed Finite Element Analysis (FEA) computer modeling for the stress, strain, and deformation that will result during launch. The heater head lateral load test directly supported evaluation of the analysis and validation of the design to meet launch requirements. This paper provides an overview of each element within the test and presents assessment of the modeling as well as experimental results of this task.

Lateral Load Testing of the Advanced Stirling Convertor (ASC-E2) Heater Head

NASA Technical Reports Server (NTRS)

Cornell, Peggy A.; Krause, David L.; Davis, Glen; Robbie, Malcolm G.; Gubics, David A.

2010-01-01

Free-piston Stirling convertors are fundamental to the development of NASA s next generation of radioisotope power system, the Advanced Stirling Radioisotope Generator (ASRG). The ASRG will use General Purpose Heat Source (GPHS) modules as the energy source and Advanced Stirling Convertors (ASCs) to convert heat into electrical energy, and is being developed by Lockheed Martin under contract to the Department of Energy. Achieving flight status mandates that the ASCs satisfy design as well as flight requirements to ensure reliable operation during launch. To meet these launch requirements, GRC performed a series of quasi-static mechanical tests simulating the pressure, thermal, and external loading conditions that will be experienced by an ASC E2 heater head assembly. These mechanical tests were collectively referred to as lateral load tests since a primary external load lateral to the heater head longitudinal axis was applied in combination with the other loading conditions. The heater head was subjected to the operational pressure, axial mounting force, thermal conditions, and axial and lateral launch vehicle acceleration loadings. To permit reliable prediction of the heater head s structural performance, GRC completed Finite Element Analysis (FEA) computer modeling for the stress, strain, and deformation that will result during launch. The heater head lateral load test directly supported evaluation of the analysis and validation of the design to meet launch requirements. This paper provides an overview of each element within the test and presents assessment of the modeling as well as experimental results of this task.

Thermal fatigue life evaluation of SnAgCu solder joints in a multi-chip power module

NASA Astrophysics Data System (ADS)

Barbagallo, C.; Malgioglio, G. L.; Petrone, G.; Cammarata, G.

2017-05-01

For power devices, the reliability of thermal fatigue induced by thermal cycling has been prioritized as an important concern. The main target of this work is to apply a numerical procedure to assess the fatigue life for lead-free solder joints, that represent, in general, the weakest part of the electronic modules. Starting from a real multi-chip power module, FE-based models were built-up by considering different conditions in model implementation in order to simulate, from one hand, the worst working condition for the module and, from another one, the module standing into a climatic test room performing thermal cycles. Simulations were carried-out both in steady and transient conditions in order to estimate the module thermal maps, the stress-strain distributions, the effective plastic strain distributions and finally to assess the number of cycles to failure of the constitutive solder layers.

Microstructure Evolution and Protrusion of Electroplated Cu-Filled Through-Silicon Vias Subjected to Thermal Cyclic Loading

NASA Astrophysics Data System (ADS)

Chen, Si; An, Tong; Qin, Fei; Chen, Pei

2017-10-01

Through-silicon vias (TSVs) have become an important technology for three-dimensional integrated circuit (3D IC) packaging. Protrusion of electroplated Cu-filled vias is a critical reliability issue for TSV technology. In this work, thermal cycling tests were carried out to identify how the microstructure affects protrusion during thermal cycling. Cu protrusion occurs when the loading temperature is higher than 149°C. During the first five thermal cycles, the grain size of Cu plays a dominant role in the protrusion behavior. Larger Cu grain size before thermal cycling results in greater Cu protrusion. With increasing thermal cycle number, the effect of the Cu grain size reduces and the microstrain begins to dominate the Cu protrusion behavior. Higher magnitude of microstrain within Cu results in greater protrusion increment during subsequent thermal cycles. When the thermal cycle number reaches 25, the protrusion rate of Cu slows down due to strain hardening. After 30 thermal cycles, the Cu protrusion stabilizes within the range of 1.92 μm to 2.09 μm.

Reliability of High Power Laser Diode Arrays Operating in Long Pulse Mode

NASA Technical Reports Server (NTRS)

Amzajerdian, Farzin; Meadows, Byron L.; Barnes, Bruce W.; Lockard, George E.; Singh, Upendra N.; Kavaya, Michael J.; Baker, Nathaniel R.

2006-01-01

Reliability and lifetime of quasi-CW laser diode arrays are greatly influenced by their thermal characteristics. This paper examines the thermal properties of laser diode arrays operating in long pulse duration regime.

Thermal–hydraulic–mechanical modeling of a large-scale heater test to investigate rock salt and crushed salt behavior under repository conditions for heat-generating nuclear waste

DOE PAGES

Blanco-Martín, Laura; Wolters, Ralf; Rutqvist, Jonny; ...

2016-04-28

The Thermal Simulation for Drift Emplacement heater test is modeled with two simulators for coupled thermal-hydraulic-mechanical processes. Results from the two simulators are in very good agreement. The comparison between measurements and numerical results is also very satisfactory, regarding temperature, drift closure and rock deformation. Concerning backfill compaction, a parameter calibration through inverse modeling was performed due to insufficient data on crushed salt reconsolidation, particularly at high temperatures. We conclude that the two simulators investigated have the capabilities to reproduce the data available, which increases confidence in their use to reliably investigate disposal of heat-generating nuclear waste in saliferous geosystems.

Thermal–hydraulic–mechanical modeling of a large-scale heater test to investigate rock salt and crushed salt behavior under repository conditions for heat-generating nuclear waste

DOE Office of Scientific and Technical Information (OSTI.GOV)

Blanco-Martín, Laura; Wolters, Ralf; Rutqvist, Jonny

The Thermal Simulation for Drift Emplacement heater test is modeled with two simulators for coupled thermal-hydraulic-mechanical processes. Results from the two simulators are in very good agreement. The comparison between measurements and numerical results is also very satisfactory, regarding temperature, drift closure and rock deformation. Concerning backfill compaction, a parameter calibration through inverse modeling was performed due to insufficient data on crushed salt reconsolidation, particularly at high temperatures. We conclude that the two simulators investigated have the capabilities to reproduce the data available, which increases confidence in their use to reliably investigate disposal of heat-generating nuclear waste in saliferous geosystems.

Effect of Cyclic Thermo-Mechanical Loads on Fatigue Reliability in Polymer Matrix Composites

NASA Technical Reports Server (NTRS)

Shah, A. R.; Murthy, P. L. N.; Chamis, C. C.

1996-01-01

A methodology to compute probabilistic fatigue life of polymer matrix laminated composites has been developed and demonstrated. Matrix degradation effects caused by long term environmental exposure and mechanical/thermal cyclic loads are accounted for in the simulation process. A unified time-temperature-stress dependent multi-factor interaction relationship developed at NASA Lewis Research Center has been used to model the degradation/aging of material properties due to cyclic loads. The fast probability integration method is used to compute probabilistic distribution of response. Sensitivities of fatigue life reliability to uncertainties in the primitive random variables (e.g., constituent properties, fiber volume ratio, void volume ratio, ply thickness, etc.) computed and their significance in the reliability- based design for maximum life is discussed. The effect of variation in the thermal cyclic loads on the fatigue reliability for a (0/+/- 45/90)(sub s) graphite/epoxy laminate with a ply thickness of 0.127 mm, with respect to impending failure modes has been studied. The results show that, at low mechanical cyclic loads and low thermal cyclic amplitudes, fatigue life for 0.999 reliability is most sensitive to matrix compressive strength, matrix modulus, thermal expansion coefficient, and ply thickness. Whereas at high mechanical cyclic loads and high thermal cyclic amplitudes, fatigue life at 0.999 reliability is more sensitive to the shear strength of matrix, longitudinal fiber modulus, matrix modulus, and ply thickness.

Procedures for testing and evaluating spacecraft-type heat pipes

NASA Astrophysics Data System (ADS)

Tower, L. K.; Kaufman, W. B.

1984-04-01

This report describes part of an effort to develop dependable, cost effective spacecraft thermal control heat pipes. In the program the reliability and performance of 30 commercially available heat pipes were assessed. The pipes comprised 10 groups of varying design, with aluminum and stainless steel as structural materials, and methanol and ammonia as working fluids. The factors studied were noncondensible gas accumulation and heat transfer capability in one g. The present report supplements a brief earlier report by describing in detail the procedures required to conduct a comprehensive evaluation of heat pipes for thermal control. It discusses the test facilities and testing procedures. The manner in which data may be taken for estimating useful life and comparing performance is described. Some of the pitfalls in making such judgments are illustrated. Originator supplied keywords include: heat transfer, and corrosion.

Study of silicone-based materials for the packaging of optoelectronic devices

NASA Astrophysics Data System (ADS)

Lin, Yeong-Her

The first part of this work is to evaluate the main materials used for the packaging of high power light-emitting diodes (LEDs), i.e., the die attach materials, the encapsulant materials, and high color rendering index(CRI) sol-gel composite materials. All of these materials had been discussed the performance, reliability, and issues in high power LED packages. High power white LEDs are created either from blue or near-ultraviolet chips encapsulated with a yellow phosphor, or from red-green-blue LED light mixing systems. The phosphor excited by blue LED chip was mostly used in experiment of this dissertation. The die attach materials contains filler particles possessing a maximum particle size less than 1.5 mum in diameter blended with epoxy polymer matrix. Such compositions enable thin bond line thickness, which decreases thermal resistance that exists between thermal interface materials and the corresponding mating surfaces. The thermal conductivity of nano silver die attach materials is relatively low, the thermal resistance from the junction to board is just 1.6 KW-1 in the bond line thickness of 5.3 mum, which is much lower than the thermal resistance using conventional die attach materials. The silicone die attach adhesive made in the lab cures through the free radical reaction of epoxy-functional organopolysiloxane and through the hydrosilylation reaction between alkenyl-functional organopolysiloxane and silicone-boned hydrogen-functional organopolysiloxane. By the combination of the free radical reaction and the hydrosilylation reaction, the low-molecular-weight silicone oil will not be out-migrated and not contaminate wire bondability to the LED chip and lead frame. Hence, the silicone die attach adhesive made in the lab can pass all reliability tests, such as operating life test JEDEC 85°C/85RH and room temperature operating life test. For LED encapsulating materials, most of commercial silicone encapsulants still suffer thermal/radiation induced degradations, and thus cause reliability issues and shorten the lifetime. A new high performance silicone has been developed and its performance has been compared with other commercial silicone products in the packaging of high power white LEDs. The high performance silicone also has better results than commercial high refractive index silicone and optical grade epoxy under JEDEC reliability standard for moisture sensitivity test. In synthesis of red dye-doped particles by sol-gel method, it is a novel method to get high color rendering index (CRI) LEDs. These red dye-doped particles, with average diameter of 5 mum, can be mixed with liquid encapsulants to form a uniform distribution in polymer matrix. The red dye-doped particles can be excited by phosphor-emitted yellow light instead of blue light from LED chip. Therefore, warm white LEDs with high CRI can be gotten at high lumen efficiency. The second part of this work is silicone elastomer for biomedical applications, especially in making urological implantable devices. A cross-linked, heat curable, addition-reaction silicone material is prepared. The material may be molded or formed into one or more medical devices. One such medical device could be a catheter used in urological applications. The material is a long term indwelling material that resists encrustation like a metal stent, but is more comfortable because it is silicone-based. The material can be made relatively cheaply compared to metal stents. Furthermore, the material is biocompatible with bladder epithelial cells.

Electronics reliability fracture mechanics. Volume 2: Fracture mechanics

NASA Astrophysics Data System (ADS)

Kallis, J.; Duncan, L.; Buechler, D.; Backes, P.; Sandkulla, D.

1992-05-01

This is the second of two volumes. The other volume (WL-TR-92-3015) is 'Causes of Failures of Shop Replaceable Units and Hybrid Microcircuits.' The objective of the Electronics Reliability Fracture Mechanics (ERFM) program was to develop and demonstrate a life prediction technique for electronic assemblies, when subjected to environmental stresses of vibration and thermal cycling, based upon the mechanical properties of the materials and packaging configurations which make up an electronic system. The application of fracture mechanics to microscale phenomena in electronic assemblies was a pioneering research effort. The small scale made the experiments very difficult; for example, the 1-mil-diameter bond wires in microelectronic devices are 1/3 the diameter of a human hair. A number of issues had to be resolved to determine whether a fracture mechanics modelling approach is correct for the selected failures; specifically, the following two issues had to be resolved: What fraction of the lifetime is spent in crack initiation? Are macro fracture mechanics techniques, used in large structures such as bridges, applicable to the tiny structures in electronic equipment? The following structural failure mechanisms were selected for modelling: bondwire fracture from mechanical cycling; bondwire fracture from thermal (power) cycling; plated through hole (PTH) fracture from thermal cycling. The bondwire fracture test specimens were A1-1 percent Si wires, representative of wires used in the parts in the modules selected for detailed investigation in this program (see Vol. 1 of this report); 1-mil-diameter wires were tested in this program. The PTH test specimens were sections of 14-layer printed wiring boards of the type used.

Use of advanced modeling techniques to optimize thermal packaging designs.

PubMed

Formato, Richard M; Potami, Raffaele; Ahmed, Iftekhar

2010-01-01

Through a detailed case study the authors demonstrate, for the first time, the capability of using advanced modeling techniques to correctly simulate the transient temperature response of a convective flow-based thermal shipper design. The objective of this case study was to demonstrate that simulation could be utilized to design a 2-inch-wall polyurethane (PUR) shipper to hold its product box temperature between 2 and 8 °C over the prescribed 96-h summer profile (product box is the portion of the shipper that is occupied by the payload). Results obtained from numerical simulation are in excellent agreement with empirical chamber data (within ±1 °C at all times), and geometrical locations of simulation maximum and minimum temperature match well with the corresponding chamber temperature measurements. Furthermore, a control simulation test case was run (results taken from identical product box locations) to compare the coupled conduction-convection model with a conduction-only model, which to date has been the state-of-the-art method. For the conduction-only simulation, all fluid elements were replaced with "solid" elements of identical size and assigned thermal properties of air. While results from the coupled thermal/fluid model closely correlated with the empirical data (±1 °C), the conduction-only model was unable to correctly capture the payload temperature trends, showing a sizeable error compared to empirical values (ΔT > 6 °C). A modeling technique capable of correctly capturing the thermal behavior of passively refrigerated shippers can be used to quickly evaluate and optimize new packaging designs. Such a capability provides a means to reduce the cost and required design time of shippers while simultaneously improving their performance. Another advantage comes from using thermal modeling (assuming a validated model is available) to predict the temperature distribution in a shipper that is exposed to ambient temperatures which were not bracketed during its validation. Thermal packaging is routinely used by the pharmaceutical industry to provide passive and active temperature control of their thermally sensitive products from manufacture through end use (termed the cold chain). In this study, the authors focus on passive temperature control (passive control does not require any external energy source and is entirely based on specific and/or latent heat of shipper components). As temperature-sensitive pharmaceuticals are being transported over longer distances, cold chain reliability is essential. To achieve reliability, a significant amount of time and resources must be invested in design, test, and production of optimized temperature-controlled packaging solutions. To shorten the cumbersome trial and error approach (design/test/design/test …), computer simulation (virtual prototyping and testing of thermal shippers) is a promising method. Although several companies have attempted to develop such a tool, there has been limited success to date. Through a detailed case study the authors demonstrate, for the first time, the capability of using advanced modeling techniques to correctly simulate the transient temperature response of a coupled conductive/convective-based thermal shipper. A modeling technique capable of correctly capturing shipper thermal behavior can be used to develop packaging designs more quickly, reducing up-front costs while also improving shipper performance.

Thermal Barrier Coatings for Advanced Gas Turbine and Diesel Engines

NASA Technical Reports Server (NTRS)

Zhu, Dongming; Miller, Robert A.

1999-01-01

Ceramic thermal barrier coatings (TBCS) have been developed for advanced gas turbine and diesel engine applications to improve engine reliability and fuel efficiency. However, durability issues of these thermal barrier coatings under high temperature cyclic conditions are still of major concern. The coating failure depends not only on the coating, but also on the ceramic sintering/creep and bond coat oxidation under the operating conditions. Novel test approaches have been established to obtain critical thermomechanical and thermophysical properties of the coating systems under near-realistic transient and steady state temperature and stress gradients encountered in advanced engine systems. This paper presents detailed experimental and modeling results describing processes occurring in the ZrO2-Y2O3 thermal barrier coating systems, thus providing a framework for developing strategies to manage ceramic coating architecture, microstructure and properties.

Thermal System Verification and Model Validation for NASA's Cryogenic Passively Cooled James Webb Space Telescope

NASA Technical Reports Server (NTRS)

Cleveland, Paul E.; Parrish, Keith A.

2005-01-01

A thorough and unique thermal verification and model validation plan has been developed for NASA s James Webb Space Telescope. The JWST observatory consists of a large deployed aperture optical telescope passively cooled to below 50 Kelvin along with a suite of several instruments passively and actively cooled to below 37 Kelvin and 7 Kelvin, respectively. Passive cooling to these extremely low temperatures is made feasible by the use of a large deployed high efficiency sunshield and an orbit location at the L2 Lagrange point. Another enabling feature is the scale or size of the observatory that allows for large radiator sizes that are compatible with the expected power dissipation of the instruments and large format Mercury Cadmium Telluride (HgCdTe) detector arrays. This passive cooling concept is simple, reliable, and mission enabling when compared to the alternatives of mechanical coolers and stored cryogens. However, these same large scale observatory features, which make passive cooling viable, also prevent the typical flight configuration fully-deployed thermal balance test that is the keystone to most space missions thermal verification plan. JWST is simply too large in its deployed configuration to be properly thermal balance tested in the facilities that currently exist. This reality, when combined with a mission thermal concept with little to no flight heritage, has necessitated the need for a unique and alternative approach to thermal system verification and model validation. This paper describes the thermal verification and model validation plan that has been developed for JWST. The plan relies on judicious use of cryogenic and thermal design margin, a completely independent thermal modeling cross check utilizing different analysis teams and software packages, and finally, a comprehensive set of thermal tests that occur at different levels of JWST assembly. After a brief description of the JWST mission and thermal architecture, a detailed description of the three aspects of the thermal verification and model validation plan is presented.

A probabilistic method to establish the reliability of carbon-carbon rocket motor nozzles. Volume 3: Stress and reliability analysis of layered composite cylinders under thermal shock

NASA Astrophysics Data System (ADS)

Heller, R. A.; Thangjitham, S.; Wang, X.

1992-04-01

The state of stress in a cylindrical structure consisting of multiple layers of carbon-carbon composite and subjected to thermal and pressure shock are analyzed using an elasticity approach. The reliability of the structure based on the weakest link concept and the Weibull distribution is also calculated. Coupled thermo-elasticity is first assumed and is shown to be unnecessary for the material considered. The effects of external and internal thermal shock as well as a superimposed pressure shock are examined. It is shown that for the geometry chosen, the structure may fail when exposed to thermal shock alone while a superimposed pressure shock can mitigate the probability of failure.

A novel approach on accelerated ageing towards reliability optimization of high concentration photovoltaic cells

NASA Astrophysics Data System (ADS)

Tsanakas, John A.; Jaffre, Damien; Sicre, Mathieu; Elouamari, Rachid; Vossier, Alexis; de Salins, Jean-Edouard; Bechou, Laurent; Levrier, Bruno; Perona, Arnaud; Dollet, Alain

2014-09-01

This paper presents a preliminary study upon a novel approach proposed for highly accelerated ageing and reliability optimization of high concentrating photovoltaic (HCPV) cells and assemblies. The intended approach aims to overcome several limitations of some current accelerated ageing tests (AAT) adopted up today, proposing the use of an alternative experimental set-up for performing faster and more realistic thermal cycles, under real sun, without the involvement of environmental chamber. The study also includes specific characterization techniques, before and after each AAT sequence, which respectively provide the initial and final diagnosis on the condition of the tested sample. The acquired data from these diagnostic/characterization methods are then used as indices to determine both quantitatively and qualitatively the severity of degradation and, thus, the ageing level for each tested HCPV assembly or cell sample. Ultimate goal of such "initial diagnosis - AAT - final diagnosis" sequences is to provide the basis for a future work on the reliability analysis of the main degradation mechanisms and confident prediction of failure propagation in HCPV cells, by means of acceleration factor (AF) and mean-time-to-failure (MTTF) estimations.

Aerogel Insulation Applications for Liquid Hydrogen Launch Vehicle Tanks

NASA Technical Reports Server (NTRS)

Fesmire, J. E.; Sass, J.

2007-01-01

Aerogel based insulation systems for ambient pressure environments were developed for liquid hydrogen (LH2) tank applications. Solutions to thermal insulation problems were demonstrated for the Space Shuttle External Tank (ET) through extensive testing at the Cryogenics Test Laboratory. Demonstration testing was performed using a 1/10th scale ET LH2 intertank unit and liquid helium as the coolant to provide the 20 K cold boundary temperature. Cryopumping tests in the range of 20K were performed using both constant mass and constant pressure methods. Long-duration tests (up to 10 hours) showed that the nitrogen mass taken up inside the intertank is reduced by a factor of nearly three for the aerogel insulated case as compared to the un-insulated (bare metal flight configuration) case. Test results including thermal stabilization, heat transfer effectiveness, and cryopumping confirm that the aerogel system eliminates free liquid nitrogen within the intertank. Physisorption (or adsorption) of liquid nitrogen within the fine pore structure of aerogel materials was also investigated. Results of a mass uptake method show that the sorption ratio (liquid nitrogen to aerogel beads) is about 62 percent by volume. A novel liquid nitrogen production method of testing the liquid nitrogen physical adsorption capacity of aerogel beads was also performed to more closely approximate the actual launch vehicle cooldown and thermal stabilization effects within the aerogel material. The extraordinary insulating effectiveness of the aerogel material shows that cryopumping is not an open-cell mass transport issue but is strictly driven by thermal communication between warm and cold surfaces. The new aerogel insulation technology is useful to solve heat transfer problem areas and to augment existing thermal protection systems on launch vehicles. Examples are given and potential benefits for producing launch systems that are more reliable, robust, reusable, and efficient are outlined.

Healing of voids in the aluminum metallization of integrated circuit chips

NASA Technical Reports Server (NTRS)

Cuddihy, Edward F.; Lawton, Russell A.; Gavin, Thomas R.

1990-01-01

The thermal stability of GaAs modulation-doped field effect transistors (MODFETs) is evaluated in order to identify failure mechanisms and validate the reliability of these devices. The transistors were exposed to thermal step-stress and characterized at ambient temperatures to indicate device reliability, especially that of the transistor ohmic contacts with and without molybdenum diffusion barriers. The devices without molybdenum exhibited important transconductance deterioration. MODFETs with molybdenum diffusion barriers were tolerant to temperatures above 300 C. This tolerance indicates that thermally activated failure mechanisms are slow at operational temperatures. Therefore, high-reliability MODFET-based circuits are possible.

Novel wireless sensor system for dynamic characterization of borehole heat exchangers.

PubMed

Martos, Julio; Montero, Álvaro; Torres, José; Soret, Jesús; Martínez, Guillermo; García-Olcina, Raimundo

2011-01-01

The design and field test of a novel sensor system based in autonomous wireless sensors to measure the temperature of the heat transfer fluid along a borehole heat exchanger (BHE) is presented. The system, by means of two special valves, inserts and extracts miniaturized wireless sensors inside the pipes of the borehole, which are carried by the thermal fluid. Each sensor is embedded in a small sphere of just 25 mm diameter and 8 gr weight, containing a transceiver, a microcontroller, a temperature sensor and a power supply. A wireless data processing unit transmits to the sensors the acquisition configuration before the measurements, and also downloads the temperature data measured by the sensor along its way through the BHE U-tube. This sensor system is intended to improve the conventional thermal response test (TRT) and it allows the collection of information about the thermal characteristics of the geological structure of subsurface and its influence in borehole thermal behaviour, which in turn, facilitates the implementation of TRTs in a more cost-effective and reliable way.

Novel Wireless Sensor System for Dynamic Characterization of Borehole Heat Exchangers

PubMed Central

Martos, Julio; Montero, Álvaro; Torres, José; Soret, Jesús; Martínez, Guillermo; García-Olcina, Raimundo

2011-01-01

The design and field test of a novel sensor system based in autonomous wireless sensors to measure the temperature of the heat transfer fluid along a borehole heat exchanger (BHE) is presented. The system, by means of two specials valves, inserts and extracts miniaturized wireless sensors inside the pipes of the borehole, which are carried by the thermal fluid. Each sensor is embedded in a small sphere of just 25 mm diameter and 8 gr weight, containing a transceiver, a microcontroller, a temperature sensor and a power supply. A wireless data processing unit transmits to the sensors the acquisition configuration before the measurements, and also downloads the temperature data measured by the sensor along its way through the BHE U-tube. This sensor system is intended to improve the conventional thermal response test (TRT) and it allows the collection of information about the thermal characteristics of the geological structure of subsurface and its influence in borehole thermal behaviour, which in turn, facilitates the implementation of TRTs in a more cost-effective and reliable way. PMID:22164005

Targeting adequate thermal stability and fire safety in selecting ionic liquid-based electrolytes for energy storage.

PubMed

Chancelier, L; Diallo, A O; Santini, C C; Marlair, G; Gutel, T; Mailley, S; Len, C

2014-02-07

The energy storage market relating to lithium based systems regularly grows in size and expands in terms of a portfolio of energy and power demanding applications. Thus safety focused research must more than ever accompany related technological breakthroughs regarding performance of cells, resulting in intensive research on the chemistry and materials science to design more reliable batteries. Formulating electrolyte solutions with nonvolatile and hardly flammable ionic liquids instead of actual carbonate mixtures could be safer. However, few definitions of thermal stability of electrolytes based on ionic liquids have been reported in the case of abuse conditions (fire, shortcut, overcharge or overdischarge). This work investigates thermal stability up to combustion of 1-butyl-3-methylimidazolium bis(trifluoromethanesulfonyl)imide ([C1C4Im][NTf2]) and 1-butyl-1-methylpyrrolidinium bis(trifluoromethanesulfonyl)imide ([PYR14][NTf2]) ionic liquids, and their corresponding electrolytes containing lithium bis(trifluoromethanesulfonyl)imide LiNTf2. Their possible routes of degradation during thermal abuse testings were investigated by thermodynamic studies under several experimental conditions. Their behaviours under fire were also tested, including the analysis of emitted compounds.

Travel-time-based thermal tracer tomography

NASA Astrophysics Data System (ADS)

Somogyvári, Márk; Bayer, Peter; Brauchler, Ralf

2016-05-01

Active thermal tracer testing is a technique to get information about the flow and transport properties of an aquifer. In this paper we propose an innovative methodology using active thermal tracers in a tomographic setup to reconstruct cross-well hydraulic conductivity profiles. This is facilitated by assuming that the propagation of the injected thermal tracer is mainly controlled by advection. To reduce the effects of density and viscosity changes and thermal diffusion, early-time diagnostics are used and specific travel times of the tracer breakthrough curves are extracted. These travel times are inverted with an eikonal solver using the staggered grid method to reduce constraints from the pre-defined grid geometry and to improve the resolution. Finally, non-reliable pixels are removed from the derived hydraulic conductivity tomograms. The method is applied to successfully reconstruct cross-well profiles as well as a 3-D block of a high-resolution fluvio-aeolian aquifer analog data set. Sensitivity analysis reveals a negligible role of the injection temperature, but more attention has to be drawn to other technical parameters such as the injection rate. This is investigated in more detail through model-based testing using diverse hydraulic and thermal conditions in order to delineate the feasible range of applications for the new tomographic approach.

Instructions for Plastic Encapsulated Microcircuit(PEM) Selection, Screening and Qualification.

NASA Technical Reports Server (NTRS)

King, Terry; Teverovsky, Alexander; Leidecker, Henning

2002-01-01

The use of Plastic Encapsulated Microcircuits (PEMs) is permitted on NASA Goddard Space Flight Center (GSFC) spaceflight applications, provided each use is thoroughly evaluated for thermal, mechanical, and radiation implications of the specific application and found to meet mission requirements. PEMs shall be selected for their functional advantage and availability, not for cost saving; the steps necessary to ensure reliability usually negate any initial apparent cost advantage. A PEM shall not be substituted for a form, fit and functional equivalent, high reliability, hermetic device in spaceflight applications. Due to the rapid change in wafer-level designs typical of commercial parts and the unknown traceability between packaging lots and wafer lots, lot specific testing is required for PEMs, unless specifically excepted by the Mission Assurance Requirements (MAR) for the project. Lot specific qualification, screening, radiation hardness assurance analysis and/or testing, shall be consistent with the required reliability level as defined in the MAR. Developers proposing to use PEMs shall address the following items in their Performance Assurance Implementation Plan: source selection (manufacturers and distributors), storage conditions for all stages of use, packing, shipping and handling, electrostatic discharge (ESD), screening and qualification testing, derating, radiation hardness assurance, test house selection and control, data collection and retention.

The x-ray telescope eROSITA: qualification of the thermal control system

NASA Astrophysics Data System (ADS)

Fürmetz, Maria; Eder, Josef; Pfeffermann, Elmar; Predehl, Peter

2014-07-01

eROSITA is the core instrument on the Spektrum-Röntgen-Gamma (SRG) mission, scheduled for launch in 2016. The main tasks of the thermal control system are heating of the mirror modules, cooling of the camera electronics, cooling of the CCD detectors and temperature control of the telescope structure in general. Special attention is paid to the camera cooling, since it is the most critical one. The complex assembly with the sevenfold symmetry of the eROSITA telescope requires an innovative design. Large distances and a very low operating temperature (-90°C to -100°C) place high demands on the cooling chain. In total, three different types of low-temperature ethane heat pipes are used to transport the heat from the cameras to two radiators outside the telescope structure. Extreme environmental temperature gradients with the Sun on the one side and the cold space on the other present a real challenge not only to the camera cooling systems, but to the overall thermal control. A thermal model of the complete telescope was used to predict the thermal behavior of the telescope and its subsystems. Through various tests, this model could be improved step by step. The most complex test was the space simulation test of the eROSITA qualification model in January 2013 at the IABG facilities in Ottobrunn, Germany. About 50 heaters, a liquid-nitrogen-cooled chamber and a Sun simulator provided realistic mission conditions. Approximately 200 temperature sensors monitored the relevant temperatures during the test. The results were predominantly within the predicted intervals and therefore not only verified the complete concept but also enabled a further refining of the thermal model. This, in turn, allows for reliable predictions of the thermal behavior during the mission. Some deviations required minor changes in the final design which were implemented and re-qualified in a separate test of the thermal control system flight model in March 2014 in the PANTER test facility of MPE. The results of both tests will be presented in this contribution.

Stress Intensity of Delamination in a Sintered-Silver Interconnection: Preprint

DOE Office of Scientific and Technical Information (OSTI.GOV)

DeVoto, D. J.; Paret, P. P.; Wereszczak, A. A.

2014-08-01

In automotive power electronics packages, conventional thermal interface materials such as greases, gels, and phase-change materials pose bottlenecks to heat removal and are also associated with reliability concerns. The industry trend is toward high thermal performance bonded interfaces for large-area attachments. However, because of coefficient of thermal expansion mismatches between materials/layers and resultant thermomechanical stresses, adhesive and cohesive fractures could occur, posing a reliability problem. These defects manifest themselves in increased thermal resistance. This research aims to investigate and improve the thermal performance and reliability of sintered-silver for power electronics packaging applications. This has been experimentally accomplished by the synthesismore » of large-area bonded interfaces between metalized substrates and copper base plates that have subsequently been subjected to thermal cycles. A finite element model of crack initiation and propagation in these bonded interfaces will allow for the interpretation of degradation rates by a crack-velocity (V)-stress intensity factor (K) analysis. A description of the experiment and the modeling approach are discussed.« less

An investigation on die crack detection using Temperature Sensitive Parameter for high speed LED mass production

NASA Astrophysics Data System (ADS)

Annaniah, Luruthudass; Devarajan, Mutharasu; San, Teoh Kok

To ensure the highest quality & long-term reliability of LED components it is necessary to examine LED dice that have sustained mechanical damage during the manufacturing process. This paper has demonstrated that detection of die crack in mass manufactured LEDs can be achieved by measuring Temperature Sensitive Parameters (TSPs) during final testing. A newly-designed apparatus and microcontroller was used for this investigation in order to achieve the millisecond switching time needed for detecting thermal transient effects and at the same time meet the expected speed for mass manufacturing. Evaluations conducted at lab scale shows that thermal transient behaviour of cracked die is significantly different than that of an undamaged die. Having an established test limits to differentiate cracked dice, large volume tests in a production environment were used to confirm the effectiveness of this test method. Failure Bin Analysis (FBA) of this high volume experiment confirmed that all the cracked die LEDs were detected and the undamaged LEDs passed this test without over-rejection. The work verifies that tests based on TSP are effective in identifying die cracks and it is believed that the method could be extended to other types of rejects that have thermal transient signatures such as die delamination.

Influence of intrinsic noise generated by a thermotesting device on thermal sensory detection and thermal pain detection thresholds.

PubMed

Pavlaković, G; Züchner, K; Zapf, A; Bachmann, C G; Graf, B M; Crozier, T A; Pavlaković, H

2009-08-01

Various factors can influence thermal perception threshold measurements and contribute significantly to unwanted variability of the tests. To minimize this variability, testing should be performed under strictly controlled conditions. Identifying the factors that increase the variability and eliminating their influence should increase reliability and reproducibility. Currently available thermotesting devices use a water-cooling system that generates a continuous noise of approximately 60 dB. In order to analyze whether this noise could influence the thermal threshold measurements we compared the thresholds obtained with a silent thermotesting device to those obtained with a commercially available device. The subjects were tested with one randomly chosen device on 1 day and with the other device 7 days later. At each session, heat, heat pain, cold, and cold pain thresholds were determined with three measurements. Bland-Altman analysis was used to assess agreement in measurements obtained with different devices and it was shown that the intersubject variability of the thresholds obtained with the two devices was comparable for all four thresholds tested. In contrast, the intrasubject variability of the thresholds for heat, heat pain, and cold pain detection was significantly lower with the silent device. Our results show that thermal sensory thresholds measured with the two devices are comparable. However, our data suggest that, for studies with repeated measurements on the same subjects, a silent thermotesting device may allow detection of smaller differences in the treatment effects and/or may permit the use of a smaller number of tested subjects. Muscle Nerve 40: 257-263, 2009.

The tantalum-cased tantalum capacitor

NASA Technical Reports Server (NTRS)

Moynihan, J. D.

1977-01-01

Tantalum-cased tantalum capacitors were tested with regard to temperature stability, capacitance ratio, surge current capabilities, shock, vibration, and thermal shock. They were found to be superior to the conventional wet slug tantalum capacitor cased in silver, since they are more resistant to sulfuric acid. The tantalum-cased tantalum capacitors are widely accepted for use in critical electronic equipment because of their excellent performance and reliability.

DOE Office of Scientific and Technical Information (OSTI.GOV)

Kochhar, G.S.; Manohar, K.

Cost is one of the major factors to be considered when choosing a thermal insulator. Design engineers continuously strive to provide the best at the lowest possible cost. In the tropics climate conditions are essentially hot and humid and a cause for daily discomfort. To some extent, air-conditioning of buildings has solved this problem. The major deterrent to air-conditioning is the exorbitant cost of imported thermal insulation materials. This has prompted a search for local, low-cost but effective thermal insulation for buildings. Coconut fiber is available at minimal cost from the copra industry in Trinidad, as it is a wastemore » product from the coconut. The viability of using coconut fiber as building thermal insulation was explored by conducting thermal conductivity tests on 200 mm X 400 mm X 60 mm thick slab-like specimens. The test equipment used was a locally designed constant temperature hot box apparatus. This apparatus was designed to test slab-like specimens under steady-state conditions. The reliability if this experimental set up was checked using Gypsum Plaster. The thermal conductivity test results for coconut fiber over the density range 30 kg/m{sup 3} to 115 kg/m{sup 3} showed the characteristic hooked shape graph for fibrous material. For the 60 mm thick specimens at a mean temperature of 39 C, a minimum thermal conductivity of 0.058 W/mK occurred at an optimum density of 85 kg/m{sup 3}. The thermal conductivity of commonly used industrial insulators, namely loose-fill expanded vermiculite, cellular glass and blanket fiber glass, at a mean temperature of 38 C are 0.066 W/mK, 0.061 W/mK and 0.052 W/mK respectively. When compared, these results show that air dried coconut fiber has far reaching potential for use as an effective building thermal insulation.« less

Engineered Structured Sorbents for the Adsorption of Carbon Dioxide and Water Vapor from Manned Spacecraft Atmospheres: Applications and Testing 2008/2009

NASA Technical Reports Server (NTRS)

Howard, David F.; Perry, Jay L.; Knox, James C.; Junaedi, Christian

2009-01-01

This paper describes efforts to improve on typical packed beds of sorbent pellets by making use of structured sorbents and alternate bed configurations to improve system efficiency and reliability. The benefits of the alternate configurations include increased structural stability gained by eliminating clay bound zeolite pellets that tend to fluidize and erode, and better thermal control during sorption to increase process efficiency. Test results that demonstrate such improvements are described and presented.

Development of a superconducting claw-pole linear test-rig

NASA Astrophysics Data System (ADS)

Radyjowski, Patryk; Keysan, Ozan; Burchell, Joseph; Mueller, Markus

2016-04-01

Superconducting generators can help to reduce the cost of energy for large offshore wind turbines, where the size and mass of the generator have a direct effect on the installation cost. However, existing superconducting generators are not as reliable as the alternative technologies. In this paper, a linear test prototype for a novel superconducting claw-pole topology, which has a stationary superconducting coil that eliminates the cryocooler coupler will be presented. The issues related to mechanical, electromagnetic and thermal aspects of the prototype will be presented.

MEMS testing and applications in automotive and aerospace industries

NASA Astrophysics Data System (ADS)

Ma, Zhichun; Chen, Xuyuan

2009-05-01

MEMS technology combines micromachining and integrated circuit fabrication technologies to produce highly reliable MEMS transducers. This paper presents an overview of MEMS transducers applications, particularly in automotive and aerospace industries, which includes inertia sensors for safety, navigation, and guidance control, thermal anemometer for temperature and heat-flux sensors in engine applications, MEMS atomizers for fuel injection, and micromachined actuators for flow control applications. Design examples for the devices in above mentioned applications are also presented and test results are given.

Cyclic Thermal Stress-Induced Degradation of Cu Metallization on Si3N4 Substrate at -40°C to 300°C

NASA Astrophysics Data System (ADS)

Lang, Fengqun; Yamaguchi, Hiroshi; Nakagawa, Hiroshi; Sato, Hiroshi

2015-01-01

The high-temperature reliability of active metal brazed copper (AMC) on Si3N4 ceramic substrates used for fabricating SiC high-temperature power modules was investigated under harsh environments. The AMC substrate underwent isothermal storage at 300°C for up to 3000 h and a thermal cycling test at -40°C to 300°C for up to 3000 cycles. During isothermal storage at 300°C, the AMC substrate exhibited high reliability, characterized by very little deformation of the copper (Cu) layer, low crack growth, and low oxidation rate of the Cu layer. Under thermal cycling conditions at -40°C to 300°C, no detachment of the Cu layer was observed even after the maximum 3000 cycles of the experiment. However, serious deformation of the Cu layer occurred and progressed as the number of thermal cycles increased, thus significantly roughening the surface of the Cu metallized layer. The cyclic thermal stress led to a significant increase in the crack growth and oxidation of the Cu layer. The maximum depth of the copper oxides reached up to 5/6 of the Cu thickness. The deformation of the Cu layer was the main cause of the decrease of the bond strength under thermal cycling conditions. The shear strength of the SiC chips bonded on the AMC substrate with a Au-12 wt.%Ge solder decreased from the original 83 MPa to 14 MPa after 3000 cycles. Therefore, the cyclic thermal stress destroyed the Cu oxides and enhanced the oxidation of the Cu layer.

High-temperature molten salt thermal energy storage systems for solar applications

NASA Technical Reports Server (NTRS)

Petri, R. J.; Claar, T. D.; Ong, E.

1983-01-01

Experimental results of compatibility screening studies of 100 salt/containment/thermal conductivity enhancement (TCE) combinations for the high temperature solar thermal application range of 704 deg to 871 C (1300 to 1600 F) are presented. Nine candidate containment/HX alloy materials and two TCE materials were tested with six candidate solar thermal alkali and alkaline earth carbonate storage salts (both reagent and technical grade of each). Compatibility tests were conducted with salt encapsulated in approx. 6.0 inch x 1 inch welded containers of test material from 300 to 3000 hours. Compatibility evaluations were end application oriented, considering the potential 30 year lifetime requirement of solar thermal power plant components. Analyses were based on depth and nature of salt side corrosion of materials, containment alloy thermal aging effects, weld integrity in salt environment, air side containment oxidation, and chemical and physical analyses of the salt. A need for more reliable, and in some cases first time determined thermophysical and transport property data was also identified for molten carbonates in the 704 to 871 C temperature range. In particular, accurate melting point (mp) measurements were performed for Li2CO3 and Na2CO3 while melting point, heat of fusion, and specific heat determinations were conducted on 81.3 weight percent Na2CO3-18.7 weight percent K2CO3 and 52.2 weight percent BaCO3-47.8 weight percent Na2CO3 to support future TES system design and ultimate scale up of solar thermal energy storage (TES) subsystems.

Coil-On-Plug Ignition for Oxygen/Methane Liquid Rocket Engines in Thermal-Vacuum Environments

NASA Technical Reports Server (NTRS)

Melcher, John C.; Atwell, Matthew J.; Morehead, Robert L.; Hurlbert, Eric A.; Bugarin, Luz; Chaidez, Mariana

2017-01-01

A coil-on-plug ignition system has been developed and tested for Liquid Oxygen (LOX)/liquid methane (LCH4) rocket engines operating in thermal vacuum conditions. The igniters were developed and tested as part of the Integrated Cryogenic Propulsion Test Article (ICPTA), previously tested as part of the Project Morpheus test vehicle. The ICPTA uses an integrated, pressure-fed, cryogenic LOX/LCH4 propulsion system including a reaction control system (RCS) and a main engine. The ICPTA was tested at NASA Glenn Research Center's Plum Brook Station in the Spacecraft Propulsion Research Facility (B-2) under vacuum and thermal vacuum conditions. A coil-on-plug ignition system has been developed to successfully demonstrate ignition reliability at these conditions while preventing corona discharge issues. The ICPTA uses spark plug ignition for both the main engine igniter and the RCS. The coil-on-plug configuration eliminates the conventional high-voltage spark plug cable by combining the coil and the spark plug into a single component. Prior to ICPTA testing at Plum Brook, component-level reaction control engine (RCE) and main engine igniter testing was conducted at NASA Johnson Space Center (JSC), which demonstrated successful hot-fire ignition using the coil-on-plug from sea-level ambient conditions down to 10(exp -2) torr. Integrated vehicle hot-fire testing at JSC demonstrated electrical and command/data system performance. Lastly, hot-fire testing at Plum Brook demonstrated successful ignitions at simulated altitude conditions at 30 torr and cold thermal-vacuum conditions at 6 torr. The test campaign successfully proved that coil-on-plug technology will enable integrated LOX/LCH4 propulsion systems in future spacecraft.

Coil-On-Plug Ignition for LOX/Methane Liquid Rocket Engines in Thermal Vacuum Environments

NASA Technical Reports Server (NTRS)

Melcher, John C.; Atwell, Matthew J.; Morehead, Robert L.; Hurlbert, Eric A.; Bugarin, Luz; Chaidez, Mariana

2017-01-01

A coil-on-plug ignition system has been developed and tested for Liquid Oxygen (LOX) / liquid methane rocket engines operating in thermal vacuum conditions. The igniters were developed and tested as part of the Integrated Cryogenic Propulsion Test Article (ICPTA), previously tested as part of the Project Morpheus test vehicle. The ICPTA uses an integrated, pressure-fed, cryogenic LOX/methane propulsion system including a reaction control system (RCS) and a main engine. The ICPTA was tested at NASA Glenn Research Center's Plum Brook Station in the Spacecraft Propulsion Research Facility (B-2) under vacuum and thermal vacuum conditions. In order to successfully demonstrate ignition reliability in the vacuum conditions and eliminate corona discharge issues, a coil-on-plug ignition system has been developed. The ICPTA uses spark-plug ignition for both the main engine igniter and the RCS. The coil-on-plug configuration eliminates the conventional high-voltage spark plug cable by combining the coil and the spark-plug into a single component. Prior to ICPTA testing at Plum Brook, component-level reaction control engine (RCE) and main engine igniter testing was conducted at NASA Johnson Space Center (JSC), which demonstrated successful hot-fire ignition using the coil-on-plug from sea-level ambient conditions down to 10(exp.-2) torr. Integrated vehicle hot-fire testing at JSC demonstrated electrical and command/data system performance. Lastly, Plum Brook testing demonstrated successful ignitions at simulated altitude conditions at 30 torr and cold thermal-vacuum conditions at 6 torr. The test campaign successfully proved that coil-on-plug technology will enable integrated LOX/methane propulsion systems in future spacecraft.

High-power VCSEL systems and applications

NASA Astrophysics Data System (ADS)

Moench, Holger; Conrads, Ralf; Deppe, Carsten; Derra, Guenther; Gronenborn, Stephan; Gu, Xi; Heusler, Gero; Kolb, Johanna; Miller, Michael; Pekarski, Pavel; Pollmann-Retsch, Jens; Pruijmboom, Armand; Weichmann, Ulrich

2015-03-01

Easy system design, compactness and a uniform power distribution define the basic advantages of high power VCSEL systems. Full addressability in space and time add new dimensions for optimization and enable "digital photonic production". Many thermal processes benefit from the improved control i.e. heat is applied exactly where and when it is needed. The compact VCSEL systems can be integrated into most manufacturing equipment, replacing batch processes using large furnaces and reducing energy consumption. This paper will present how recent technological development of high power VCSEL systems will extend efficiency and flexibility of thermal processes and replace not only laser systems, lamps and furnaces but enable new ways of production. High power VCSEL systems are made from many VCSEL chips, each comprising thousands of low power VCSELs. Systems scalable in power from watts to multiple ten kilowatts and with various form factors utilize a common modular building block concept. Designs for reliable high power VCSEL arrays and systems can be developed and tested on each building block level and benefit from the low power density and excellent reliability of the VCSELs. Furthermore advanced assembly concepts aim to reduce the number of individual processes and components and make the whole system even more simple and reliable.

Development of Standardized Material Testing Protocols for Prosthetic Liners

PubMed Central

Cagle, John C.; Reinhall, Per G.; Hafner, Brian J.; Sanders, Joan E.

2017-01-01

A set of protocols was created to characterize prosthetic liners across six clinically relevant material properties. Properties included compressive elasticity, shear elasticity, tensile elasticity, volumetric elasticity, coefficient of friction (CoF), and thermal conductivity. Eighteen prosthetic liners representing the diverse range of commercial products were evaluated to create test procedures that maximized repeatability, minimized error, and provided clinically meaningful results. Shear and tensile elasticity test designs were augmented with finite element analysis (FEA) to optimize specimen geometries. Results showed that because of the wide range of available liner products, the compressive elasticity and tensile elasticity tests required two test maxima; samples were tested until they met either a strain-based or a stress-based maximum, whichever was reached first. The shear and tensile elasticity tests required that no cyclic conditioning be conducted because of limited endurance of the mounting adhesive with some liner materials. The coefficient of friction test was based on dynamic coefficient of friction, as it proved to be a more reliable measurement than static coefficient of friction. The volumetric elasticity test required that air be released beneath samples in the test chamber before testing. The thermal conductivity test best reflected the clinical environment when thermal grease was omitted and when liner samples were placed under pressure consistent with load bearing conditions. The developed procedures provide a standardized approach for evaluating liner products in the prosthetics industry. Test results can be used to improve clinical selection of liners for individual patients and guide development of new liner products. PMID:28233885

Development of dual solid cryogens for high reliability refrigeration system

NASA Technical Reports Server (NTRS)

Caren, R. P.; Coston, R. M.

1967-01-01

High reliability solid cryogen refrigeration system consists of a container initially filled with a solid cryogen which is coupled thermally to an infrared detector by means of a link of high thermal conductivity extending from a heat exchanger within the cryogen container.

Extended temperature range ACPS thruster investigation

NASA Technical Reports Server (NTRS)

Blubaugh, A. L.; Schoenman, L.

1974-01-01

The successful hot fire demonstration of a pulsing liquid hydrogen/liquid oxygen and gaseous hydrogen/liquid oxygen attitude control propulsion system thruster is described. The test was the result of research to develop a simple, lightweight, and high performance reaction control system without the traditional requirements for extensive periods of engine thermal conditioning, or the use of complex equipment to convert both liquid propellants to gas prior to delivery to the engine. Significant departures from conventional injector design practice were employed to achieve an operable design. The work discussed includes thermal and injector manifold priming analyses, subscale injector chilldown tests, and 168 full scale and 550 N (1250 lbF) rocket engine tests. Ignition experiments, at propellant temperatures ranging from cryogenic to ambient, led to the generation of a universal spark ignition system which can reliably ignite an engine when supplied with liquid, two phase, or gaseous propellants. Electrical power requirements for spark igniter are very low.

A systems approach to solder joint fatigue in spacecraft electronic packaging

NASA Technical Reports Server (NTRS)

Ross, R. G., Jr.

1991-01-01

Differential expansion induced fatigue resulting from temperature cycling is a leading cause of solder joint failures in spacecraft. Achieving high reliability flight hardware requires that each element of the fatigue issue be addressed carefully. This includes defining the complete thermal-cycle environment to be experienced by the hardware, developing electronic packaging concepts that are consistent with the defined environments, and validating the completed designs with a thorough qualification and acceptance test program. This paper describes a useful systems approach to solder fatigue based principally on the fundamental log-strain versus log-cycles-to-failure behavior of fatigue. This fundamental behavior has been useful to integrate diverse ground test and flight operational thermal-cycle environments into a unified electronics design approach. Each element of the approach reflects both the mechanism physics that control solder fatigue, as well as the practical realities of the hardware build, test, delivery, and application cycle.

Thermal Cycle Reliability and Failure Mechanisms of CCGA and PBGA Assemblies with and without Corner Staking

NASA Technical Reports Server (NTRS)

Ghaffarian, Reza

2008-01-01

Area array packages (AAPs) with 1.27 mm pitch have been the packages of choice for commercial applications; they are now starting to be implemented for use in military and aerospace applications. Thermal cycling characteristics of plastic ball grid array (PBGA) and chip scale package assemblies, because of their wide usage for commercial applications, have been extensively reported on in literature. Thermal cycling represents the on-off environmental condition for most electronic products and therefore is a key factor that defines reliability.However, very limited data is available for thermal cycling behavior of ceramic packages commonly used for the aerospace applications. For high reliability applications, numerous AAPs are available with an identical design pattern both in ceramic and plastic packages. This paper compares assembly reliability of ceramic and plastic packages with the identical inputs/outputs(I/Os) and pattern. The ceramic package was in the form of ceramic column grid array (CCGA) with 560 I/Os peripheral array with the identical pad design as its plastic counterpart.

Adapting astronomical source detection software to help detect animals in thermal images obtained by unmanned aerial systems

NASA Astrophysics Data System (ADS)

Longmore, S. N.; Collins, R. P.; Pfeifer, S.; Fox, S. E.; Mulero-Pazmany, M.; Bezombes, F.; Goodwind, A.; de Juan Ovelar, M.; Knapen, J. H.; Wich, S. A.

2017-02-01

In this paper we describe an unmanned aerial system equipped with a thermal-infrared camera and software pipeline that we have developed to monitor animal populations for conservation purposes. Taking a multi-disciplinary approach to tackle this problem, we use freely available astronomical source detection software and the associated expertise of astronomers, to efficiently and reliably detect humans and animals in aerial thermal-infrared footage. Combining this astronomical detection software with existing machine learning algorithms into a single, automated, end-to-end pipeline, we test the software using aerial video footage taken in a controlled, field-like environment. We demonstrate that the pipeline works reliably and describe how it can be used to estimate the completeness of different observational datasets to objects of a given type as a function of height, observing conditions etc. - a crucial step in converting video footage to scientifically useful information such as the spatial distribution and density of different animal species. Finally, having demonstrated the potential utility of the system, we describe the steps we are taking to adapt the system for work in the field, in particular systematic monitoring of endangered species at National Parks around the world.

Simulating Physiological Response with a Passive Sensor Manikin and an Adaptive Thermal Manikin to Predict Thermal Sensation and Comfort

DOE Office of Scientific and Technical Information (OSTI.GOV)

Rugh, John P; Chaney, Larry; Hepokoski, Mark

2015-04-14

Reliable assessment of occupant thermal comfort can be difficult to obtain within automotive environments, especially under transient and asymmetric heating and cooling scenarios. Evaluation of HVAC system performance in terms of comfort commonly requires human subject testing, which may involve multiple repetitions, as well as multiple test subjects. Instrumentation (typically comprised of an array of temperature sensors) is usually only sparsely applied across the human body, significantly reducing the spatial resolution of available test data. Further, since comfort is highly subjective in nature, a single test protocol can yield a wide variation in results which can only be overcome bymore » increasing the number of test replications and subjects. In light of these difficulties, various types of manikins are finding use in automotive testing scenarios. These manikins can act as human surrogates from which local skin and core temperatures can be obtained, which are necessary for accurately predicting local and whole body thermal sensation and comfort using a physiology-based comfort model (e.g., the Berkeley Comfort Model). This paper evaluates two different types of manikins, i) an adaptive sweating thermal manikin, which is coupled with a human thermoregulation model, running in real-time, to obtain realistic skin temperatures; and, ii) a passive sensor manikin, which is used to measure boundary conditions as they would act on a human, from which skin and core temperatures can be predicted using a thermophysiological model. The simulated physiological responses and comfort obtained from both of these manikin-model coupling schemes are compared to those of a human subject within a vehicle cabin compartment transient heat-up scenario.« less

Microsample Characterization of Coatings for Grcop-84 for High Heat Flux Applications

NASA Technical Reports Server (NTRS)

Hemker, Kevin

2003-01-01

A multidisciplinary Johns Hopkins University-NASA Glenn team is undertaking a collaborative research program to elucidate and model the thermal stability and mechanical integrity of candidate coatings for GRCop-84. GRCop-84 is a high conductivity, high strength copper alloy that was recently developed at NASA Glenn for use in high temperature, high heat flux applications. With potential applications in rocket motor combustion chamber liners, nozzle ramps and other actively cooled structures, this new material offers great potential for decreasing weight and increasing reliability of third generation reusable launch vehicles. Current emphasis has turned toward the development of environmentally resistant and thermal barrier coatings for this alloy. Metallic coatings such as NiCrAlY and Cu-8-30%Cr have shown promise in: prohibiting blanching, reducing dog-house failures, increasing operating temperatures and decreasing cooling requirements. The focus of this research program is to develop a fundamental understanding of the substrate-coating interactions that occur during thermal cycling (inter-diffusion, viscoplasticity, morphological evolution, crack formation, etc.) and to derive a science-based protocol for future coating selection, optimization and reliability assurance. The microsample tensile testing approach adopted for this study allows us to characterize small-scale and highly scale-specific coatings and properties in a way not possible by conventional means. In addition to providing much needed design data, the integration of microsample testing with detailed microstructural observations provides a mechanistic foundation for coating optimization and life prediction modeling.

Analysis of the variation of range parameters of thermal cameras

NASA Astrophysics Data System (ADS)

Bareła, Jarosław; Kastek, Mariusz; Firmanty, Krzysztof; Krupiński, Michał

2016-10-01

Measured range characteristics may vary considerably (up to several dozen percent) between different samples of the same camera type. The question is whether the manufacturing process somehow lacks repeatability or the commonly used measurement procedures themselves need improvement. The presented paper attempts to deal with the aforementioned question. The measurement method has been thoroughly analyzed as well as the measurement test bed. Camera components (such as detector and optics) have also been analyzed and their key parameters have been measured, including noise figures of the entire system. Laboratory measurements are the most precise method used to determine range parameters of a thermal camera. However, in order to obtain reliable results several important conditions have to be fulfilled. One must have the test equipment capable of measurement accuracy (uncertainty) significantly better than the magnitudes of measured quantities. The measurements must be performed in a controlled environment thus excluding the influence of varying environmental conditions. The personnel must be well-trained, experienced in testing the thermal imaging devices and familiar with the applied measurement procedures. The measurement data recorded for several dozen of cooled thermal cameras (from one of leading camera manufacturers) have been the basis of the presented analysis. The measurements were conducted in the accredited research laboratory of Institute of Optoelectronics (Military University of Technology).

A differential approach to microcomputer test battery development and implementation

NASA Technical Reports Server (NTRS)

Kennedy, R. S.; Baltzley, D. R.; Osteen, M. K.; Turnage, J. J.

1988-01-01

The present microcomputer-based performance test battery emphasizes psychometric theory and utility for repeated-measures applications during extended exposure to various environmental stressors. In the menu that has been defined at the current state of this system's development, there are more than 30 'qualified' mental tests which stabilize in less than 10 min and possess test-retest reliabilities greater than 0.7 for a three-minute test/work period. The battery encompasses tests of cognition, information processing, psychomotor skill, memory, mood, etc. Several of the tests have demonstrated sensitivity to chemoradiotherapy, sleep loss, hypoxia, amphetamines, thermal stress, sensory deprivation, altitude, fatigue, and alcohol use. Recommendations are presented for 6-, 12-, and 22-min batteries.

A Method to Estimate the Hydraulic Conductivity of the Ground by TRT Analysis.

PubMed

Liuzzo Scorpo, Alberto; Nordell, Bo; Gehlin, Signhild

2017-01-01

The knowledge of hydraulic properties of aquifers is important in many engineering applications. Careful design of ground-coupled heat exchangers requires that the hydraulic characteristics and thermal properties of the aquifer must be well understood. Knowledge of groundwater flow rate and aquifer thermal properties is the basis for proper design of such plants. Different methods have been developed in order to estimate hydraulic conductivity by evaluating the transport of various tracers (chemical, heat etc.); thermal response testing (TRT) is a specific type of heat tracer that allows including the hydraulic properties in an effective thermal conductivity value. Starting from these considerations, an expeditious, graphical method was proposed to estimate the hydraulic conductivity of the aquifer, using TRT data and plausible assumption. Suggested method, which is not yet verified or proven to be reliable, should be encouraging further studies and development in this direction. © 2016, National Ground Water Association.

Thermal transport and thermopower of bcc U-Mo splat-cooled alloys

NASA Astrophysics Data System (ADS)

Falkowski, M.; Buturlim, V.; Paukov, M.; Havela, L.

2018-05-01

In order to characterize the electron and thermal transport properties in splat-cooled U-T alloys (T is transition metal), we measured the thermopower S and thermal conductivity κ of selected splat-cooled U-Mo alloys with 0, 11, 12.5, 15 and 17 at % Mo concentrations, as a function of temperature. Additionally, we compare our data with the results of S(T) and κ(T) for pure α-U bulk material. Moreover, what particularly motivated us for undertaking above mentioned investigation was the opportunity for prove the functionality of the TTO (Thermal Transport Option) insert of PPMS apparatus for such form of samples. Working with rapidly solidified materials in the form of splats, i.e. foils of typical thickness ∼ 0.2 mm, or even less, we need to test first whether the TTO output can be taken as reliable for the sample geometry, being far from typical bulk bar-shaped samples.

Thermal energy storage characteristics of micro-nanoencapsulated heneicosane and octacosane with poly(methylmethacrylate) shell.

PubMed

Sarı, Ahmet; Alkan, Cemil; Biçer, Alper

2016-05-01

In this study, PMMA/heneicosane (C21) and PMMA/octacosane (C28) micro-nano capsules were fabricated via emulsion polymerisation method. The chemical structures of the fabricated capsules were verified with the FT-IR spectroscopy analysis. The results of POM, SEM and PSD analysis indicated that most of the capsules were consisted of micro/nano-sized spheres with compact surface. The DSC measurements showed that the capsules had melting temperature in the range of about 39-60 °C and latent heat energy storage capacity in the range of about 138-152 J/g. The results of TGA showed that sublimit temperature values regarding the first degradation steps of both capsules were quite over the phase change or working temperatures of encapsulated paraffins. The thermal cycling test exhibited that the capsules had good thermal reliability and chemical stability. Additionally, the prepared capsules had reasonably high thermal conductivity.

Design process for applying the nonlocal thermal transport iSNB model to a Polar-Drive ICF simulation

NASA Astrophysics Data System (ADS)

Cao, Duc; Moses, Gregory; Delettrez, Jacques; Collins, Timothy

2014-10-01

A design process is presented for the nonlocal thermal transport iSNB (implicit Schurtz, Nicolai, and Busquet) model to provide reliable nonlocal thermal transport in polar-drive ICF simulations. Results from the iSNB model are known to be sensitive to changes in the SNB ``mean free path'' formula, and the latter's original form required modification to obtain realistic preheat levels. In the presented design process, SNB mean free paths are first modified until the model can match temperatures from Goncharov's thermal transport model in 1D temperature relaxation simulations. Afterwards the same mean free paths are tested in a 1D polar-drive surrogate simulation to match adiabats from Goncharov's model. After passing the two previous steps, the model can then be run in a full 2D polar-drive simulation. This research is supported by the University of Rochester Laboratory for Laser Energetics.

Accelerated Thermal Cycling and Failure Mechanisms for BGA and CSP Assemblies

NASA Technical Reports Server (NTRS)

Ghaffarian, Reza

2000-01-01

This paper reviews the accelerated thermal cycling test methods that are currently used by industry to characterize the interconnect reliability of commercial-off-the-shelf (COTS) ball grid array (BGA) and chip scale package (CSP) assemblies. Acceleration induced failure mechanisms varied from conventional surface mount (SM) failures for CSPs. Examples of unrealistic life projections for other CSPs are also presented. The cumulative cycles to failure for ceramic BGA assemblies performed under different conditions, including plots of their two Weibull parameters, are presented. The results are for cycles in the range of -30 C to 100 C, -55 C to 100 C, and -55 C to 125 C. Failure mechanisms as well as cycles to failure for thermal shock and thermal cycling conditions in the range of -55 C to 125 C were compared. Projection to other temperature cycling ranges using a modified Coffin-Manson relationship is also presented.

A New Reliability Analysis Model of the Chegongzhuang Heat-Supplying Tunnel Structure Considering the Coupling of Pipeline Thrust and Thermal Effect

PubMed Central

Zhang, Jiawen; He, Shaohui; Wang, Dahai; Liu, Yangpeng; Yao, Wenbo; Liu, Xiabing

2018-01-01

Based on the operating Chegongzhuang heat-supplying tunnel in Beijing, the reliability of its lining structure under the action of large thrust and thermal effect is studied. According to the characteristics of a heat-supplying tunnel service, a three-dimensional numerical analysis model was established based on the mechanical tests on the in-situ specimens. The stress and strain of the tunnel structure were obtained before and after the operation. Compared with the field monitoring data, the rationality of the model was verified. After extracting the internal force of the lining structure, the improved method of subset simulation was proposed as the performance function to calculate the reliability of the main control section of the tunnel. In contrast to the traditional calculation method, the analytic relationship between the sample numbers in the subset simulation method and Monte Carlo method was given. The results indicate that the lining structure is greatly influenced by coupling in the range of six meters from the fixed brackets, especially the tunnel floor. The improved subset simulation method can greatly save computation time and improve computational efficiency under the premise of ensuring the accuracy of calculation. It is suitable for the reliability calculation of tunnel engineering, because “the lower the probability, the more efficient the calculation.” PMID:29401691

Probabilistic Simulation of Combined Thermo-Mechanical Cyclic Fatigue in Composites

NASA Technical Reports Server (NTRS)

Chamis, Christos C.

2011-01-01

A methodology to compute probabilistically-combined thermo-mechanical fatigue life of polymer matrix laminated composites has been developed and is demonstrated. Matrix degradation effects caused by long-term environmental exposure and mechanical/thermal cyclic loads are accounted for in the simulation process. A unified time-temperature-stress-dependent multifactor-interaction relationship developed at NASA Glenn Research Center has been used to model the degradation/aging of material properties due to cyclic loads. The fast probability-integration method is used to compute probabilistic distribution of response. Sensitivities of fatigue life reliability to uncertainties in the primitive random variables (e.g., constituent properties, fiber volume ratio, void volume ratio, ply thickness, etc.) computed and their significance in the reliability-based design for maximum life is discussed. The effect of variation in the thermal cyclic loads on the fatigue reliability for a (0/+/-45/90)s graphite/epoxy laminate with a ply thickness of 0.127 mm, with respect to impending failure modes has been studied. The results show that, at low mechanical-cyclic loads and low thermal-cyclic amplitudes, fatigue life for 0.999 reliability is most sensitive to matrix compressive strength, matrix modulus, thermal expansion coefficient, and ply thickness. Whereas at high mechanical-cyclic loads and high thermal-cyclic amplitudes, fatigue life at 0.999 reliability is more sensitive to the shear strength of matrix, longitudinal fiber modulus, matrix modulus, and ply thickness.

Probabilistic Simulation for Combined Cycle Fatigue in Composites

NASA Technical Reports Server (NTRS)

Chamis, Christos C.

2010-01-01

A methodology to compute probabilistic fatigue life of polymer matrix laminated composites has been developed and demonstrated. Matrix degradation effects caused by long term environmental exposure and mechanical/thermal cyclic loads are accounted for in the simulation process. A unified time-temperature-stress dependent multifactor interaction relationship developed at NASA Glenn Research Center has been used to model the degradation/aging of material properties due to cyclic loads. The fast probability integration method is used to compute probabilistic distribution of response. Sensitivities of fatigue life reliability to uncertainties in the primitive random variables (e.g., constituent properties, fiber volume ratio, void volume ratio, ply thickness, etc.) computed and their significance in the reliability-based design for maximum life is discussed. The effect of variation in the thermal cyclic loads on the fatigue reliability for a (0/+/- 45/90)s graphite/epoxy laminate with a ply thickness of 0.127 mm, with respect to impending failure modes has been studied. The results show that, at low mechanical cyclic loads and low thermal cyclic amplitudes, fatigue life for 0.999 reliability is most sensitive to matrix compressive strength, matrix modulus, thermal expansion coefficient, and ply thickness. Whereas at high mechanical cyclic loads and high thermal cyclic amplitudes, fatigue life at 0.999 reliability is more sensitive to the shear strength of matrix, longitudinal fiber modulus, matrix modulus, and ply thickness.

Probabilistic Simulation of Combined Thermo-Mechanical Cyclic Fatigue in Composites

NASA Technical Reports Server (NTRS)

Chamis, Christos C.

2010-01-01

A methodology to compute probabilistically-combined thermo-mechanical fatigue life of polymer matrix laminated composites has been developed and is demonstrated. Matrix degradation effects caused by long-term environmental exposure and mechanical/thermal cyclic loads are accounted for in the simulation process. A unified time-temperature-stress-dependent multifactor-interaction relationship developed at NASA Glenn Research Center has been used to model the degradation/aging of material properties due to cyclic loads. The fast probability-integration method is used to compute probabilistic distribution of response. Sensitivities of fatigue life reliability to uncertainties in the primitive random variables (e.g., constituent properties, fiber volume ratio, void volume ratio, ply thickness, etc.) computed and their significance in the reliability-based design for maximum life is discussed. The effect of variation in the thermal cyclic loads on the fatigue reliability for a (0/+/-45/90)s graphite/epoxy laminate with a ply thickness of 0.127 mm, with respect to impending failure modes has been studied. The results show that, at low mechanical-cyclic loads and low thermal-cyclic amplitudes, fatigue life for 0.999 reliability is most sensitive to matrix compressive strength, matrix modulus, thermal expansion coefficient, and ply thickness. Whereas at high mechanical-cyclic loads and high thermal-cyclic amplitudes, fatigue life at 0.999 reliability is more sensitive to the shear strength of matrix, longitudinal fiber modulus, matrix modulus, and ply thickness.

Novel dynamic thermal characterization of multifunctional concretes with microencapsulated phase change materials

NASA Astrophysics Data System (ADS)

Pisello, Anna Laura; Fabiani, Claudia; D'Alessandro, Antonella; Cabeza, Luisa F.; Ubertini, Filippo; Cotana, Franco

2017-04-01

Concrete is widely applied in the construction sector for its reliable mechanical performance, its easiness of use and low costs. It also appears promising for enhancing the thermal-energy behavior of buildings thanks to its capability to be doped with multifunctional fillers. In fact, key studies acknowledged the benefits of thermally insulated concretes for applications in ceilings and walls. At the same time, thermal capacity also represents a key property to be optimized, especially for lightweight constructions. In this view, Thermal-Energy Storage (TES) systems have been recently integrated into building envelopes for increasing thermal inertia. More in detail, numerical experimental investigations showed how Phase Change materials (PCMs), as an acknowledged passive TES strategy, can be effectively included in building envelope, with promising results in terms of thermal buffer potentiality. In particular, this work builds upon previous papers aimed at developing the new PCM-filled concretes for structural applications and optimized thermalenergy efficiency, and it is focused on the development of a new experimental method for testing such composite materials in thermal-energy dynamic conditions simulated in laboratory by exposing samples to environmentally controlled microclimate while measuring thermal conductivity and diffusivity by means of transient plane source techniques. The key findings show how the new composites are able to increasingly delay the thermal wave with increasing the PCM concentration and how the thermal conductivity varies during the course of the phase change, in both melting and solidification processes. The new analysis produces useful findings in proposing an effective method for testing composite materials with adaptive thermal performance, much needed by the scientific community willing to study building envelopes dynamics.

Investigation of low cost, high reliability sealing techniques for hybrid microcircuits, phase 1

NASA Technical Reports Server (NTRS)

Perkins, K. L.; Licari, J. J.

1976-01-01

A preliminary investigation was made to determine the feasibility of using adhesive package sealing for hybrid microcircuits. Major effort consisted of: (1) surveying representative hybrid manufacturers to assess the current use of adhesives for package sealing; (2) making a cost comparison of metallurgical versus adhesive package sealing; (3) determining the seal integrity of gold plated flatpack type packages sealed with selected adhesives, thermal shock, temperature cycling, mechanical shock, and constant acceleration test environments; and (4) defining a more comprehensive study to continue the evaluation of adhesives for package sealing. Results showed that 1.27 cm square gold plated flatpack type packages sealed with the film adhesives and the paste adhesive retained their seal integrity after all tests, and that similarly prepared 2.54 cm square packages retained their seal integrity after all tests except the 10,000 g's constant acceleration test. It is concluded that these results are encouraging, but by no means sufficient to establish the suitability of adhesives for sealing high reliability hybrid microcircuits.

Nanocharacterization of the adhesion effect and bending stiffness in optical MEMS

NASA Astrophysics Data System (ADS)

Pustan, Marius; Birleanu, Corina; Dudescu, Cristian

2017-11-01

The scope of this paper is the reliability design and testing of flexible MEMS components as clamp-clamp beams for the out-of-plane displacement. The field of implementation of such structures is in optical relevant applications such as the optical microsensors or optical microswitches. Moreover these structures can be successfully implemented in RF switches or in the other MEMS applications. The research studies presented in this paper consider the analytical and numerical analysis follow by the experimental validation. The mechanical and tribological characteristics such as the sample static response under an applied force and the adhesion effect between the flexible structure and substrate are investigated. The samples under test are fabricated from a reflective material - gold. Experimental investigations are performed by atomic force microscopy in order to determine the response of the gold microbridges under an applied force. Moreover, to identify the proper geometry that is less sensitive to a thermal gradient, different geometrical configurations of microbridges are tested under different temperatures. An etalon structure is considered as a reference beam and it is compared with the other samples fabricated in the same geometrical dimensions but with some additional rectangular holes performed on the flexible plate. The scope of holes is to reduce the temperature influence on the mechanical behaviour of clamp-clamp beam from application where a thermal gradient occurs. During numerical analysis and experimental investigations, the temperature of samples is increased from 20 °C to 100 °C and the sample response is monitored. A comparison between numerical and experimental results is provided at the end of paper. The research results are useful for designers to predict the behaviour of material and structure from optical or thermal applications in order to improve the reliability and the MEMS lifetime.

Test-retest and interobserver reliability of quantitative sensory testing according to the protocol of the German Research Network on Neuropathic Pain (DFNS): a multi-centre study.

PubMed

Geber, Christian; Klein, Thomas; Azad, Shahnaz; Birklein, Frank; Gierthmühlen, Janne; Huge, Volker; Lauchart, Meike; Nitzsche, Dorothee; Stengel, Maike; Valet, Michael; Baron, Ralf; Maier, Christoph; Tölle, Thomas; Treede, Rolf-Detlef

2011-03-01

Quantitative sensory testing (QST) is an instrument to assess positive and negative sensory signs, helping to identify mechanisms underlying pathologic pain conditions. In this study, we evaluated the test-retest reliability (TR-R) and the interobserver reliability (IO-R) of QST in patients with sensory disturbances of different etiologies. In 4 centres, 60 patients (37 male and 23 female, 56.4±1.9years) with lesions or diseases of the somatosensory system were included. QST comprised 13 parameters including detection and pain thresholds for thermal and mechanical stimuli. QST was performed in the clinically most affected test area and a less or unaffected control area in a morning and an afternoon session on 2 consecutive days by examiner pairs (4 QSTs/patient). For both, TR-R and IO-R, there were high correlations (r=0.80-0.93) at the affected test area, except for wind-up ratio (TR-R: r=0.67; IO-R: r=0.56) and paradoxical heat sensations (TR-R: r=0.35; IO-R: r=0.44). Mean IO-R (r=0.83, 31% unexplained variance) was slightly lower than TR-R (r=0.86, 26% unexplained variance, P<.05); the difference in variance amounted to 5%. There were no differences between study centres. In a subgroup with an unaffected control area (n=43), reliabilities were significantly better in the test area (TR-R: r=0.86; IO-R: r=0.83) than in the control area (TR-R: r=0.79; IO-R: r=0.71, each P<.01), suggesting that disease-related systematic variance enhances reliability of QST. We conclude that standardized QST performed by trained examiners is a valuable diagnostic instrument with good test-retest and interobserver reliability within 2days. With standardized training, observer bias is much lower than random variance. Quantitative sensory testing performed by trained examiners is a valuable diagnostic instrument with good interobserver and test-retest reliability for use in patients with sensory disturbances of different etiologies to help identify mechanisms of neuropathic and non-neuropathic pain. Copyright © 2010 International Association for the Study of Pain. Published by Elsevier B.V. All rights reserved.

Metal-wool heat shields for space shuttle. [design, fabrication, and attachment to structure

NASA Technical Reports Server (NTRS)

Miller, R. C.; Clure, J. L.

1974-01-01

The packaging of metal wool for reusable thermal heat shields applied to aerodynamic and other surfaces for the space shuttle was analyzed and designed, and samples were fabricated and experimentally studied. Parametric trends were prepared for selected configurations. An all-metal thermally efficient, reliable, reusable and producible heat shield system was designed and structurally tested for use on spacecraft aerodynamic surfaces where temperatures do not exceed 810 K. Stainless steel sheet, primarily for structure and secondarily in the transverse plane for thermal expansion, was shown to accommodate thermal expansion in all directions when restrained at the edges and heated to 1360 K. Aerodynamic loads of 0.35 x 1000,000 newtons/sq meter, and higher, may be easily accepted by structures of this design. Seven all-metal thermal protection specimens, 12.7 cm square and 2.5 cm thick were fabricated and are being experimentally evaluated at simulated shuttle entry conditions in an arc jet facility.

Perspective on thermal barrier coatings for industrial gas turbine applications

NASA Technical Reports Server (NTRS)

Mutasim, Zaher; Brentnall, William

1995-01-01

Thermal barrier coatings (TBC's) have been used in high thrust aircraft engines for many years, and have proved to be very effective in providing thermal protection and increasing engine efficiencies. TBC life requirements for aircraft engines are typically less than those required for industrial gas turbines. This paper describes current and future applications of TBC's in industrial gas turbine engines. Early testing and applications of TBC's is reviewed. Areas of concern from the engine designer's and materials engineer's perspective are identified and evaluated. This paper focuses on the key factors that are expected to influence utilization of TBC's in advanced industrial gas turbine engines. It is anticipated that reliable, durable and highly effective coating systems will be produced that will ultimately improve engine efficiency and performance.

Development and optimization of a stove-powered thermoelectric generator

NASA Astrophysics Data System (ADS)

Mastbergen, Dan

Almost a third of the world's population still lacks access to electricity. Most of these people use biomass stoves for cooking which produce significant amounts of wasted thermal energy, but no electricity. Less than 1% of this energy in the form of electricity would be adequate for basic tasks such as lighting and communications. However, an affordable and reliable means of accomplishing this is currently nonexistent. The goal of this work is to develop a thermoelectric generator to convert a small amount of wasted heat into electricity. Although this concept has been around for decades, previous attempts have failed due to insufficient analysis of the system as a whole, leading to ineffective and costly designs. In this work, a complete design process is undertaken including concept generation, prototype testing, field testing, and redesign/optimization. Detailed component models are constructed and integrated to create a full system model. The model encompasses the stove operation, thermoelectric module, heat sinks, charging system and battery. A 3000 cycle endurance test was also conducted to evaluate the effects of operating temperature, module quality, and thermal interface quality on the generator's reliability, lifetime and cost effectiveness. The results from this testing are integrated into the system model to determine the lowest system cost in $/Watt over a five year period. Through this work the concept of a stove-based thermoelectric generator is shown to be technologically and economically feasible. In addition, a methodology is developed for optimizing the system for specific regional stove usage habits.

Development of a Pebble-Bed Liquid-Nitrogen Evaporator/Superheater for the BRL 1/6th Scale Large Blast/Thermal Simulator Test Bed. Phase 1. Prototype Design and Analysis

DTIC Science & Technology

1991-08-01

specifications are taken primarily from the 1983 version of the ASME Boiler and Pressure Vessel Code . Other design requirements were developea from standard safe...rules and practices of the American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code to provide a safe and reliable system

Fiber Optic Cable Thermal Preparation to Ensure Stable Operation

NASA Technical Reports Server (NTRS)

Thoames Jr, William J.; Chuska, Rick F.; LaRocca, Frank V.; Switzer, Robert C.; Macmurphy, Shawn L.; Ott, Melanie N.

2008-01-01

Fiber optic cables are widely used in modern systems that must provide stable operation during exposure to changing environmental conditions. For example, a fiber optic cable on a satellite may have to reliably function over a temperature range of -50 C up to 125 C. While the system requirements for a particular application will dictate the exact method by which the fibers should be prepared, this work will examine multiple ruggedized fibers prepared in different fashions and subjected to thermal qualification testing. The data show that if properly conditioned the fiber cables can provide stable operation, but if done incorrectly, they will have large fluctuations in transmission.

Thermal and Structural Analysis of Helicopter Transmission Housings Using NASTRAN

NASA Technical Reports Server (NTRS)

Howells, R. W.; Sciarra, J. J.; Ng, G. S.

1976-01-01

The application of NASTRAN to improve the design of helicopter transmission housings is described. A finite element model of the complete forward rotor transmission housing for the Boeing Vertol CH-47C helicopter was used to study thermal distortion and stress, stress and deflection due to static and dynamic loads, load paths, and design optimization by the control of structural energy distribution. The analytical results are correlated with test data and used to reduce weight and to improve strength, service life, failsafety, and reliability. The techniques presented, although applied herein to helicopter transmissions, are sufficiently general to be applicable to any power transmission system.

SMART empirical approaches for predicting field performance of PV modules from results of reliability tests

NASA Astrophysics Data System (ADS)

Hardikar, Kedar Y.; Liu, Bill J. J.; Bheemreddy, Venkata

2016-09-01

Gaining an understanding of degradation mechanisms and their characterization are critical in developing relevant accelerated tests to ensure PV module performance warranty over a typical lifetime of 25 years. As newer technologies are adapted for PV, including new PV cell technologies, new packaging materials, and newer product designs, the availability of field data over extended periods of time for product performance assessment cannot be expected within the typical timeframe for business decisions. In this work, to enable product design decisions and product performance assessment for PV modules utilizing newer technologies, Simulation and Mechanism based Accelerated Reliability Testing (SMART) methodology and empirical approaches to predict field performance from accelerated test results are presented. The method is demonstrated for field life assessment of flexible PV modules based on degradation mechanisms observed in two accelerated tests, namely, Damp Heat and Thermal Cycling. The method is based on design of accelerated testing scheme with the intent to develop relevant acceleration factor models. The acceleration factor model is validated by extensive reliability testing under different conditions going beyond the established certification standards. Once the acceleration factor model is validated for the test matrix a modeling scheme is developed to predict field performance from results of accelerated testing for particular failure modes of interest. Further refinement of the model can continue as more field data becomes available. While the demonstration of the method in this work is for thin film flexible PV modules, the framework and methodology can be adapted to other PV products.

Thermal Management and Reliability of Power Electronics and Electric Machines

DOE Office of Scientific and Technical Information (OSTI.GOV)

Narumanchi, Sreekant

2016-09-19

Increasing the number of electric-drive vehicles (EDVs) on America's roads has been identified as a strategy with near-term potential for dramatically decreasing the nation's dependence on oil - by the U.S. Department of Energy, the federal cross-agency EV-Everywhere Challenge, and the automotive industry. Mass-market deployment will rely on meeting aggressive technical targets, including improved efficiency and reduced size, weight, and cost. Many of these advances will depend on optimization of thermal management. Effective thermal management is critical to improving the performance and ensuring the reliability of EDVs. Efficient heat removal makes higher power densities and lower operating temperatures possible, andmore » in turn enables cost and size reductions. The National Renewable Energy Laboratory (NREL), along with DOE and industry partners is working to develop cost-effective thermal management solutions to increase device and component power densities. In this presentation, the activities in recent years related to thermal management and reliability of automotive power electronics and electric machines are presented.« less

Thermal energy storage for low grade heat in the organic Rankine cycle

NASA Astrophysics Data System (ADS)

Soda, Michael John

Limits of efficiencies cause immense amounts of thermal energy in the form of waste heat to be vented to the atmosphere. Up to 60% of unrecovered waste heat is classified as low or ultra-low quality, making recovery difficult or inefficient. The organic Rankine cycle can be used to generate mechanical power and electricity from these low temperatures where other thermal cycles are impractical. A variety of organic working fluids are available to optimize the ORC for any target temperature range. San Diego State University has one such experimental ORC using R245fa, and has been experimenting with multiple expanders. One limitation of recovering waste heat is the sporadic or cyclical nature common to its production. This inconsistency makes sizing heat recovery ORC systems difficult for a variety of reasons including off-design-point efficiency loss, increased attrition from varying loads, unreliable outputs, and overall system costs. Thermal energy storage systems can address all of these issues by smoothing the thermal input to a constant and reliable level and providing back-up capacity for times when the thermal input is deactivated. Multiple types of thermal energy storage have been explored including sensible, latent, and thermochemical. Latent heat storage involves storing thermal energy in the reversible phase change of a phase change material, or PCM, and can have several advantages over other modalities including energy storage density, cost, simplicity, reliability, relatively constant temperature output, and temperature customizability. The largest obstacles to using latent heat storage include heat transfer rates, thermal cycling stability, and potentially corrosive PCMs. Targeting 86°C, the operating temperature of SDSU's experimental ORC, multiple potential materials were explored and tested as potential PCMs including Magnesium Chloride Hexahydrate (MgCl2˙6H2O), Magnesium Nitrate Hexahydrate (Mg(NO3)2˙6H 2O), montan wax, and carnauba wax. The addition of graphite to augment heat transfer rates was also tested. Melting and solidification temperatures largely matched predictions. The magnesium salts were found to be less stable under thermal cycling than the waxes. Graphite was only soluble in the waxes. Mixtures of magnesium salts and waxes yielded a layered composite with the less dense waxes creating a sealing layer over the salt layer that significantly increased the stability of the magnesium salts. Research into optimum heat exchangers and storage vessels for these applications indicates that horizontally oriented aluminum pipes with vertically oriented aluminum fins would be the best method of storing and retrieving energy. Fin spacing can be predicted by an equation based on target temperatures and PCM characteristics.

A novel technique to monitor thermal discharges using thermal infrared imaging.

PubMed

Muthulakshmi, A L; Natesan, Usha; Ferrer, Vincent A; Deepthi, K; Venugopalan, V P; Narasimhan, S V

2013-09-01

Coastal temperature is an important indicator of water quality, particularly in regions where delicate ecosystems sensitive to water temperature are present. Remote sensing methods are highly reliable for assessing the thermal dispersion. The plume dispersion from the thermal outfall of the nuclear power plant at Kalpakkam, on the southeast coast of India, was investigated from March to December 2011 using thermal infrared images along with field measurements. The absolute temperature as provided by the thermal infrared (TIR) images is used in the Arc GIS environment for generating a spatial pattern of the plume movement. Good correlation of the temperature measured by the TIR camera with the field data (r(2) = 0.89) make it a reliable method for the thermal monitoring of the power plant effluents. The study portrays that the remote sensing technique provides an effective means of monitoring the thermal distribution pattern in coastal waters.

Operation of SOI P-Channel Field Effect Transistors, CHT-PMOS30, under Extreme Temperatures

NASA Technical Reports Server (NTRS)

Patterson, Richard; Hammoud, Ahmad

2009-01-01

Electronic systems are required to operate under extreme temperatures in NASA planetary exploration and deep space missions. Electronics on-board spacecraft must also tolerate thermal cycling between extreme temperatures. Thermal management means are usually included in today s spacecraft systems to provide adequate temperature for proper operation of the electronics. These measures, which may include heating elements, heat pipes, radiators, etc., however add to the complexity in the design of the system, increases its cost and weight, and affects its performance and reliability. Electronic parts and circuits capable of withstanding and operating under extreme temperatures would reflect in improvement in system s efficiency, reducing cost, and improving overall reliability. Semiconductor chips based on silicon-on-insulator (SOI) technology are designed mainly for high temperature applications and find extensive use in terrestrial well-logging fields. Their inherent design offers advantages over silicon devices in terms of reduced leakage currents, less power consumption, faster switching speeds, and good radiation tolerance. Little is known, however, about their performance at cryogenic temperatures and under wide thermal swings. Experimental investigation on the operation of SOI, N-channel field effect transistors under wide temperature range was reported earlier [1]. This work examines the performance of P-channel devices of these SOI transistors. The electronic part investigated in this work comprised of a Cissoid s CHT-PMOS30, high temperature P-channel MOSFET (metal-oxide semiconductor field-effect transistor) device [2]. This high voltage, medium-power transistor is designed for geothermal well logging applications, aerospace and avionics, and automotive industry, and is specified for operation in the temperature range of -55 C to +225 C. Table I shows some specifications of this transistor [2]. The CHT-PMOS30 device was characterized at various temperatures over the range of -190 C to +225 C in terms of its voltage/current characteristic curves. The test temperatures included +22, -50, -100, -150, -175, -190, +50, +100, +150, +175, +200, and +225 C. Limited thermal cycling testing was also performed on the device. These tests consisted of subjecting the transistor to a total of twelve thermal cycles between -190 C and +225 C. A temperature rate of change of 10 C/min and a soak time at the test temperature of 10 minutes were used throughout this work. Post-cycling measurements were also performed at selected temperatures. In addition, re-start capability at extreme temperatures, i.e. power switched on while the device was soaking for a period of 20 minutes at the test temperatures of -190 C and +225 C, was investigated.

Battery Pack Life Estimation through Cell Degradation Data and Pack Thermal Modeling for BAS+ Li-Ion Batteries. Cooperative Research and Development Final Report, CRADA Number CRD-12-489

DOE Office of Scientific and Technical Information (OSTI.GOV)

Smith, Kandler

Battery Life estimation is one of the key inputs required for Hybrid applications for all GM Hybrid/EV/EREV/PHEV programs. For each Hybrid vehicle program, GM has instituted multi-parameter Design of Experiments generating test data at Cell level and also Pack level on a reduced basis. Based on experience, generating test data on a pack level is found to be very expensive, resource intensive and sometimes less reliable. The proposed collaborative project will focus on a methodology to estimate Battery life based on cell degradation data combined with pack thermal modeling. NREL has previously developed cell-level battery aging models and pack-level thermal/electricalmore » network models, though these models are currently not integrated. When coupled together, the models are expected to describe pack-level thermal and aging response of individual cells. GM and NREL will use data collected for GM's Bas+ battery system for evaluation of the proposed methodology and assess to what degree these models can replace pack-level aging experiments in the future.« less

High-Temperature Strain Sensing for Aerospace Applications

NASA Technical Reports Server (NTRS)

Piazza, Anthony; Richards, Lance W.; Hudson, Larry D.

2008-01-01

Thermal protection systems (TPS) and hot structures are utilizing advanced materials that operate at temperatures that exceed abilities to measure structural performance. Robust strain sensors that operate accurately and reliably beyond 1800 F are needed but do not exist. These shortcomings hinder the ability to validate analysis and modeling techniques and hinders the ability to optimize structural designs. This presentation examines high-temperature strain sensing for aerospace applications and, more specifically, seeks to provide strain data for validating finite element models and thermal-structural analyses. Efforts have been made to develop sensor attachment techniques for relevant structural materials at the small test specimen level and to perform laboratory tests to characterize sensor and generate corrections to apply to indicated strains. Areas highlighted in this presentation include sensors, sensor attachment techniques, laboratory evaluation/characterization of strain measurement, and sensor use in large-scale structures.

Sprayable Phase Change Coating Thermal Protection Material

NASA Technical Reports Server (NTRS)

Richardson, Rod W.; Hayes, Paul W.; Kaul, Raj

2005-01-01

NASA has expressed a need for reusable, environmentally friendly, phase change coating that is capable of withstanding the heat loads that have historically required an ablative thermal insulation. The Space Shuttle Program currently relies on ablative materials for thermal protection. The problem with an ablative insulation is that, by design, the material ablates away, in fulfilling its function of cooling the underlying substrate, thus preventing the insulation from being reused from flight to flight. The present generation of environmentally friendly, sprayable, ablative thermal insulation (MCC-l); currently use on the Space Shuttle SRBs, is very close to being a reusable insulation system. In actual flight conditions, as confirmed by the post-flight inspections of the SRBs, very little of the material ablates. Multi-flight thermal insulation use has not been qualified for the Space Shuttle. The gap that would have to be overcome in order to implement a reusable Phase Change Coating (PCC) is not unmanageable. PCC could be applied robotically with a spray process utilizing phase change material as filler to yield material of even higher strength and reliability as compared to MCC-1. The PCC filled coatings have also demonstrated potential as cryogenic thermal coatings. In experimental thermal tests, a thin application of PCC has provided the same thermal protection as a much thicker and heavier application of a traditional ablative thermal insulation. In addition, tests have shown that the structural integrity of the coating has been maintained and phase change performance after several aero-thermal cycles was not affected. Experimental tests have also shown that, unlike traditional ablative thermal insulations, PCC would not require an environmental seal coat, which has historically been required to prevent moisture absorption by the thermal insulation, prevent environmental degradation, and to improve the optical and aerodynamic properties. In order to reduce the launch and processing costs of a reusable space vehicle to an affordable level, refurbishment costs must be substantially reduced. A key component of such a cost effective approach is the use of a reusable, phase change, thermal protection coating.

Design of Electrical Systems for Rocket Propulsion Test Facilities at the John C. Stennis Space Center

NASA Technical Reports Server (NTRS)

Hughes, Mark S.; Davis, Dawn M.; Bakker, Henry J.; Jensen, Scott L.

2007-01-01

This viewgraph presentation reviews the design of the electrical systems that are required for the testing of rockets at the Rocket Propulsion Facility at NASA Stennis Space Center (NASA SSC). NASA/SSC s Mission in Rocket Propulsion Testing Is to Acquire Test Performance Data for Verification, Validation and Qualification of Propulsion Systems Hardware. These must be accurate reliable comprehensive and timely. Data acquisition in a rocket propulsion test environment is challenging: severe temporal transient dynamic environments, large thermal gradients, vacuum to 15 ksi pressure regimes SSC has developed and employs DAS, control systems and control systems and robust instrumentation that effectively satisfies these challenges.

Carbon dioxide and water vapor high temperature electrolysis

NASA Technical Reports Server (NTRS)

Isenberg, Arnold O.; Verostko, Charles E.

1989-01-01

The design, fabrication, breadboard testing, and the data base obtained for solid oxide electrolysis systems that have applications for planetary manned missions and habitats are reviewed. The breadboard tested contains sixteen tubular cells in a closely packed bundle for the electrolysis of carbon dioxide and water vapor. The discussion covers energy requirements, volume, weight, and operational characteristics related to the measurement of the reactant and product gas compositions, temperature distribution along the electrolyzer tubular cells and through the bundle, and thermal energy losses. The reliability of individual cell performance in the bundle configuration is assessed.

Annual Report to the NASA Administrator by the Aerospace Safety Advisory Panel on the Space Shuttle Program. Part 2: Summary of Information Developed in the Panel's Fact-Finding Activities

NASA Technical Reports Server (NTRS)

1977-01-01

The panel focused its attention on those areas that are considered most significant for flight success and safety. Elements required for the Approach and Landing Test Program, the Orbital Flight Test Program, and those management systems and their implementation which directly affect safety, reliability, and quality control, were investigated. Ground facilities and the training programs for the ground and flight crews were studied. Of special interest was the orbiter thermal protection subsystems.

How Do You Measure That Ceramic Property?

NASA Technical Reports Server (NTRS)

Salem, Jonathan; Helfinstine, John; Quinn, George; Gonczy, Stephen

2011-01-01

By using the dozens of consensus test standards and practices developed by the Advanced Ceramics Committee of ASTM, C-28, the measurement of mechanical, physical, thermal, and performance properties can be properly performed. The what, how, how not, and why are clearly illustrated for beginning as well as experienced testers. Using these standards will provide accurate, reliable, and complete data for rigorous comparisons with other test results. The C-28 Committee has involved academics, and producers, and users of ceramics to write and continually update more than 45 standards since the committee's inception in 1986.

Response of Al-Based Micro- and Nanocomposites to Rapid Fluctuations in Thermal Environments

NASA Astrophysics Data System (ADS)

Dash, K.; Ray, B. C.

2018-05-01

The focus of this work is to highlight the relative response of Al-based micro- and nanocomposites in the form of enhancement in flexural strength via induced thermal stresses at high and cryogenic temperatures in ex situ and in situ atmospheres. In this investigation, we have tried to explore the reliability, matrix-reinforcement interaction and microstructural integrity of these materials in their service period by designing appropriate heat treatment regimes. Al-Al2O3 micro- and nanocomposites had been fabricated by powder processing method. The micro- and nanocomposites were subjected to down-thermal shock (from positive to negative temperature) and up-thermal shock (from negative to positive temperature) with varying thermal gradients. For isothermal conditioning, the composites were exposed to + 80 and - 80 °C for 1 h separately. High-temperature three-point flexural tests were performed at 100 and 250 °C on the composites. All the composites subjected to thermal shock and isothermal conditioning was tested in three-point flexural mode post-treatments. Al-1 vol.% Al2O3 nanocomposite's flexural strength improved to 118 MPa post-thermal shock treatment of gradient of 160 °C. The Al-5 and 10 vol.% Al2O3 microcomposites possessed flexural strength of 200 and 99.8 MPa after thermal shock treatment of gradient of 160 and 80 °C, respectively. The observed improvement in flexural strength of micro- and nanocomposites post-thermal excursions were compared and have been discussed with the support of fractography. The microcomposites showed a higher positive scale of response to the thermal excursions as compared to that of the nanocomposites.

A hybrid electronically scanned pressure module for cryogenic environments

NASA Technical Reports Server (NTRS)

Chapman, J. J.; Hopson, P., Jr.; Kruse, N.

1995-01-01

Pressure is one of the most important parameters measured when testing models in wind tunnels. For models tested in the cryogenic environment of the National Transonic Facility at NASA Langley Research Center, the technique of utilizing commercially available multichannel pressure modules inside the models is difficult due to the small internal volume of the models and the requirement of keeping the pressure transducer modules within an acceptable temperature range well above the -173 degrees C tunnel temperature. A prototype multichannel pressure transducer module has been designed and fabricated with stable, repeatable sensors and materials optimized for reliable performance in the cryogenic environment. The module has 16 single crystal silicon piezoresistive pressure sensors electrostatically bonded to a metalized Pyrex substrate for sensing the wind tunnel model pressures. An integral temperature sensor mounted on each silicon micromachined pressure sensor senses real-time temperature fluctuations to within 0.1 degrees C to correct for thermally induced non-random sensor drift. The data presented here are from a prototype sensor module tested in the 0.3 M cryogenic tunnel and thermal equilibrium conditions in an environmental chamber which approximates the thermal environment (-173 degrees C to +60 degrees C) of the National Transonic Facility.

Advanced Stirling Convertor Testing at NASA Glenn Research Center

NASA Technical Reports Server (NTRS)

Wilson, Scott D.; Poriti, Sal

2010-01-01

The NASA Glenn Research Center (GRC) has been testing high-efficiency free-piston Stirling convertors for potential use in radioisotope power systems (RPSs) since 1999. The current effort is in support of the Advanced Stirling Radioisotope Generator (ASRG), which is being developed by the U.S. Department of Energy (DOE), Lockheed Martin Space Systems Company (LMSSC), Sunpower, Inc., and the NASA GRC. This generator would use two high-efficiency Advanced Stirling Convertors (ASCs) to convert thermal energy from a radioisotope heat source into electricity. As reliability is paramount to a RPS capable of providing spacecraft power for potential multi-year missions, GRC provides direct technology support to the ASRG flight project in the areas of reliability, convertor and generator testing, high-temperature materials, structures, modeling and analysis, organics, structural dynamics, electromagnetic interference (EMI), and permanent magnets to reduce risk and enhance reliability of the convertor as this technology transitions toward flight status. Convertor and generator testing is carried out in short- and long-duration tests designed to characterize convertor performance when subjected to environments intended to simulate launch and space conditions. Long duration testing is intended to baseline performance and observe any performance degradation over the life of the test. Testing involves developing support hardware that enables 24/7 unattended operation and data collection. GRC currently has 14 Stirling convertors under unattended extended operation testing, including two operating in the ASRG Engineering Unit (ASRG-EU). Test data and high-temperature support hardware are discussed for ongoing and future ASC tests with emphasis on the ASC-E and ASC-E2.

Stress and Reliability Analysis of a Metal-Ceramic Dental Crown

NASA Technical Reports Server (NTRS)

Anusavice, Kenneth J; Sokolowski, Todd M.; Hojjatie, Barry; Nemeth, Noel N.

1996-01-01

Interaction of mechanical and thermal stresses with the flaws and microcracks within the ceramic region of metal-ceramic dental crowns can result in catastrophic or delayed failure of these restorations. The objective of this study was to determine the combined influence of induced functional stresses and pre-existing flaws and microcracks on the time-dependent probability of failure of a metal-ceramic molar crown. A three-dimensional finite element model of a porcelain fused-to-metal (PFM) molar crown was developed using the ANSYS finite element program. The crown consisted of a body porcelain, opaque porcelain, and a metal substrate. The model had a 300 Newton load applied perpendicular to one cusp, a load of 30ON applied at 30 degrees from the perpendicular load case, directed toward the center, and a 600 Newton vertical load. Ceramic specimens were subjected to a biaxial flexure test and the load-to-failure of each specimen was measured. The results of the finite element stress analysis and the flexure tests were incorporated in the NASA developed CARES/LIFE program to determine the Weibull and fatigue parameters and time-dependent fracture reliability of the PFM crown. CARES/LIFE calculates the time-dependent reliability of monolithic ceramic components subjected to thermomechanical and/Or proof test loading. This program is an extension of the CARES (Ceramics Analysis and Reliability Evaluation of Structures) computer program.

Reliability Testing on the CTI-Cryogenic 1 Watt Integral Cooler (HD- 1033C/UA)

DTIC Science & Technology

1989-09-01

SUBJECT TERMS (Continue on reverse if necessary and identify by block numbe) FIELD GROUP SUB- GROUP Cryocooler, Stirling Cycle, Cryogenics 19, ABSTRCT...the Army. C2NVEO also maintains configuration management control of the forward-looking infrared (FLIR) Common Module coolers used in thermal imagers... controlled high/low temperature chamber. * A microprocessor which was programmed to automatically cycle the temperature in the chamber in accordance

James Webb Space Telescope (JWST) Integrated Science Instruments Module (ISIM) Cryo-Vacuum (CV) Test Campaign Summary

NASA Technical Reports Server (NTRS)

Yew, Calinda; Lui, Yan; Whitehouse, Paul; Banks, Kimberly

2016-01-01

JWST Integrated Science Instruments Module (ISIM) completed its system-level space simulation testing program at the NASA Goddard Space Flight Center (GSFC). In March 2016, ISIM was successfully delivered to the next level of integration with the Optical Telescope Element (OTE), to form OTIS (OTE + ISIM), after concluding a series of three cryo-vacuum (CV) tests. During these tests, the complexity of the mission has generated challenging requirements that demand highly reliable system performance and capabilities from the Space Environment Simulator (SES) vacuum chamber. The first test served as a risk reduction test; the second test provided the initial verification of the fully-integrated flight instruments; and the third test verified the system in its final flight configuration following mechanical environmental tests (vibration and acoustics). From one test to the next, shortcomings of the facility were uncovered and associated improvements in operational capabilities and reliability of the facility were required to enable the project to verify system-level requirements. This paper: (1) provides an overview of the integrated mechanical and thermal facility systems required to achieve the objectives of JWST ISIM testing, (2) compares the overall facility performance and instrumentation results from the three ISIM CV tests, and (3) summarizes lessons learned from the ISIM testing campaign.

Bayesian Approach for Reliability Assessment of Sunshield Deployment on JWST

NASA Technical Reports Server (NTRS)

Kaminskiy, Mark P.; Evans, John W.; Gallo, Luis D.

2013-01-01

Deployable subsystems are essential to mission success of most spacecraft. These subsystems enable critical functions including power, communications and thermal control. The loss of any of these functions will generally result in loss of the mission. These subsystems and their components often consist of unique designs and applications, for which various standardized data sources are not applicable for estimating reliability and for assessing risks. In this study, a Bayesian approach for reliability estimation of spacecraft deployment was developed for this purpose. This approach was then applied to the James Webb Space Telescope (JWST) Sunshield subsystem, a unique design intended for thermal control of the observatory's telescope and science instruments. In order to collect the prior information on deployable systems, detailed studies of "heritage information", were conducted extending over 45 years of spacecraft launches. The NASA Goddard Space Flight Center (GSFC) Spacecraft Operational Anomaly and Reporting System (SOARS) data were then used to estimate the parameters of the conjugative beta prior distribution for anomaly and failure occurrence, as the most consistent set of available data and that could be matched to launch histories. This allows for an emperical Bayesian prediction for the risk of an anomaly occurrence of the complex Sunshield deployment, with credibility limits, using prior deployment data and test information.

Reliable high-power diode lasers: thermo-mechanical fatigue aspects

NASA Astrophysics Data System (ADS)

Klumel, Genady; Gridish, Yaakov; Szafranek, Igor; Karni, Yoram

2006-02-01

High power water-cooled diode lasers are finding increasing demand in biomedical, cosmetic and industrial applications, where repetitive cw (continuous wave) and pulsed cw operation modes are required. When operating in such modes, the lasers experience numerous complete thermal cycles between "cold" heat sink temperature and the "hot" temperature typical of thermally equilibrated cw operation. It is clearly demonstrated that the main failure mechanism directly linked to repetitive cw operation is thermo-mechanical fatigue of the solder joints adjacent to the laser bars, especially when "soft" solders are used. Analyses of the bonding interfaces were carried out using scanning electron microscopy. It was observed that intermetallic compounds, formed already during the bonding process, lead to the solders fatigue both on the p- and n-side of the laser bar. Fatigue failure of solder joints in repetitive cw operation reduces useful lifetime of the stacks to hundreds hours, in comparison with more than 10,000 hours lifetime typically demonstrated in commonly adopted non-stop cw reliability testing programs. It is shown, that proper selection of package materials and solders, careful design of fatigue sensitive parts and burn-in screening in the hard pulse operation mode allow considerable increase of lifetime and reliability, without compromising the device efficiency, optical power density and compactness.

Synthesis, Characterization And Modeling Of Functionally Graded Multifunctional Hybrid Composites For Extreme Environments

DTIC Science & Technology

2017-04-04

research thrust areas are designed to enable the development of reliable, damage tolerant, lightweight structures with excellent thermal management...46 2. RESEARCH THRUST AREA: MULTISCALE CHARACTERIZATION AND MODELING .................................... 56 2.1 DESIGN OF MATERIALS...The research thrust areas are designed to enable the development of reliable, damage tolerant, lightweight structures with excellent thermal

Enabling More than Moore: Accelerated Reliability Testing and Risk Analysis for Advanced Electronics Packaging

NASA Technical Reports Server (NTRS)

Ghaffarian, Reza; Evans, John W.

2014-01-01

For five decades, the semiconductor industry has distinguished itself by the rapid pace of improvement in miniaturization of electronics products-Moore's Law. Now, scaling hits a brick wall, a paradigm shift. The industry roadmaps recognized the scaling limitation and project that packaging technologies will meet further miniaturization needs or ak.a "More than Moore". This paper presents packaging technology trends and accelerated reliability testing methods currently being practiced. Then, it presents industry status on key advanced electronic packages, factors affecting accelerated solder joint reliability of area array packages, and IPC/JEDEC/Mil specifications for characterizations of assemblies under accelerated thermal and mechanical loading. Finally, it presents an examples demonstrating how Accelerated Testing and Analysis have been effectively employed in the development of complex spacecraft thereby reducing risk. Quantitative assessments necessarily involve the mathematics of probability and statistics. In addition, accelerated tests need to be designed which consider the desired risk posture and schedule for particular project. Such assessments relieve risks without imposing additional costs. and constraints that are not value added for a particular mission. Furthermore, in the course of development of complex systems, variances and defects will inevitably present themselves and require a decision concerning their disposition, necessitating quantitative assessments. In summary, this paper presents a comprehensive view point, from technology to systems, including the benefits and impact of accelerated testing in offsetting risk.

Fracture Behaviors of Sn-Cu Intermetallic Compound Layer in Ball Grid Array Induced by Thermal Shock

NASA Astrophysics Data System (ADS)

Shen, Jun; Zhai, Dajun; Cao, Zhongming; Zhao, Mali; Pu, Yayun

2014-02-01

In this work, thermal shock reliability testing and finite-element analysis (FEA) of solder joints between ball grid array components and printed circuit boards with Cu pads were used to investigate the failure mechanism of solder interconnections. The morphologies, composition, and thickness of Sn-Cu intermetallic compounds (IMC) at the interface of Sn-3.0Ag-0.5Cu lead-free solder alloy and Cu substrates were investigated by scanning electron microscopy and transmission electron microscopy. Based on the experimental observations and FEA results, it can be recognized that the origin and propagation of cracks are caused primarily by the difference between the coefficient of thermal expansion of different parts of the packaged products, the growth behaviors and roughness of the IMC layer, and the grain size of the solder balls.

Gravity Probe B spacecraft description

NASA Astrophysics Data System (ADS)

Bennett, Norman R.; Burns, Kevin; Katz, Russell; Kirschenbaum, Jon; Mason, Gary; Shehata, Shawky

2015-11-01

The Gravity Probe B spacecraft, developed, integrated, and tested by Lockheed Missiles & Space Company and later Lockheed Martin Corporation, consisted of structures, mechanisms, command and data handling, attitude and translation control, electrical power, thermal control, flight software, and communications. When integrated with the payload elements, the integrated system became the space vehicle. Key requirements shaping the design of the spacecraft were: (1) the tight mission timeline (17 months, 9 days of on-orbit operation), (2) precise attitude and translational control, (3) thermal protection of science hardware, (4) minimizing aerodynamic, magnetic, and eddy current effects, and (5) the need to provide a robust, low risk spacecraft. The spacecraft met all mission requirements, as demonstrated by dewar lifetime meeting specification, positive power and thermal margins, precision attitude control and drag-free performance, reliable communications, and the collection of more than 97% of the available science data.

Physico-Geometrical Kinetics of Solid-State Reactions in an Undergraduate Thermal Analysis Laboratory

ERIC Educational Resources Information Center

Koga, Nobuyoshi; Goshi, Yuri; Yoshikawa, Masahiro; Tatsuoka, Tomoyuki

2014-01-01

An undergraduate kinetic experiment of the thermal decomposition of solids by microscopic observation and thermal analysis was developed by investigating a suitable reaction, applicable techniques of thermal analysis and microscopic observation, and a reliable kinetic calculation method. The thermal decomposition of sodium hydrogen carbonate is…

TAB interconnects for space concentrator solar cell arrays

NASA Technical Reports Server (NTRS)

Avery, J.; Bauman, J. S.; Gallagher, P.; Yerkes, J. W.

1993-01-01

The Boeing Company has evaluated the use of Tape Automated Bonding (TAB) and Surface Mount Technology (SMT) for a highly reliable, low cost interconnect for concentrator solar cell arrays. TAB and SMT are currently used in the electronics industry for chip interconnects and printed circuit board assembly. TAB tape consists of sixty-four 3-mil/1-oz tin-plated copper leads on 8-mil centers. The leads are thermocompression gang bonded to GaAs concentrator solar cell with silver contacts. This bond, known as an Inner Lead Bond (ILB), allows for pretesting and sorting capability via nondestruct wire bond pull and flash testing. Destructive wire pull tests resulted in preferred mid-span failures. Improvements in fill factor were attributed to decreased contact resistance on TAB bonded cells. Preliminary thermal cycling and aging tests were shown excellent bond strength and metallurgical results. Auger scans of bond sites reveals an Ag-Cu-Tin composition. Improper bonds are identified through flash testing as a performance degradation. On going testing of cells are underway at Lewis Research Center. SMT techniques are utilized to excise and form TAB leads post ILB. The formed leads' shape isolates thermal mismatches between the cells and the flex circuit they are mounted on. TABed cells are picked and placed with a gantry x-y-z positioning system with pattern recognition. Adhesives are selected to avoid thermal expansion mismatch and promote thermal transfer to the flex circuit. TAB outer lead bonds are parallel gap welded (PGW) to the flex circuit to finish the concentrator solar cell subassembly.

Effects of PCB Pad Metal Finishes on the Cu-Pillar/Sn-Ag Micro Bump Joint Reliability of Chip-on-Board (COB) Assembly

NASA Astrophysics Data System (ADS)

Kim, Youngsoon; Lee, Seyong; Shin, Ji-won; Paik, Kyung-Wook

2016-06-01

While solder bumps have been used as the bump structure to form the interconnection during the last few decades, the continuing scaling down of devices has led to a change in the bump structure to Cu-pillar/Sn-Ag micro-bumps. Cu-pillar/Sn-Ag micro-bump interconnections differ from conventional solder bump interconnections in terms of their assembly processing and reliability. A thermo-compression bonding method with pre-applied b-stage non-conductive films has been adopted to form solder joints between Cu pillar/Sn-Ag micro bumps and printed circuit board vehicles, using various pad metal finishes. As a result, various interfacial inter-metallic compounds (IMCs) reactions and stress concentrations occur at the Cu pillar/Sn-Ag micro bumps joints. Therefore, it is necessary to investigate the influence of pad metal finishes on the structural reliability of fine pitch Cu pillar/Sn-Ag micro bumps flip chip packaging. In this study, four different pad surface finishes (Thin Ni ENEPIG, OSP, ENEPIG, ENIG) were evaluated in terms of their interconnection reliability by thermal cycle (T/C) test up to 2000 cycles at temperatures ranging from -55°C to 125°C and high-temperature storage test up to 1000 h at 150°C. The contact resistances of the Cu pillar/Sn-Ag micro bump showed significant differences after the T/C reliability test in the following order: thin Ni ENEPIG > OSP > ENEPIG where the thin Ni ENEPIG pad metal finish provided the best Cu pillar/Sn-Ag micro bump interconnection in terms of bump joint reliability. Various IMCs formed between the bump joint areas can account for the main failure mechanism.

Automation is an Effective Way to Improve Quality of Verification (Calibration) of Measuring Instruments

NASA Astrophysics Data System (ADS)

Golobokov, M.; Danilevich, S.

2018-04-01

In order to assess calibration reliability and automate such assessment, procedures for data collection and simulation study of thermal imager calibration procedure have been elaborated. The existing calibration techniques do not always provide high reliability. A new method for analyzing the existing calibration techniques and developing new efficient ones has been suggested and tested. A type of software has been studied that allows generating instrument calibration reports automatically, monitoring their proper configuration, processing measurement results and assessing instrument validity. The use of such software allows reducing man-hours spent on finalization of calibration data 2 to 5 times and eliminating a whole set of typical operator errors.

High reliability level on single-mode 980nm-1060 nm diode lasers for telecommunication and industrial applications

NASA Astrophysics Data System (ADS)

Van de Casteele, J.; Bettiati, M.; Laruelle, F.; Cargemel, V.; Pagnod-Rossiaux, P.; Garabedian, P.; Raymond, L.; Laffitte, D.; Fromy, S.; Chambonnet, D.; Hirtz, J. P.

2008-02-01

We demonstrate very high reliability level on 980-1060nm high-power single-mode lasers through multi-cell tests. First, we show how our chip design and technology enables high reliability levels. Then, we aged 758 devices during 9500 hours among 6 cells with high current (0.8A-1.2A) and high submount temperature (65°C-105°C) for the reliability demonstration. Sudden catastrophic failure is the main degradation mechanism observed. A statistical failure rate model gives an Arrhenius thermal activation energy of 0.51eV and a power law forward current acceleration factor of 5.9. For high-power submarine applications (360mW pump module output optical power), this model exhibits a failure rate as low as 9 FIT at 13°C, while ultra-high power terrestrial modules (600mW) lie below 220 FIT at 25°C. Wear-out phenomena is observed only for very high current level without any reliability impact under 1.1A. For the 1060nm chip, step-stress tests were performed and a set of devices were aged during more than 2000 hours in different stress conditions. First results are in accordance with 980nm product with more than 100khours estimated MTTF. These reliability and performance features of 980-1060nm laser diodes will make high-power single-mode emitters the best choice for a number of telecommunication and industrial applications in the next few years.

Solid Insulated Switchgear and Investigation of its Mechanical and Electrical Reliability

NASA Astrophysics Data System (ADS)

Sato, Junichi; Kinoshita, Susumu; Sakaguchi, Osamu; Miyagawa, Masaru; Shimizu, Toshio; Homma, Mitsutaka

SF6 gas is applied widely to medium voltage switchgear because of its high insulation reliability and down-sizing ability. However, SF6 gas was placed on the list of greenhouse gases under the Kyoto Protocol in 1997. Since then, the investigation and development concerning SF6-free or less has carried out activity. Therefore, we paid attention to the solid material which has higher dielectric strength than SF6, and we have newly developed solid insulated switchgear (SIS) achieved by molding all main circuit. A new epoxy casting material is applied, which contains a great deal of spherical silica and a small amount of rubber particles. This new material has the high mechanical strength, high thermal resistance, high toughness, and also high dielectric strength because of directly molding the vacuum bottle, down-sizing and reliability. This paper describes about the technology of a new epoxy casting material which achieves the SIS. In addition, the mechanical and electrical reliability test of SIS applied a new epoxy resin are carried out, and effectiveness of the development material and the mechanical and electrical reliability of SIS are verified.

TiO x -Based Thermoelectric Modules: Manufacturing, Properties, and Operational Behavior

NASA Astrophysics Data System (ADS)

Martin, Hans-Peter; Pönicke, Andreas; Kluge, Martin; Sichert, Ina; Rost, Axel; Conze, Susan; Wätzig, Katja; Schilm, Jochen; Michaelis, Alexander

2016-03-01

Substoichiometric titanium oxides are attractive thermoelectric materials for high-temperature modules. Their advantages are availability, economy, and safety. This paper gives results of thermoelectric data on scale-up titanium suboxides, manufacturing technologies of TiO x modules, glass coating as an option for oxidation protection, and test results of TiO x modules. The thermoelectric efficiency of TiO x is low compared with established thermoelectric materials. However, TiO x is very attractive for economic reasons, and there are still expectations for efficiency rise by modification of the material's microstructure. TiO x can be produced in large quantities of several tens of kilograms. A manufacturing process for TiO x -based unileg n-type modules has been established, including all technological steps. The design of the TiO x -based modules was optimized for the thermoelectric conversion process and thermal robustness. A test device was used for experimental analysis with maximum temperature of 600°C at the hot side and 100°C at the cold side. This initial test revealed similar power output and internal resistance of all fabricated modules. Furthermore, thermal cycles with increasing and decreasing temperatures at the hot side were realized to characterize the reliability and stability of the modules. Additionally, modules were tested in a hot gas test rig to simulate the thermal stresses during power generation in the exhaust line of a passenger car.

Brief Communication: A low-cost Arduino®-based wire extensometer for earth flow monitoring

NASA Astrophysics Data System (ADS)

Guerriero, Luigi; Guerriero, Giovanni; Grelle, Gerardo; Guadagno, Francesco M.; Revellino, Paola

2017-06-01

Continuous monitoring of earth flow displacement is essential for the understanding of the dynamic of the process, its ongoing evolution and designing mitigation measures. Despite its importance, it is not always applied due to its expense and the need for integration with additional sensors to monitor factors controlling movement. To overcome these problems, we developed and tested a low-cost Arduino-based wire-rail extensometer integrating a data logger, a power system and multiple digital and analog inputs. The system is equipped with a high-precision position transducer that in the test configuration offers a measuring range of 1023 mm and an associated accuracy of ±1 mm, and integrates an operating temperature sensor that should allow potential thermal drift that typically affects this kind of systems to be identified and corrected. A field test, conducted at the Pietrafitta earth flow where additional monitoring systems had been installed, indicates a high reliability of the measurement and a high monitoring stability without visible thermal drift.

Brayton advanced heat receiver development program

NASA Technical Reports Server (NTRS)

Heidenreich, G. R.; Downing, R. S.; Lacey, Dovie E.

1989-01-01

NASA Lewis Research Center is managing an advanced solar dynamic (ASD) space power program. The objective of the ASD program is to develop small and lightweight solar dynamic systems which show significant improvement in efficiency and specific mass over the baseline design derived from the Space Station Freedom technology. The advanced heat receiver development program is a phased program to design, fabricate and test elements of a 7-kWe heat-receiver/thermal-energy-storage subsystem. Receivers for both Brayton and Stirling heat engines are being developed under separate contracts. Phase I, described here, is the current eighteen month effort to design and perform critical technology experiments on innovative concepts designed to reduce mass without compromising thermal efficiency and reliability.

Development and validation of purged thermal protection systems for liquid hydrogen fuel tanks of hypersonic vehicles

NASA Technical Reports Server (NTRS)

Helenbrook, R. D.; Colt, J. Z.

1977-01-01

An economical, lightweight, safe, efficient, reliable, and reusable insulation system was developed for hypersonic cruise vehicle hydrogen fuel tanks. Results indicate that, a nitrogen purged, layered insulation system with nonpermeable closed-cell insulation next to the cryogenic tank and a high service temperature fibrous insulation surrounding it, is potentially an attractive solution to the insulation problem. For the postulated hypersonic flight the average unit weight of the purged insulation system (including insulation, condensate and fuel boil off) is 6.31 kg/sq m (1.29 psf). Limited cyclic tests of large specimens of closed cell polymethacrylimide foam indicate it will withstand the expected thermal cycle.

Electric Motor Thermal Management R&D. Annual Report

DOE Office of Scientific and Technical Information (OSTI.GOV)

Bennion, Kevin

With the push to reduce component volumes, lower costs, and reduce weight without sacrificing performance or reliability, the challenges associated with thermal management increase for power electronics and electric motors. Thermal management for electric motors will become more important as the automotive industry continues the transition to more electrically dominant vehicle propulsion systems. The transition to more electrically dominant propulsion systems leads to higher-power duty cycles for electric drive systems. Thermal constraints place significant limitations on how electric motors ultimately perform, and as thermal management improves, there will be a direct trade-off between motor performance, efficiency, cost, and the sizingmore » of electric motors to operate within the thermal constraints. The goal of this research project is to support broad industry demand for data, analysis methods, and experimental techniques to improve and better understand motor thermal management. Work in FY15 focused on two areas related to motor thermal management: passive thermal performance and active convective cooling. Passive thermal performance emphasized the thermal impact of materials and thermal interfaces among materials within an assembled motor. The research tasks supported the publication of test methods and data for thermal contact resistances and direction-dependent thermal conductivity within an electric motor. Active convective cooling focused on measuring convective heat-transfer coefficients using automatic transmission fluid (ATF). Data for average convective heat transfer coefficients for direct impingement of ATF jets was published. Also, experimental hardware for mapping local-scale and stator-scale convective heat transfer coefficients for ATF jet impingement were developed.« less

Power Electronics Thermal Management Research: Annual Progress Report

DOE Office of Scientific and Technical Information (OSTI.GOV)

Moreno, Gilberto

The objective for this project is to develop thermal management strategies to enable efficient and high-temperature wide-bandgap (WBG)-based power electronic systems (e.g., emerging inverter and DC-DC converter). Reliable WBG devices are capable of operating at elevated temperatures (≥ 175 °Celsius). However, packaging WBG devices within an automotive inverter and operating them at higher junction temperatures will expose other system components (e.g., capacitors and electrical boards) to temperatures that may exceed their safe operating limits. This creates challenges for thermal management and reliability. In this project, system-level thermal analyses are conducted to determine the effect of elevated device temperatures on invertermore » components. Thermal modeling work is then conducted to evaluate various thermal management strategies that will enable the use of highly efficient WBG devices with automotive power electronic systems.« less

Furnace Cyclic Oxidation Behavior of Multicomponent Low Conductivity Thermal Barrier Coatings

NASA Astrophysics Data System (ADS)

Zhu, Dongming; Nesbitt, James A.; Barrett, Charles A.; McCue, Terry R.; Miller, Robert A.

2004-03-01

Ceramic thermal barrier coatings (TBCs) will play an increasingly important role in advanced gas turbine engines due to their ability to further increase engine operating temperatures and reduce cooling, thus helping achieve future engine low emission, high efficiency, and improved reliability goals. Advanced multicomponent zirconia (ZrO2)-based TBCs are being developed using an oxide defect clustering design approach to achieve the required coating low thermal conductivity and high-temperature stability. Although the new composition coatings were not yet optimized for cyclic durability, an initial durability screening of the candidate coating materials was conducted using conventional furnace cyclic oxidation tests. In this paper, furnace cyclic oxidation behavior of plasma-sprayed ZrO2-based defect cluster TBCs was investigated at 1163°C using 45 min hot-time cycles. The ceramic coating failure mechanisms were studied using scanning electron microscopy (SEM) combined with x-ray diffraction (XRD) phase analysis after the furnace tests. The coating cyclic lifetime is also discussed in relation to coating processing, phase structures, dopant concentration, and other thermo-physical properties.

In situ baking method for degassing of a kicker magnet in accelerator beam line

DOE Office of Scientific and Technical Information (OSTI.GOV)

Kamiya, Junichiro, E-mail: kamiya.junichiro@jaea.go.jp; Ogiwara, Norio; Yanagibashi, Toru

In this study, the authors propose a new in situ degassing method by which only kicker magnets in the accelerator beam line are baked out without raising the temperature of the vacuum chamber to prevent unwanted thermal expansion of the chamber. By simply installing the heater and thermal radiation shield plates between the kicker magnet and the chamber wall, most of the heat flux from the heater directs toward the kicker magnet. The result of the verification test showed that each part of the kicker magnet was heated to above the target temperature with a small rise in the vacuummore » chamber temperature. A graphite heater was selected in this application to bake-out the kicker magnet in the beam line to ensure reliability and easy maintainability of the heater. The vacuum characteristics of graphite were suitable for heater operation in the beam line. A preliminary heat-up test conducted in the accelerator beam line also showed that each part of the kicker magnet was successfully heated and that thermal expansion of the chamber was negligibly small.« less

Design of an integrated fuel processor for residential PEMFCs applications

NASA Astrophysics Data System (ADS)

Seo, Yu Taek; Seo, Dong Joo; Jeong, Jin Hyeok; Yoon, Wang Lai

KIER has been developing a novel fuel processing system to provide hydrogen rich gas to residential PEMFCs system. For the effective design of a compact hydrogen production system, each unit process for steam reforming and water gas shift, has a steam generator and internal heat exchangers which are thermally and physically integrated into a single packaged hardware system. The newly designed fuel processor (prototype II) showed a thermal efficiency of 78% as a HHV basis with methane conversion of 89%. The preferential oxidation unit with two staged cascade reactors, reduces, the CO concentration to below 10 ppm without complicated temperature control hardware, which is the prerequisite CO limit for the PEMFC stack. After we achieve the initial performance of the fuel processor, partial load operation was carried out to test the performance and reliability of the fuel processor at various loads. The stability of the fuel processor was also demonstrated for three successive days with a stable composition of product gas and thermal efficiency. The CO concentration remained below 10 ppm during the test period and confirmed the stable performance of the two-stage PrOx reactors.

Reliability issues for a bolometer detector for ITER at high operating temperatures.

PubMed

Meister, H; Kannamüller, M; Koll, J; Pathak, A; Penzel, F; Trautmann, T; Detemple, P; Schmitt, S; Langer, H

2012-10-01

The first detector prototypes for the ITER bolometer diagnostic featuring a 12.5 μm thick Pt-absorber have been realized and characterized in laboratory tests. The results show linear dependencies of the calibration parameters and are in line with measurements of prototypes with thinner absorbers. However, thermal cycling tests up to 450 °C of the prototypes with thick absorbers demonstrated that their reliability at these elevated operating temperatures is not yet sufficient. Profilometer measurements showed a deflection of the membrane hinting to stresses due to the deposition processes of the absorber. Finite element analysis (FEA) managed to reproduce the deflection and identified the highest stresses in the membrane in the region around the corners of the absorber. FEA was further used to identify changes in the geometry of the absorber with a positive impact on the intrinsic stresses of the membrane. However, further improvements are still necessary.

Temperature prediction of space flight experiments by computer thermal analysis

NASA Technical Reports Server (NTRS)

Birdsong, M. B.; Luttges, M. W.

1994-01-01

Life sciences experiments are especially sensitive to temperature. A small temperature difference between otherwise identical samples can cause various differences in biological reaction rates. Knowledge of experimental temperatures and temperature histories help to distinguish the effects of microgravity and temperature on spaceflight experiments compared to ground based studies, and allow appropriate controls and sensitivity tests. Up to the present time, the Orbiter (Space Shuttle) has not generally provided temperature measurement instrumentation inside ambient lockers located in the Mid-deck of the Orbiter, or inside similar facilities such as Spacehab and Spacelab, but many pieces of hardware do have temperature recording capability. Most of these temperatures, however, have only been roughly measured or estimated. Such reported experimental temperatures, while accurate within a range of several degrees Celsius, are of limited utility to biological researchers. The temperature controlled lockers used in spaceflight, such as Commerical-Refrigeration Incubation Modules (C-R/IMs), severely reduce the mass and volume available for test samples and do not necessarily provide uniform thermal environments. While these test carriers avoid some of the experimental temperature variations of the ambient lockers, the number of samples which can be accommodated in these temperature controlled units is limited. In the present work, improved models of thermal prediction and control were sought. Temperatures are predicted by thermal analysis software using empirical temperatures recorded during STS-57. These temperatures are compared to data recorded throughout the mission using Ambient Temperature Recorders (ATRs) located within several payload lockers. Additional test cases are undertaken using controlled ground experiments to more precisely determine the reliability of the thermal model. The approach presented should increase the utility of various spaceflight carriers in the support of biological and material science research and ground control studies done in preparation for flight.

Temperature prediction of space flight experiments by computer thermal analysis.

PubMed

Birdsong, M B; Luttges, M W

1995-02-01

Life sciences experiments are especially sensitive to temperature. A small temperature difference between otherwise identical samples can cause various differences in biological reaction rates. Knowledge of experimental temperatures and temperature histories help to distinguish the effects of microgravity and temperature on spaceflight experiments compared to ground based studies, and allow appropriate controls and sensitivity tests. Up to the present time, the Orbiter (Space Shuttle) has not generally provided temperature measurement instrumentation inside ambient lockers located in the Mid-deck of the Orbiter, or inside similar facilities such as Spacehab and Spacelab, but many pieces of hardware do have temperature recording capability. Most of these temperatures, however, have only been roughly measured or estimated. Such reported experimental temperatures, while accurate within a range of several degrees Celsius, are of limited utility to biological researchers. The temperature controlled lockers used in spaceflight, such as Commercial-Refrigeration Incubation Modules (C-R/IMs), severely reduce the mass and volume available for test samples and do not necessarily provide uniform thermal environments. While these test carriers avoid some of the experimental temperature variations of the ambient lockers, the number of samples which can be accommodated in these temperature controlled units is limited. In the present work, improved models of thermal prediction and control were sought. Temperatures are predicted by thermal analysis software using empirical temperatures recorded during STS-57. These temperatures are compared to data recorded throughout the mission using Ambient Temperature Recorders (ATRs) located within several payload lockers. Additional test cases are undertaken using controlled ground experiments to more precisely determine the reliability of the thermal model. The approach presented should increase the utility of various spaceflight carriers in the support of biological and material science research and ground control studies done in preparation for flight.

The advisability of prototypic testing for space nuclear systems

NASA Astrophysics Data System (ADS)

Lenard, Roger X.

2005-07-01

From October 1987 until 1993, the US Department of Defense conducted the Space Nuclear Thermal Propulsion program. This program's objective was to design and develop a high specific impulse, high thrust-to-weight nuclear thermal rocket engine for upper stage applications. The author was the program manager for this program until 1992. Numerous analytical, programmatic and experimental results were generated during this period of time. This paper reviews the accomplishments of the program and highlights the importance of prototypic testing for all aspects of a space nuclear program so that a reliable and safe system compliant with all regulatory requirements can be effectively engineered. Specifically, the paper will recount how many non-prototypic tests we performed only to have more representative tests consistently generate different results. This was particularly true in area of direct nuclear heat generation. As nuclear tests are generally much more expensive than non-nuclear tests, programs attempt to avoid such tests in favor of less expensive non-nuclear tests. Each time this approach was followed, the SNTP program found these tests to not be verified by nuclear heated testing. Hence the author recommends that wherever possible, a spiral development approach that includes exploratory and confirmatory experimental testing be employed to ensure a viable design.

Developments in Test Facility and Data Networking for the Altitude Test Stand at the John C. Stennis Space Center: A General Overview

NASA Technical Reports Server (NTRS)

Hebert, Phillip W.

2008-01-01

NASA/SSC's Mission in Rocket Propulsion Testing Is to Acquire Test Performance Data for Verification, Validation and Qualification of Propulsion Systems Hardware: Accurate, Reliable, Comprehensive, and Timely. Data Acquisition in a Rocket Propulsion Test Environment Is Challenging: a) Severe Temporal Transient Dynamic Environments; b) Large Thermal Gradients; c) Vacuum to high pressure regimes. A-3 Test Stand Development is equally challenging with respect to accommodating vacuum environment, operation of a CSG system, and a large quantity of data system and control channels to determine proper engine performance as well as Test Stand operation. SSC is currently in the process of providing modernized DAS, Control Systems, Video, and network systems for the A-3 Test Stand to overcome these challenges.

Body of Knowledge (BOK) for Leadless Quad Flat No-Lead/bottom Termination Components (QFN/BTC) Package Trends and Reliability

NASA Technical Reports Server (NTRS)

Ghaffarian, Reza

2014-01-01

Bottom terminated components and quad flat no-lead (BTC/QFN) packages have been extensively used by commercial industry for more than a decade. Cost and performance advantages and the closeness of the packages to the boards make them especially unique for radio frequency (RF) applications. A number of high-reliability parts are now available in this style of package configuration. This report presents a summary of literature surveyed and provides a body of knowledge (BOK) gathered on the status of BTC/QFN and their advanced versions of multi-row QFN (MRQFN) packaging technologies. The report provides a comprehensive review of packaging trends and specifications on design, assembly, and reliability. Emphasis is placed on assembly reliability and associated key design and process parameters because they show lower life than standard leaded package assembly under thermal cycling exposures. Inspection of hidden solder joints for assuring quality is challenging and is similar to ball grid arrays (BGAs). Understanding the key BTC/QFN technology trends, applications, processing parameters, workmanship defects, and reliability behavior is important when judicially selecting and narrowing the follow-on packages for evaluation and testing, as well as for the low risk insertion in high-reliability applications.

Body of Knowledge (BOK) for Leadless Quad Flat No-Lead/Bottom Termination Components (QFN/BTC) Package Trends and Reliability

NASA Technical Reports Server (NTRS)

Ghaffarian, Reza

2014-01-01

Bottom terminated components and quad flat no-lead (BTC/QFN) packages have been extensively used by commercial industry for more than a decade. Cost and performance advantages and the closeness of the packages to the boards make them especially unique for radio frequency (RF) applications. A number of high-reliability parts are now available in this style of package configuration. This report presents a summary of literature surveyed and provides a body of knowledge (BOK) gathered on the status of BTC/QFN and their advanced versions of multi-row QFN (MRQFN) packaging technologies. The report provides a comprehensive review of packaging trends and specifications on design, assembly, and reliability. Emphasis is placed on assembly reliability and associated key design and process parameters because they show lower life than standard leaded package assembly under thermal cycling exposures. Inspection of hidden solder joints for assuring quality is challenging and is similar to ball grid arrays (BGAs). Understanding the key BTC/QFN technology trends, applications, processing parameters, workmanship defects, and reliability behavior is important when judicially selecting and narrowing the follow-on packages for evaluation and testing, as well as for the low risk insertion in high-reliability applications.

Thermal and Environmental Barrier Coatings for Advanced Propulsion Engine Systems

NASA Technical Reports Server (NTRS)

Zhu, Dong-Ming; Miller, Robert A.

2004-01-01

Ceramic thermal and environmental barrier coatings (TEBCs) are used in gas turbine engines to protect engine hot-section components in the harsh combustion environments, and extend component lifetimes. For future high performance engines, the development of advanced ceramic barrier coating systems will allow these coatings to be used to simultaneously increase engine operating temperature and reduce cooling requirements, thereby leading to significant improvements in engine power density and efficiency. In order to meet future engine performance and reliability requirements, the coating systems must be designed with increased high temperature stability, lower thermal conductivity, and improved thermal stress and erosion resistance. In this paper, ceramic coating design and testing considerations will be described for high temperature and high-heat-flux engine applications in hot corrosion and oxidation, erosion, and combustion water vapor environments. Further coating performance and life improvements will be expected by utilizing advanced coating architecture design, composition optimization, and improved processing techniques, in conjunction with modeling and design tools.

Effects of Thermal Cycling on Control and Irradiated EPC 2nd Generation GaN FETs

NASA Technical Reports Server (NTRS)

Patterson, Richard L.; Scheick, Leif; Lauenstein, Jean-Marie; Casey, Megan; Hammoud, Ahmad

2013-01-01

The power systems for use in NASA space missions must work reliably under harsh conditions including radiation, thermal cycling, and exposure to extreme temperatures. Gallium nitride semiconductors show great promise, but information pertaining to their performance is scarce. Gallium nitride N-channel enhancement-mode field effect transistors made by EPC Corporation in a 2nd generation of manufacturing were exposed to radiation followed by long-term thermal cycling in order to address their reliability for use in space missions. Results of the experimental work are presented and discussed.

Viscosity and thermal conductivity coefficients of gaseous and liquid oxygen

NASA Technical Reports Server (NTRS)

Hanley, H. J. M.; Mccarty, R. D.; Sengers, J. V.

1974-01-01

Equations and tables are presented for the viscosity and thermal conductivity coefficients of gaseous and liquid oxygen at temperatures between 80 K and 400 K for pressures up to 200 atm. and at temperatures between 80 K and 2000 K for the dilute gas. A description of the anomalous behavior of the thermal conductivity in the critical region is included. The tabulated coefficients are reliable to within about 15% except for a region in the immediate vicinity of the critical point. Some possibilities for future improvements of this reliability are discussed.

Cryogenic Insulation Standard Data and Methodologies Project

NASA Technical Reports Server (NTRS)

Summerfield, Burton; Thompson, Karen; Zeitlin, Nancy; Mullenix, Pamela; Fesmire, James; Swanger, Adam

2015-01-01

Extending some recent developments in the area of technical consensus standards for cryogenic thermal insulation systems, a preliminary Inter-Laboratory Study of foam insulation materials was performed by NASA Kennedy Space Center and LeTourneau University. The initial focus was ambient pressure cryogenic boil off testing using the Cryostat-400 flat-plate instrument. Completion of a test facility at LETU has enabled direct, comparative testing, using identical cryostat instruments and methods, and the production of standard thermal data sets for a number of materials under sub-ambient conditions. The two sets of measurements were analyzed and indicate there is reasonable agreement between the two laboratories. Based on cryogenic boiloff calorimetry, new equipment and methods for testing thermal insulation systems have been successfully developed. These boiloff instruments (or cryostats) include both flat plate and cylindrical models and are applicable to a wide range of different materials under a wide range of test conditions. Test measurements are generally made at large temperature difference (boundary temperatures of 293 K and 78 K are typical) and include the full vacuum pressure range. Results are generally reported in effective thermal conductivity (ke) and mean heat flux (q) through the insulation system. The new cryostat instruments provide an effective and reliable way to characterize the thermal performance of materials under subambient conditions. Proven in through thousands of tests of hundreds of material systems, they have supported a wide range of aerospace, industry, and research projects. Boiloff testing technology is not just for cryogenic testing but is a cost effective, field-representative methodology to test any material or system for applications at sub-ambient temperatures. This technology, when adequately coupled with a technical standards basis, can provide a cost-effective, field-representative methodology to test any material or system for applications at sub-ambient to cryogenic temperatures. A growing need for energy efficiency and cryogenic applications is creating a worldwide demand for improved thermal insulation systems for low temperatures. The need for thermal characterization of these systems and materials raises a corresponding need for insulation test standards and thermal data targeted for cryogenic-vacuum applications. Such standards have a strong correlation to energy, transportation, and environment and the advancement of new materials technologies in these areas. In conjunction with this project, two new standards on cryogenic insulation were recently published by ASTM International: C1774 and C740. Following the requirements of NPR 7120.10, Technical Standards for NASA Programs and Projects, the appropriate information in this report can be provided to the NASA Chief Engineer as input for NASA's annual report to NIST, as required by OMB Circular No. A-119, describing NASA's use of voluntary consensus standards and participation in the development of voluntary consensus standards and bodies.

Optimization of a bolometer detector for ITER based on Pt absorber on SiN membrane.

PubMed

Meister, H; Eich, T; Endstrasser, N; Giannone, L; Kannamüller, M; Kling, A; Koll, J; Trautmann, T; Detemple, P; Schmitt, S

2010-10-01

Any plasma diagnostic in ITER must be able to operate at temperatures in excess of 200 °C and neutron loads corresponding to 0.1 dpa over its lifetime. To achieve this aim for the bolometer diagnostic, a miniaturized metal resistor bolometer detector based on Pt absorbers galvanically deposited on SiN membranes is being developed. The first two generations of detectors featured up to 4.5 μm thick absorbers. Results from laboratory tests are presented characterizing the dependence of their calibration constants under thermal loads up to 450 °C. Several detectors have been tested in ASDEX Upgrade providing reliable data but also pointing out the need for further optimization. A laser trimming procedure has been implemented to reduce the mismatch in meander resistances below 1% for one detector and the thermal drifts from this mismatch.

Optimization of a bolometer detector for ITER based on Pt absorber on SiN membranea)

NASA Astrophysics Data System (ADS)

Meister, H.; Eich, T.; Endstrasser, N.; Giannone, L.; Kannamüller, M.; Kling, A.; Koll, J.; Trautmann, T.; ASDEX Upgrade Team; Detemple, P.; Schmitt, S.

2010-10-01

Any plasma diagnostic in ITER must be able to operate at temperatures in excess of 200 °C and neutron loads corresponding to 0.1 dpa over its lifetime. To achieve this aim for the bolometer diagnostic, a miniaturized metal resistor bolometer detector based on Pt absorbers galvanically deposited on SiN membranes is being developed. The first two generations of detectors featured up to 4.5 μm thick absorbers. Results from laboratory tests are presented characterizing the dependence of their calibration constants under thermal loads up to 450 °C. Several detectors have been tested in ASDEX Upgrade providing reliable data but also pointing out the need for further optimization. A laser trimming procedure has been implemented to reduce the mismatch in meander resistances below 1% for one detector and the thermal drifts from this mismatch.

Transient Reliability Analysis Capability Developed for CARES/Life

NASA Technical Reports Server (NTRS)

Nemeth, Noel N.

2001-01-01

The CARES/Life software developed at the NASA Glenn Research Center provides a general-purpose design tool that predicts the probability of the failure of a ceramic component as a function of its time in service. This award-winning software has been widely used by U.S. industry to establish the reliability and life of a brittle material (e.g., ceramic, intermetallic, and graphite) structures in a wide variety of 21st century applications.Present capabilities of the NASA CARES/Life code include probabilistic life prediction of ceramic components subjected to fast fracture, slow crack growth (stress corrosion), and cyclic fatigue failure modes. Currently, this code can compute the time-dependent reliability of ceramic structures subjected to simple time-dependent loading. For example, in slow crack growth failure conditions CARES/Life can handle sustained and linearly increasing time-dependent loads, whereas in cyclic fatigue applications various types of repetitive constant-amplitude loads can be accounted for. However, in real applications applied loads are rarely that simple but vary with time in more complex ways such as engine startup, shutdown, and dynamic and vibrational loads. In addition, when a given component is subjected to transient environmental and or thermal conditions, the material properties also vary with time. A methodology has now been developed to allow the CARES/Life computer code to perform reliability analysis of ceramic components undergoing transient thermal and mechanical loading. This means that CARES/Life will be able to analyze finite element models of ceramic components that simulate dynamic engine operating conditions. The methodology developed is generalized to account for material property variation (on strength distribution and fatigue) as a function of temperature. This allows CARES/Life to analyze components undergoing rapid temperature change in other words, components undergoing thermal shock. In addition, the capability has been developed to perform reliability analysis for components that undergo proof testing involving transient loads. This methodology was developed for environmentally assisted crack growth (crack growth as a function of time and loading), but it will be extended to account for cyclic fatigue (crack growth as a function of load cycles) as well.

Numerical-experimental analysis of a carbon-phenolic composite via plasma jet ablation test

NASA Astrophysics Data System (ADS)

Guilherme Silva Pesci, Pedro; Araújo Machado, Humberto; Silva, Homero de Paula e.; Cley Paterniani Rita, Cristian; Petraconi Filho, Gilberto; Cocchieri Botelho, Edson

2018-06-01

Materials used in space vehicles components are subjected to thermally aggressive environments when exposed to atmospheric reentry. In order to protect the payload and the vehicle itself, ablative composites are employed as TPS (Thermal Protection System). The development of TPS materials generally go through phases of obtaining, atmospheric reentry tests and comparison with a mathematical model. The state of the art presents some reentry tests in a subsonic or supersonic arc-jet facility, and a complex type of mathematical model, which normally requires large computational cost. This work presents a reliable method for estimate the performance of ablative composites, combining empirical and experimental data. Tests of composite materials used in thermal protection systems through exposure to a plasma jet are performed, where the heat fluxes emulate those present in atmospheric reentry of space vehicles components. The carbon/phenolic material samples have been performed in the hypersonic plasma tunnel of Plasma and Process Laboratory, available in Aeronautics Institute of Technology (ITA), by a plasma torch with a 50 kW DC power source. The plasma tunnel parameters were optimized to reproduce the conditions close to the critical re-entry point of the space vehicles payloads developed by the Aeronautics and Space Institute (IAE). The specimens in study were developed and manufactured in Brazil. Mass loss and specific mass loss rates of the samples and the back surface temperatures, as a function of the exposure time to the thermal flow, were determined. A computational simulation based in a two-front ablation model was performed, in order to compare the tests and the simulation results. The results allowed to estimate the ablative behavior of the tested material and to validate the theoretical model used in the computational simulation for its use in geometries close to the thermal protection systems used in the Brazilian space and suborbital vehicles.

Stress and reliability analyses of multilayered composite cylinder under thermal and mechanical loads

NASA Astrophysics Data System (ADS)

Wang, Xiaohua

The coupling resulting from the mutual influence of material thermal and mechanical parameters is examined in the thermal stress analysis of a multilayered isotropic composite cylinder subjected to sudden axisymmetric external and internal temperature. The method of complex frequency response functions together with the Fourier transform technique is utilized. Because the coupling parameters for some composite materials, such as carbon-carbon, are very small, the effect of coupling is neglected in the orthotropic thermal stress analysis. The stress distributions in multilayered orthotropic cylinders subjected to sudden axisymmetric temperature loading combined with dynamic pressure as well as asymmetric temperature loading are also obtained. The method of Fourier series together with the Laplace transform is utilized in solving the heat conduction equation and thermal stress analysis. For brittle materials, like carbon-carbon composites, the strength variability is represented by two or three parameter Weibull distributions. The 'weakest link' principle which takes into account both the carbon-carbon composite cylinders. The complex frequency response analysis is performed on a multilayered orthotropic cylinder under asymmetrical thermal load. Both deterministic and random thermal stress and reliability analyses can be based on the results of this frequency response analysis. The stress and displacement distributions and reliability of rocket motors under static or dynamic line loads are analyzed by an elasticity approach. Rocket motors are modeled as long hollow multilayered cylinders with an air core, a thick isotropic propellant inner layer and a thin orthotropic kevlar-epoxy case. The case is treated as a single orthotropic layer or a ten layered orthotropic structure. Five material properties and the load are treated as random variable with normal distributions when the reliability of the rocket motor is analyzed by the first-order, second-moment method (FOSM).

Successful Completion of the JWST OGSE2 Cryogenic Test at JSC Chamber-A While Managing Numerous Challenges

NASA Technical Reports Server (NTRS)

Park, Sang C.; Brinckerhoff, Pamela; Franck, Randy; Schweickart, Rusty; Thomson, Shaun; Burt, Bill; Ousley, Wes

2016-01-01

The James Webb Space Telescope (JWST) Optical Telescope Element (OTE) assembly is the largest optically stable infrared-optimized telescope currently being manufactured and assembled, and scheduled for launch in 2018. The JWST OTE, including the primary mirrors, secondary mirror, and the Aft Optics Subsystems (AOS) are designed to be passively cooled and operate at near 45 degrees Kelvin. Due to the size of its large sunshield in relation to existing test facilities, JWST cannot be optically or thermally tested as a complete observatory-level system at flight temperatures. As a result, the telescope portion along with its instrument complement will be tested as a single unit very late in the program, and on the program schedule critical path. To mitigate schedule risks, a set of 'pathfinder' cryogenic tests will be performed to reduce program risks by demonstrating the optical testing capabilities of the facility, characterizing telescope thermal performance, and allowing project personnel to learn valuable testing lessons off-line. This paper describes the 'pathfinder' cryogenic test program, focusing on the recently completed second test in the series called the Optical Ground Support Equipment 2 (OGSE2) test. The JWST OGSE2 was successfully completed within the allocated project schedule while faced with numerous conflicting thermal requirements during cool-down to the final cryogenic operational temperatures, and during warm-up after the cryo-stable optical tests. The challenges include developing a pre-test cool-down and warm-up profiles without a reliable method to predict the thermal behaviors in a rarified helium environment, and managing the test article hardware safety driven by the project Limits and Constraints (L&C's). Furthermore, OGSE2 test included the time critical Aft Optics Subsystem (AOS), a part of the flight Optical Telescope Element that would need to be placed back in the overall telescope assembly integrations. The OGSE2 test requirements included the strict adherence of the project contamination controls due to the presence of the contamination sensitive flight optical elements. The test operations required close coordination of numerous personnel while they being exposed and trained for the 'final' combined OTE and instrument cryo-test in 2017. This paper will also encompass the OGSE2 thermal data look-back review.

Environmental testing to prevent on-orbit TDRS failures

NASA Technical Reports Server (NTRS)

Cutler, Robert M.

1994-01-01

Can improved environmental testing prevent on-orbit component failures such as those experienced in the Tracking and Data Relay Satellite (TDRS) constellation? TDRS communications have been available to user spacecraft continuously for over 11 years, during which the five TDRS's placed in orbit have demonstrated their redundancies and robustness by surviving 26 component failures. Nevertheless, additional environmental testing prior to launch could prevent the occurrence of some types of failures, and could help to maintain communication services. Specific testing challenges involve traveling wave tube assemblies (TWTA's) whose lives may decrease with on-off cycling, and heaters that are subject to thermal cycles. The development of test conditions and procedures should account for known thermal variations. Testing may also have the potential to prevent failures in which components such as diplexers have had their lives dramatically shortened because of particle migration in a weightless environment. Reliability modeling could be used to select additional components that could benefit from special testing, but experience shows that this approach has serious limitations. Through knowledge of on-orbit experience, and with advances in testing, communication satellite programs might avoid the occurrence of some types of failures, and extend future spacecraft longevity beyond the current TDRS design life of ten years. However, determining which components to test, and how must testing to do, remain problematical.

Application of SAW method for multiple-criteria comparative analysis of the reliability of heat supply organizations

NASA Astrophysics Data System (ADS)

Akhmetova, I. G.; Chichirova, N. D.

2016-12-01

Heat supply is the most energy-consuming sector of the economy. Approximately 30% of all used primary fuel-and-energy resources is spent on municipal heat-supply needs. One of the key indicators of activity of heat-supply organizations is the reliability of an energy facility. The reliability index of a heat supply organization is of interest to potential investors for assessing risks when investing in projects. The reliability indices established by the federal legislation are actually reduced to a single numerical factor, which depends on the number of heat-supply outages in connection with disturbances in operation of heat networks and the volume of their resource recovery in the calculation year. This factor is rather subjective and may change in a wide range during several years. A technique is proposed for evaluating the reliability of heat-supply organizations with the use of the simple additive weighting (SAW) method. The technique for integrated-index determination satisfies the following conditions: the reliability level of the evaluated heat-supply system is represented maximum fully and objectively; the information used for the reliability-index evaluation is easily available (is located on the Internet in accordance with demands of data-disclosure standards). For reliability estimation of heat-supply organizations, the following indicators were selected: the wear of equipment of thermal energy sources, the wear of heat networks, the number of outages of supply of thermal energy (heat carrier due to technological disturbances on heat networks per 1 km of heat networks), the number of outages of supply of thermal energy (heat carrier due to technologic disturbances on thermal energy sources per 1 Gcal/h of installed power), the share of expenditures in the cost of thermal energy aimed at recovery of the resource (renewal of fixed assets), coefficient of renewal of fixed assets, and a coefficient of fixed asset retirement. A versatile program is developed and the analysis of heat-supply organizations is performed by the example of the Republic of Tatarstan. The assessment system is based on construction of comparative ratings of heat-supply organizations. A rating is the assessment of reliability of the organization, is characterized by a numerical value, and makes it possible to compare organizations engaged in the same kind of activity between each other.

Thermal cycling reliability of Cu/SnAg double-bump flip chip assemblies for 100 μm pitch applications

NASA Astrophysics Data System (ADS)

Son, Ho-Young; Kim, Ilho; Lee, Soon-Bok; Jung, Gi-Jo; Park, Byung-Jin; Paik, Kyung-Wook

2009-01-01

A thick Cu column based double-bump flip chip structure is one of the promising alternatives for fine pitch flip chip applications. In this study, the thermal cycling (T/C) reliability of Cu/SnAg double-bump flip chip assemblies was investigated, and the failure mechanism was analyzed through the correlation of T/C test and the finite element analysis (FEA) results. After 1000 thermal cycles, T/C failures occurred at some Cu/SnAg bumps located at the edge and corner of chips. Scanning acoustic microscope analysis and scanning electron microscope observations indicated that the failure site was the Cu column/Si chip interface. It was identified by a FEA where the maximum stress concentration was located during T/C. During T/C, the Al pad between the Si chip and a Cu column bump was displaced due to thermomechanical stress. Based on the low cycle fatigue model, the accumulation of equivalent plastic strain resulted in thermal fatigue deformation of the Cu column bumps and ultimately reduced the thermal cycling lifetime. The maximum equivalent plastic strains of some bumps at the chip edge increased with an increased number of thermal cycles. However, equivalent plastic strains of the inner bumps did not increase regardless of the number of thermal cycles. In addition, the z-directional normal plastic strain ɛ22 was determined to be compressive and was a dominant component causing the plastic deformation of Cu/SnAg double bumps. As the number of thermal cycles increased, normal plastic strains in the perpendicular direction to the Si chip and shear strains were accumulated on the Cu column bumps at the chip edge at low temperature region. Thus it was found that the Al pad at the Si chip/Cu column interface underwent thermal fatigue deformation by compressive normal strain and the contact loss by displacement failure of the Al pad, the main T/C failure mode of the Cu/SnAg flip chip assembly, then occurred at the Si chip/Cu column interface shear strain deformation during T/C.

Interconnect fatigue design for terrestrial photovoltaic modules

NASA Technical Reports Server (NTRS)

Mon, G. R.; Moore, D. M.; Ross, R. G., Jr.

1982-01-01

The results of comprehensive investigation of interconnect fatigue that has led to the definition of useful reliability-design and life-prediction algorithms are presented. Experimental data indicate that the classical strain-cycle (fatigue) curve for the interconnect material is a good model of mean interconnect fatigue performance, but it fails to account for the broad statistical scatter, which is critical to reliability prediction. To fill this shortcoming the classical fatigue curve is combined with experimental cumulative interconnect failure rate data to yield statistical fatigue curves (having failure probability as a parameter) which enable (1) the prediction of cumulative interconnect failures during the design life of an array field, and (2) the unambiguous--ie., quantitative--interpretation of data from field-service qualification (accelerated thermal cycling) tests. Optimal interconnect cost-reliability design algorithms are derived based on minimizing the cost of energy over the design life of the array field.

Interconnect fatigue design for terrestrial photovoltaic modules

NASA Astrophysics Data System (ADS)

Mon, G. R.; Moore, D. M.; Ross, R. G., Jr.

1982-03-01

The results of comprehensive investigation of interconnect fatigue that has led to the definition of useful reliability-design and life-prediction algorithms are presented. Experimental data indicate that the classical strain-cycle (fatigue) curve for the interconnect material is a good model of mean interconnect fatigue performance, but it fails to account for the broad statistical scatter, which is critical to reliability prediction. To fill this shortcoming the classical fatigue curve is combined with experimental cumulative interconnect failure rate data to yield statistical fatigue curves (having failure probability as a parameter) which enable (1) the prediction of cumulative interconnect failures during the design life of an array field, and (2) the unambiguous--ie., quantitative--interpretation of data from field-service qualification (accelerated thermal cycling) tests. Optimal interconnect cost-reliability design algorithms are derived based on minimizing the cost of energy over the design life of the array field.

Laser Shearography Inspection of TPS (Thermal Protection System) Cork on RSRM (Reusable Solid Rocket Motors)

NASA Technical Reports Server (NTRS)

Lingbloom, Mike; Plaia, Jim; Newman, John

2006-01-01

Laser Shearography is a viable inspection method for detection of de-bonds and voids within the external TPS (thermal protection system) on to the Space Shuttle RSRM (reusable solid rocket motors). Cork samples with thicknesses up to 1 inch were tested at the LTI (Laser Technology Incorporated) laboratory using vacuum-applied stress in a vacuum chamber. The testing proved that the technology could detect cork to steel un-bonds using vacuum stress techniques in the laboratory environment. The next logical step was to inspect the TPS on a RSRM. Although detailed post flight inspection has confirmed that ATK Thiokol's cork bonding technique provides a reliable cork to case bond, due to the Space Shuttle Columbia incident there is a great interest in verifying bond-lines on the external TPS. This interest provided and opportunity to inspect a RSRM motor with Laser Shearography. This paper will describe the laboratory testing and RSRM testing that has been performed to date. Descriptions of the test equipment setup and techniques for data collection and detailed results will be given. The data from the test show that Laser Shearography is an effective technology and readily adaptable to inspect a RSRM.

Thermal Protection Materials

NASA Technical Reports Server (NTRS)

Johnson, Sylvia M.

2011-01-01

Thermal protection materials and systems (TPS) are required to protect a vehicle returning from space or entering an atmosphere. The selection of the material depends on the heat flux, heat load, pressure, and shear and other mechanical loads imposed on the material, which are in turn determined by the vehicle configuration and size, location on the vehicle, speed, a trajectory, and the atmosphere. In all cases the goal is to use a material that is both reliable and efficient for the application. Reliable materials are well understood and have sufficient test data under the appropriate conditions to provide confidence in their performance. Efficiency relates to the behavior of a material under the specific conditions that it encounters TPS that performs very well at high heat fluxes may not be efficient at lower heat fluxes. Mass of the TPS is a critical element of efficiency. This talk will review the major classes of TPS, reusable or insulating materials and ablators. Ultra high temperature ceramics for sharp leading edges will also be reviewed. The talk will focus on the properties and behavior of these materials.

Test-retest reliability of evoked heat stimulation BOLD fMRI.

PubMed

Upadhyay, Jaymin; Lemme, Jordan; Anderson, Julie; Bleakman, David; Large, Thomas; Evelhoch, Jeffrey L; Hargreaves, Richard; Borsook, David; Becerra, Lino

2015-09-30

To date, the blood oxygenated-level dependent (BOLD) functional magnetic resonance imaging (fMRI) technique has enabled an objective and deeper understanding of pain processing mechanisms embedded within the human central nervous system (CNS). In order to further comprehend the benefits and limitations of BOLD fMRI in the context of pain as well as the corresponding subjective pain ratings, we evaluated the univariate response, test-retest reliability and confidence intervals (CIs) at the 95% level of both data types collected during evoked stimulation of 40°C (non-noxious), 44°C (mildly noxious) and a subject-specific temperature eliciting a 7/10 pain rating. The test-retest reliability between two scanning sessions was determined by calculating group-level interclass correlation coefficients (ICCs) and at the single-subject level. Across the three stimuli, we initially observed a graded response of increasing magnitude for both VAS (visual analog score) pain ratings and fMRI data. Test-retest reliability was observed to be highest for VAS pain ratings obtained during the 7/10 pain stimulation (ICC=0.938), while ICC values of pain fMRI data for a distribution of CNS structures ranged from 0.5 to 0.859 (p<0.05). Importantly, the upper and lower confidence interval CI bounds reported herein could be utilized in subsequent trials involving healthy volunteers to hypothesize the magnitude of effect required to overcome inherent variability of either VAS pain ratings or BOLD responses evoked during innocuous or noxious thermal stimulation. Copyright © 2015 Elsevier B.V. All rights reserved.

Photovoltaic module bypass diode encapsulation

NASA Technical Reports Server (NTRS)

Shepard, N. J., Jr.

1983-01-01

The design and processing techniques necessary to incorporate bypass diodes within the module encapsulant are presented. The Semicon PN junction diode cells were selected. Diode junction to heat spreader thermal resistance measurements, performed on a variety of mounted diode chip types and sizes, have yielded values which are consistently below 1 deg C per watt, but show some instability when thermally cycled over the temperature range from -40 to 150 deg C. Three representative experimental modules, each incorporating integral bypass diode/heat spreader assemblies of various sizes, were designed. Thermal testing of these modules enabled the formulation of a recommended heat spreader plate sizing relationship. The production cost of three encapsulated bypass diode/heat spreader assemblies were compared with similarly rated externally mounted packaged diodes. It is concluded that, when proper designed and installed, these bypass diode devices will improve the overall reliability of a terrestrial array over a 20 year design lifetime.

Purity of Gaussian states: Measurement schemes and time evolution in noisy channels

DOE Office of Scientific and Technical Information (OSTI.GOV)

Paris, Matteo G.A.; Illuminati, Fabrizio; Serafini, Alessio

2003-07-01

We present a systematic study of the purity for Gaussian states of single-mode continuous variable systems. We prove the connection of purity to observable quantities for these states, and show that the joint measurement of two conjugate quadratures is necessary and sufficient to determine the purity at any time. The statistical reliability and the range of applicability of the proposed measurement scheme are tested by means of Monte Carlo simulated experiments. We then consider the dynamics of purity in noisy channels. We derive an evolution equation for the purity of general Gaussian states both in thermal and in squeezed thermalmore » baths. We show that purity is maximized at any given time for an initial coherent state evolving in a thermal bath, or for an initial squeezed state evolving in a squeezed thermal bath whose asymptotic squeezing is orthogonal to that of the input state.« less

Operational Experience from Solar Thermal Energy Projects

NASA Technical Reports Server (NTRS)

Cameron, C. P.

1984-01-01

Over the past few years, Sandia National Laboratories were involved in the design, construction, and operation of a number of DOE-sponsored solar thermal energy systems. Among the systems currently in operation are several industrial process heat projects and the Modular Industrial Solar Retrofit qualification test systems, all of which use parabolic troughs, and the Shenandoah Total Energy Project, which uses parabolic dishes. Operational experience has provided insight to both desirable and undesirable features of the designs of these systems. Features of these systems which are also relevant to the design of parabolic concentrator thermal electric systems are discussed. Other design features discussed are system control functions which were found to be especially convenient or effective, such as local concentrator controls, rainwash controls, and system response to changing isolation. Drive systems are also discussed with particular emphasis of the need for reliability and the usefulness of a manual drive capability.

Comprehensive interpretation of thermal dileptons measured at the CERN super proton synchrotron.

PubMed

van Hees, Hendrik; Rapp, Ralf

2006-09-08

Employing thermal dilepton rates based on a medium-modified electromagnetic correlation function we show that recent dimuon spectra of the NA60 Collaboration in central In-In collisions at the CERN-SPS can be understood in terms of radiation from a hot and dense hadronic medium. Earlier calculated in-medium rho-meson spectral functions provide an accurate description of the data up to dimuon invariant masses of about M approximately or equal to 0.9 GeV, with good sensitivity to the predicted rho-meson line shape, identifying baryon-induced modifications as the prevalent ones. A reliable evaluation of the contribution enables the study of further medium effects: at masses M>0.9 GeV, 4-pion type annihilation accounts for the experimentally observed excess (possibly augmented by effects of "chiral mixing"), while predictions for thermal emission from in-medium omega and phi mesons may be tested in the future.

Microstructure and Thermal Reliability of Microcapsules Containing Phase Change Material with Self-Assembled Graphene/Organic Nano-Hybrid Shells.

PubMed

Wang, Xianfeng; Guo, Yandong; Su, Junfeng; Zhang, Xiaolong; Han, Ningxu; Wang, Xinyu

2018-05-24

In recent decades, microcapsules containing phase change materials (microPCMs) have been the center of much attention in the field of latent thermal energy storage. The aim of this work was to prepare and investigate the microstructure and thermal conductivity of microPCMs containing self-assembled graphene/organic hybrid shells. Paraffin was used as a phase change material, which was successfully microencapsulated by graphene and polymer forming hybrid composite shells. The physicochemical characters of microPCM samples were investigated including mean size, shell thickness, and chemical structure. Scanning electron microscope (SEM) results showed that the microPCMs were spherical particles and graphene enhanced the degree of smoothness of the shell surface. The existence of graphene in the shells was proved by using the methods of X-ray photoelectron spectroscopy (XPS), transmission electron microscopy (TEM), and atomic force microscopy (AFM). It was found that graphene hybrid shells were constructed by forces of electric charge absorption and long-molecular entanglement. MicroPCMs with graphene had a higher degradation temperature of 300 °C. Graphene greatly enhanced the thermal stability of microPCMs. The thermal conductivity tests indicated that the phase change temperature of microPCMs was regulated by the graphene additive because of enhancement of the thermal barrier of the hybrid shells. Differential scanning calorimetry (DSC) tests proved that the latent thermal energy capability of microPCMs had been improved with a higher heat conduction rate. In addition, infrared thermograph observations implied that the microPCMs had a sensitivity response to heat during the phase change cycling process because of the excellent thermal conductivity of graphene.

Mechanism of electromigration failure in Damascene processed copper interconnects

NASA Astrophysics Data System (ADS)

Michael, Nancy Lyn

2002-11-01

A major unresolved issue in Cu interconnect reliability is the interface role in the failure mechanism of real structures. The present study investigates failure in single-level damascene Cu interconnects with variations in interface condition, passivation and barrier, and linewidth. In the first phase, accelerated electromigration testing of 0.25mum Cu interconnects capped with SiN or SiCN, shows that lifetime and failure mode vary with capping layer. The first mode, seen primarily in SiN samples, is characterized by gradual resistance increase and extensive interface damage, believed to result from failure led by interface electromigration. The competing failure mode, found in SiCN capped samples, is characterized by abrupt resistance increase and localized voiding. The second phase fixes SiCN as the capping material and varies barrier material and line width. The three barrier materials, Ta, TaN, and Ta/TaN, produce similar lifetime statistics and failure is abrupt. Line width, however, does have a strong influence on failure time. The line width/grain size ratio ranged from 0.53 to 2.2 but does not correlate with mean time to failure (MTF). The strong dependence on interface fraction, combined with the conclusion from phase one that interface electromigration is not rate controlling, suggests another mechanism related to the interface is a controlling factor. The possibility that contamination and defects at the interface are key to this failure mode was investigated using electro-thermal fatigue (ETF). In ETF, where lines are simultaneously subjected to thermal cycling and constant current, damage caused by thermal stress is accelerated. Tests reveal that in 80 nm lines, transient failure occurs at times far below MTF in electromigration tests at higher temperatures. Failure found in ETF is clearly a result of damage growth due to thermal/mechanical stress rather than electromigration. At the stress levels created by the moderate ETF test conditions, the only place voids are likely to nucleate and grow is at pre-existing defects and impurities. In narrower lines, where smaller voids can cause catastrophic damage, defects have a greater effect on MTF. Results from this investigation suggest that impurities and defects in the Cu and at the interface, must be carefully controlled to make reliable narrow Cu interconnects.

Robust Platinum Resistor Thermometer (PRT) Sensors and Reliable Bonding for Space Missions

NASA Technical Reports Server (NTRS)

Cucullu, Gordy C., III; Mikhaylov, Rebecca; Rajeshuni, Ramesham; Petkov, Mihail; Hills, David; Uribe, Jose; Okuno, James; De Los Santos, Greg

2013-01-01

Platinum resistance thermometers (PRTs) provide accurate temperature measurements over a wide temperature range and are used extensively on space missions due to their simplicity and linearity. A standard on spacecraft, PRTs are used to provide precision temperature control and vehicle health assessment. This paper reviews the extensive reliability testing of platinum resistor thermometer sensors (PRTs) and bonding methods used on the Mars Science Laboratory (MSL) mission and for the upcoming Soil Moisture Active Passive (SMAP) mission. During the Mars Exploration Rover (MER) mission, several key, JPL-packaged PRTs failed on those rovers prior to and within 1-Sol of landing due to thermally induced stresses. Similar failures can be traced back to other JPL missions dating back thirty years. As a result, MSL sought out a PRT more forgiving to the packaging configurations used at JPL, and extensively tested the Honeywell HRTS-5760-B-U-0-12 sensor to successfully demonstrate suitable robustness to thermal cycling. Specifically, this PRT was cycled 2,000 times, simulating three Martian winters and summers. The PRTs were bonded to six substrate materials (Aluminum 7050, treated Magnesium AZ231-B, Stainless Steel 304, Albemet, Titanium 6AL4V, and G-10), using four different aerospace adhesives--two epoxies and two silicones--that conformed to MSL's low out-gassing requirements. An additional epoxy was tested in a shorter environmental cycling test, when the need for a different temperature range adhesive was necessary for mobility and actuator hardware late in the fabrication process. All of this testing, along with electrostatic discharge (ESD) and destructive part analyses, demonstrate that this PRT is highly robust, and not subject to the failure of PRTs on previous missions. While there were two PRTs that failed during fabrication, to date there have been no in-flight PRT failures on MSL, including those on the Curiosity rover. Since MSL, the sensor has gone through a change in construction such that the manufacturer significantly restricts the minimum temperature. However, significant subsequent testing was performed with this new version of the part to show that it indeed is still robust to at least Mars minimum temperatures of -135(sup o)C. The additional completed testing will be described. This work has resulted in a successful sensor package qualification and a reliable bonding method suitable for use over large temperature extremes.

Robust Platinum Resistor Thermometer (PRT) Sensors and Reliable Bonding for Space Missions

NASA Technical Reports Server (NTRS)

Cucullu, Gordy C. III; Mikhaylov, Rebecca; Ramesham, Rajeshuni; Petkov, Mihail; Hills, David; Uribe, Jose; Okuno, James; De Los Santos, Greg

2013-01-01

Platinum resistance thermometers (PRTs) provide accurate temperature measurements over a wide temperature range and are used extensively on space missions due to their simplicity and linearity. A standard on spacecraft, PRTs are used to provide precision temperature control and vehicle health assessment. This paper reviews the extensive reliability testing of platinum resistor thermometer sensors (PRTs) and bonding methods used on the Mars Science Laboratory (MSL) mission and for the upcoming Soil Moisture Active Passive (SMAP) mission. During the Mars Exploration Rover (MER) mission, several key, JPL-packaged PRTs failed on those rovers prior to and within 1-Sol of landing due to thermally induced stresses. Similar failures can be traced back to other JPL missions dating back thirty years. As a result, MSL sought out a PRT more forgiving to the packaging configurations used at JPL, and extensively tested the Honeywell HRTS-5760-B-U-0-12 sensor to successfully demonstrate suitable robustness to thermal cycling. Specifically, this PRT was cycled 2,000 times, simulating three Martian winters and summers. The PRTs were bonded to six substrate materials (Aluminum 7050, treated Magnesium AZ231-B, Stainless Steel 304, Albemet, Titanium 6AL4V, and G-10), using four different aerospace adhesives--two epoxies and two silicones--that conformed to MSL's low out-gassing requirements. An additional epoxy was tested in a shorter environmental cycling test, when the need for a different temperature range adhesive was necessary for mobility and actuator hardware late in the fabrication process. All of this testing, along with electrostatic discharge (ESD) and destructive part analyses, demonstrate that this PRT is highly robust, and not subject to the failure of PRTs on previous missions. While there were two PRTs that failed during fabrication, to date there have been no in-flight PRT failures on MSL, including those on the Curiosity rover. Since MSL, the sensor has gone through a change in construction such that the manufacturer significantly restricts the minimum temperature. However, significant subsequent testing was performed with this new version of the part to show that it indeed is still robust to at least Mars minimum temperatures of -135 degrees Centigrade. The additional completed testing will be described. This work has resulted in a successful sensor package qualification and a reliable bonding method suitable for use over large temperature extremes

Ultracompliant Heterogeneous Copper-Tin Nanowire Arrays Making a Supersolder.

PubMed

Gong, Wei; Li, Pengfei; Zhang, Yunheng; Feng, Xuhui; Major, Joshua; DeVoto, Douglas; Paret, Paul; King, Charles; Narumanchi, Sreekant; Shen, Sheng

2018-06-13

Due to the substantial increase in power density, thermal interface resistance that can constitute more than 50% of the total thermal resistance has generally become a bottleneck for thermal management in electronics. However, conventional thermal interface materials (TIMs) such as solder, epoxy, gel, and grease cannot fulfill the requirements of electronics for high-power and long-term operation. Here, we demonstrate a high-performance TIM consisting of a heterogeneous copper-tin nanowire array, which we term "supersolder" to emulate the role of conventional solders in bonding various surfaces. The supersolder is ultracompliant with a shear modulus 2-3 orders of magnitude lower than traditional solders and can reduce the thermal resistance by two times as compared with the state-of-the-art TIMs. This supersolder also exhibits excellent long-term reliability with >1200 thermal cycles over a wide temperature range. By resolving this critical thermal bottleneck, the supersolder enables electronic systems, ranging from microelectronics and portable electronics to massive data centers, to operate at lower temperatures with higher power density and reliability.

Analysis of simplified heat transfer models for thermal property determination of nano-film by TDTR method

NASA Astrophysics Data System (ADS)

Wang, Xinwei; Chen, Zhe; Sun, Fangyuan; Zhang, Hang; Jiang, Yuyan; Tang, Dawei

2018-03-01

Heat transfer in nanostructures is of critical importance for a wide range of applications such as functional materials and thermal management of electronics. Time-domain thermoreflectance (TDTR) has been proved to be a reliable measurement technique for the thermal property determinations of nanoscale structures. However, it is difficult to determine more than three thermal properties at the same time. Heat transfer model simplifications can reduce the fitting variables and provide an alternative way for thermal property determination. In this paper, two simplified models are investigated and analyzed by the transform matrix method and simulations. TDTR measurements are performed on Al-SiO2-Si samples with different SiO2 thickness. Both theoretical and experimental results show that the simplified tri-layer model (STM) is reliable and suitable for thin film samples with a wide range of thickness. Furthermore, the STM can also extract the intrinsic thermal conductivity and interfacial thermal resistance from serial samples with different thickness.

A Thermal Melt Probe System for Extensive, Low-Cost Instrument Deployment Within and Beneath Ice Sheets

NASA Astrophysics Data System (ADS)

Winebrenner, D. P.; Elam, W. T.; Carpenter, M.; Kintner, P., III

2014-12-01

More numerous observations within and beneath ice sheets are needed to address a broad variety of important questions concerning ice sheets and climate. However, emplacement of instruments continues to be constrained by logistical burdens, especially in cold ice a kilometer or more thick. Electrically powered thermal melt probes are inherently logistically light and efficient, especially for reaching greater depths in colder ice. They therefore offer a means of addressing current measurement problems, but have been limited historically by a lack of technology for reliable operation at the necessary voltages and powers. Here we report field tests in Greenland of two new melt probes. We operated one probe at 2.2 kilowatts (kW) and 1050 volts (V), achieving a depth of 400 m in the ice in ~ 120 hours, without electrical failure. That depth is the second greatest achieved thus far with a thermal melt probe, exceeded only by one deployment to 1005 m in Greenland in 1968, which ended in an electrical failure. Our test run took place in two intervals separated by a year, with the probe frozen at 65 m depth during the interim, after which we re-established communication, unfroze the probe, and proceeded to the greater depth. During the second field test we operated a higher-power probe, initially at 2.5 kW and 1500 V and progressing to 4.5 kW and 2000 V. Initial data indicate that this probe achieved a descent rate of 8 m/hr, which if correct would be the fastest rate yet achieved for such probes. Moreover, we observed maintenance of vertical probe travel using pendulum steering throughout both tests, as well as autonomous descent without operator-intervention after launch. The latter suggests potential for crews of 1-2 to operate several melt probes concurrently. However, the higher power probe did suffer electrical failure of a heating element after 7 hours of operation at 2000 V (24 hours after the start of the test), contrary to expectations based on laboratory component and system testing. We are therefore revising the probe heaters using a newer but more development-intensive technology. With probe systems now validated in our tests, this will result in a reliable means to emplace instruments for studies of subglacial hydrology, ice dynamics, and possible subglacial ecologies.

Design of the thermal insulating test system for doors and windows of buildings

NASA Astrophysics Data System (ADS)

Yu, Yan; Qi, Jinqing; Xu, Yunwei; Wu, Hao; Ou, Jinping

2011-04-01

Thermal insulating properties of doors and widows are important parameter to measure the quality of windows and doors. This paper develops the thermal insulating test system of doors and windows for large temperature difference in winter in north of China according to national standards. This system is integrated with temperature measurement subsystem, temperature control subsystem, the heating power measurement subsystem, and heat transfer coefficient calculated subsystem. The temperature measurement subsystem includes temperature sensor which is implemented by sixty-four thermocouple sensors to measure the key positions of cold room and hot room, and the temperature acquisition unit which adopts Agilent 34901A data acquisition card to achieve self-compensation and accurate temperature capture. The temperature control subsystem including temperature controller and compressor system is used to control the temperature between 0 degree to 20 degree for hot room and -20 degree to 0 degree for cold room. The hot room controller uses fuzzy control algorithm to achieve accurate control of temperature and the cold room controller firstly uses compressor to achieve coarse control and then uses more accurate temperature controller unit to obtain constant temperature(-20 degree). The heating power measurement is mainly to get the heat power of hot room heating devices. After above constant temperature environment is constructed, software of the test system is developed. Using software, temperature data and heat power data can be accurately got and then the heat transfer coefficient, representing the thermal insulating properties of doors and widows, is calculated using the standard formula. Experimental results show that the test system is simple, reliable and precise. It meets the testing requirements of national standard and has a good application prospect.

Computational fluid dynamic (CFD) investigation of thermal uniformity in a thermal cycling based calibration chamber for MEMS

NASA Astrophysics Data System (ADS)

Gui, Xulong; Luo, Xiaobing; Wang, Xiaoping; Liu, Sheng

2015-12-01

Micro-electrical-mechanical system (MEMS) has become important for many industries such as automotive, home appliance, portable electronics, especially with the emergence of Internet of Things. Volume testing with temperature compensation has been essential in order to provide MEMS based sensors with repeatability, consistency, reliability, and durability, but low cost. Particularly, in the temperature calibration test, temperature uniformity of thermal cycling based calibration chamber becomes more important for obtaining precision sensors, as each sensor is different before the calibration. When sensor samples are loaded into the chamber, we usually open the door of the chamber, then place fixtures into chamber and mount the samples on the fixtures. These operations may affect temperature uniformity in the chamber. In order to study the influencing factors of sample-loading on the temperature uniformity in the chamber during calibration testing, numerical simulation work was conducted first. Temperature field and flow field were simulated in empty chamber, chamber with open door, chamber with samples, and chamber with fixtures, respectively. By simulation, it was found that opening chamber door, sample size and number of fixture layers all have effects on flow field and temperature field. By experimental validation, it was found that the measured temperature value was consistent with the simulated temperature value.

Method to Increase Performance of Foil Bearings Through Passive Thermal Management

NASA Technical Reports Server (NTRS)

Bruckner, Robert

2013-01-01

This invention is a new approach to designing foil bearings to increase their load capacity and improve their reliability through passive thermal management. In the present case, the bearing is designed in such a way as to prevent the carryover of lubricant from the exit of one sector to the inlet of the ensuing sector of the foil bearing. When such passive thermal management techniques are used, bearing load capacity is improved by multiples, and reliability is enhanced when compared to current foil bearings. This concept has recently been tested and validated, and shows that load capacity performance of foil bearings can be improved by a factor of two at relatively low speeds with potentially greater relative improvements at higher speeds. Such improvements in performance with respect to speed are typical of foil bearings. Additionally, operation of these newly conceived bearings shows much more reliability and repeatable performance. This trait can be exploited in machine design to enhance safety, reliability, and overall performance. Finally, lower frictional torque has been demonstrated when operating at lower (non-load capacity) loads, thus providing another improvement above the current state of the art. The objective of the invention is to incorporate features into a foil bearing that both enhance passive thermal management and temperature control, while at the same time improve the hydrodynamic (load capacity) performance of the foil bearing. Foil bearings are unique antifriction devices that can utilize the working fluid of a machine as a lubricant (typically air for turbines and motors, liquids for pumps), and as a coolant to remove excess energy due to frictional heating. The current state of the art of foil bearings utilizes forced cooling of the bearing and shaft, which represents poor efficiency and poor reliability. This invention embodies features that utilize the bearing geometry in such a manner as to both support load and provide an inherent and passive cooling mechanism. This cooling mechanism functions in such a way as to prevent used (higher temperature) lubricant from being carried over from the exit of one sector into the entry of the next sector of the foil bearing. The disclosed innovation is an improved foil bearing design that reduces or eliminates the need for force cooling of the bearing, while at the same time improving the load capacity of the bearing by at least a factor of two. These improvements are due to the elimination of lubricant carryover from the trailing edge of one sector into the leading edge of the next, and the mixing of used lubricant with the surrounding ambient fluid.

Performance demonstration of hydrogen advanced loop heat pipe for 20-30K cryocooling of far infrared sensors

NASA Astrophysics Data System (ADS)

Hoang, Triem T.; O'Connell, Tamara A.; Ku, Jentung; Butler, C. D.; Swanson, Theodore D.

2005-08-01

The James Webb Space Telescope (JWST) program have identified the need for cryogenic cooling transport devices that (i) provide robust/reliable thermal management for Infrared (IR) sensors/detectors in the temperature range of 20-30K, (ii) minimize vibration effects of mechanical cryocoolers on the instruments, (iii) reduce spatial temperature gradients in cryogenic components, and (iv) afford long continuous service life of the telescope. Passive two-phase capillary cooling technologies such as heat pipes, Loop Heat Pipes (LHPs), and Capillary pumped Loops (CPLs) have proven themselves capable of performing necessary thermal control functions for room temperature applications. They have no mechanical moving part to wear out or to introduce unwanted vibration to the instruments and, hence, are reliable and maintenancefree. However, utilizing these capillary devices for cryogenic cooling still remains a challenge because of difficulties involving the system start-up and operation in a warm environment. An advanced concept of LHP using Hydrogen as the working fluid was recently developed to demonstrate the cryocooling transport capabilities in the temperature range of 20-30K. A full-size demonstration test loop - appropriately called H2-ALHP_2 - was constructed and performance tested extensively in a thermal vacuum chamber. It was designed specifically to manage "heat parasitics" from a warm surrounding, enabling it to start up from an initially supercritical state and operate without requiring a rigid heat shield. Like room temperature LHPs, the H2-ALHP transport lines were made of small-diameter stainless steel tubing that are flexible enough to isolate the cryocooler-induced vibration from the IR instruments. In addition, focus of the H2-ALHP research and development effort was also placed on the system weight saving for space-based applications.

Application Specific Electronic Module Program (ASEM), Final Technical Report.

DTIC Science & Technology

1994-12-14

relatively high temperatures , may induce a metal break or other continuity problems. Secondly, the improved electrical environment at the module level vs...wafer probe can permit higher speed tests to be applied, isolating marginal die. Thirdly, high reliability screens, such as temperature cycling, bum-in...The high temperature aging is done at 150’ C for 500 hours. The thermal cycle treatments are from 0- 100 0 C and 3 cycles per hour are done. The

Evaluation of commercially-available spacecraft-type heat pipes

NASA Technical Reports Server (NTRS)

Kaufman, W. B.; Tower, L. K.

1978-01-01

As part of an effort to develop reliable, cost effective spacecraft thermal control heat pipes, life tests on 30 commercially available heat pipes in 10 groups of different design and material combinations were conducted. Results for seven groups were reported herein. Materials are aluminum and stainless steel, and working fluids are methanol and ammonia. The formation of noncondensible gas was observed for times exceeding 11,000 hours. The heat transport capacities of the pipes were also determined.

Flexible Chip Scale Package and Interconnect for Implantable MEMS Movable Microelectrodes for the Brain

PubMed Central

Jackson, Nathan; Muthuswamy, Jit

2009-01-01

We report here a novel approach called MEMS microflex interconnect (MMFI) technology for packaging a new generation of Bio-MEMS devices that involve movable microelectrodes implanted in brain tissue. MMFI addresses the need for (i) operating space for movable parts and (ii) flexible interconnects for mechanical isolation. We fabricated a thin polyimide substrate with embedded bond-pads, vias, and conducting traces for the interconnect with a backside dry etch, so that the flexible substrate can act as a thin-film cap for the MEMS package. A double gold stud bump rivet bonding mechanism was used to form electrical connections to the chip and also to provide a spacing of approximately 15–20 µm for the movable parts. The MMFI approach achieved a chip scale package (CSP) that is lightweight, biocompatible, having flexible interconnects, without an underfill. Reliability tests demonstrated minimal increases of 0.35 mΩ, 0.23 mΩ and 0.15 mΩ in mean contact resistances under high humidity, thermal cycling, and thermal shock conditions respectively. High temperature tests resulted in an increase in resistance of > 90 mΩ when aluminum bond pads were used, but an increase of ~ 4.2 mΩ with gold bond pads. The mean-time-to-failure (MTTF) was estimated to be at least one year under physiological conditions. We conclude that MMFI technology is a feasible and reliable approach for packaging and interconnecting Bio-MEMS devices. PMID:20160981

Multiphase Flow Technology Impacts on Thermal Control Systems for Exploration

NASA Technical Reports Server (NTRS)

McQuillen, John; Sankovic, John; Lekan, Jack

2006-01-01

The Two-Phase Flow Facility (TPHIFFy) Project focused on bridging the critical knowledge gap by developing and demonstrating critical multiphase fluid products for advanced life support, thermal management and power conversion systems that are required to enable the Vision for Space Exploration. Safety and reliability of future systems will be enhanced by addressing critical microgravity fluid physics issues associated with flow boiling, condensation, phase separation, and system stability. The project included concept development, normal gravity testing, and reduced gravity aircraft flight campaigns, in preparation for the development of a space flight experiment implementation. Data will be utilized to develop predictive models that could be used for system design and operation. A single fluid, two-phase closed thermodynamic loop test bed was designed, assembled and tested. The major components in this test bed include: a boiler, a condenser, a phase separator and a circulating pump. The test loop was instrumented with flow meters, thermocouples, pressure transducers and both high speed and normal speed video cameras. A low boiling point surrogate fluid, FC-72, was selected based on scaling analyses using preliminary designs for operational systems. Preliminary results are presented which include flow regime transitions and some observations regarding system stability.

Solar Thermal Upper Stage Cryogen System Engineering Checkout Test

NASA Technical Reports Server (NTRS)

Olsen, A. D; Cady, E. C.; Jenkins, D. S.

1999-01-01

The Solar Thermal Upper Stage technology (STUSTD) program is a solar thermal propulsion technology program cooperatively sponsored by a Boeing led team and by NASA MSFC. A key element of its technology program is development of a liquid hydrogen (LH2) storage and supply system which employs multi-layer insulation, liquid acquisition devices, active and passive thermodynamic vent systems, and variable 40W tank heaters to reliably provide near constant pressure H2 to a solar thermal engine in the low-gravity of space operation. The LH2 storage and supply system is designed to operate as a passive, pressure fed supply system at a constant pressure of about 45 psia. During operation of the solar thermal engine over a small portion of the orbit the LH2 storage and supply system propulsively vents through the enjoy at a controlled flowrate. During the long coast portion of the orbit, the LH2 tank is locked up (unvented). Thus, all of the vented H2 flow is used in the engine for thrust and none is wastefully vented overboard. The key to managing the tank pressure and therefore the H2 flow to the engine is to manage and balance the energy flow into the LH2 tank with the MLI and tank heaters with the energy flow out of the LH2 tank through the vented H2 flow. A moderate scale (71 cu ft) LH2 storage and supply system was installed and insulated at the NASA MSFC Test Area 300. The operation of the system is described in this paper. The test program for the LH2 system consisted of two parts: 1) a series of engineering tests to characterize the performance of the various components in the system: and 2) a 30-day simulation of a complete LEO and GEO transfer mission. This paper describes the results of the engineering tests, and correlates these results with analytical models used to design future advanced Solar Orbit Transfer Vehicles.

Effect of structure and morphology on thermal and electrical properties of polycarbonate film capacitors

NASA Astrophysics Data System (ADS)

Yen, S. P. S.; Lewis, C. R.

Research is reported to identify polycarbonate (PC) film characteristics and fabrication procedures which extend the reliable performance range of PC capacitors to 125 C without derating, and establish quality control techniques and transfer technology to US PC film manufacturers. The approach chosen to solve these problems was to develop techniques for fabricating biaxially oriented (BX) 2 microns or thinner PC film with a low dissipation factor up to 140 C; isotropic dimensional stability; high crystallinity; and high voltage breakdown strength. The PC film structure and morphology was then correlated to thermal and electrical capacitor behavior. Analytical techniques were developed to monitor film quality during capacitor fabrication, and as a result, excellent performance was demonstrated during initial capacitor testing.

Experimental study of refrigeration performance based on linear Fresnel solar thermal photovoltaic system

NASA Astrophysics Data System (ADS)

Song, Jinghui; Yuan, Hui; Xia, Yunfeng; Kan, Weimin; Deng, Xiaowen; Liu, Shi; Liang, Wanlong; Deng, Jianhua

2018-03-01

This paper introduces the working principle and system constitution of the linear Fresnel solar lithium bromide absorption refrigeration cycle, and elaborates several typical structures of absorption refrigeration cycle, including single-effect, two-stage cycle and double-effect lithium bromide absorption refrigeration cycle A 1.n effect absorption chiller system based on the best parameters was introduced and applied to a linear Fresnel solar absorption chiller system. Through the field refrigerator performance test, the results show: Based on this heat cycle design and processing 1.n lithium bromide absorption refrigeration power up to 35.2KW, It can meet the theoretical expectations and has good flexibility and reliability, provides guidance for the use of solar thermal energy.

Modular thrust subsystem approaches to solar electric propulsion module design

NASA Technical Reports Server (NTRS)

Cake, J. E.; Sharp, G. R.; Oglebay, J. C.; Shaker, F. J.; Zavesky, R. J.

1976-01-01

Three approaches are presented for packaging the elements of a 30 cm ion thruster subsystem into a modular thrust subsystem. The individual modules, when integrated into a conceptual solar electric propulsion module are applicable to a multimission set of interplanetary flights with the space shuttle interim upper stage as the launch vehicle. The emphasis is on the structural and thermal integration of the components into the modular thrust subsystems. Thermal control for the power processing units is either by direct radiation through louvers in combination with heat pipes or an all heat pipe system. The propellant storage and feed system and thruster gimbal system concepts are presented. The three approaches are compared on the basis of mass, cost, testing, interfaces, simplicity, reliability, and maintainability.

Modular thrust subsystem approaches to solar electric propulsion module design

NASA Technical Reports Server (NTRS)

Cake, J. E.; Sharp, G. R.; Oglebay, J. C.; Shaker, F. J.; Zevesky, R. J.

1976-01-01

Three approaches are presented for packaging the elements of a 30 cm ion thrustor subsystem into a modular thrust subsystem. The individual modules, when integrated into a conceptual solar electric propulsion module are applicable to a multimission set of interplanetary flights with the Space Shuttle/Interim Upper Stage as the launch vehicle. The emphasis is on the structural and thermal integration of the components into the modular thrust subsystems. Thermal control for the power processing units is either by direct radiation through louvers in combination with heat pipes of an all heat pipe system. The propellant storage and feed system and thrustor gimbal system concepts are presented. The three approaches are compared on the basis of mass, cost, testing, interfaces, simplicity, reliability, and maintainability.

Magnetic field dependence of spin torque switching in nanoscale magnetic tunnel junctions

NASA Astrophysics Data System (ADS)

Yang, Liu; Rowlands, Graham; Katine, Jordan; Langer, Juergen; Krivorotov, Ilya

2012-02-01

Magnetic random access memory based on spin transfer torque effect in nanoscale magnetic tunnel junctions (STT-RAM) is emerging as a promising candidate for embedded and stand-alone computer memory. An important performance parameter of STT-RAM is stability of its free magnetic layer against thermal fluctuations. Measurements of the free layer switching probability as a function of sub-critical voltage at zero effective magnetic field (read disturb rate or RDR measurements) have been proposed as a method for quantitative evaluation of the free layer thermal stability at zero voltage. In this presentation, we report RDR measurement as a function of external magnetic field, which provide a test of the RDR method self-consistency and reliability.

Thermal and Electrical Effects of Partial Shade in Monolithic Thin-Film Photovoltaic Modules: Preprint

DOE Office of Scientific and Technical Information (OSTI.GOV)

Silverman, Timothy J.; Deceglie, Michael G.; Sun, Xingshu

2015-09-02

Photovoltaic cells can be damaged by reverse bias stress, which arises during service when a monolithically integrated thin-film module is partially shaded. We introduce a model for describing a module's internal thermal and electrical state, which cannot normally be measured. Using this model and experimental measurements, we present several results with relevance for reliability testing and module engineering: Modules with a small breakdown voltage experience less stress than those with a large breakdown voltage, with some exceptions for modules having light-enhanced reverse breakdown. Masks leaving a small part of the masked cells illuminated can lead to very high temperature andmore » current density compared to masks covering entire cells.« less

Thermal and Electrical Effects of Partial Shade in Monolithic Thin-Film Photovoltaic Modules

DOE Office of Scientific and Technical Information (OSTI.GOV)

Silverman, Timothy J.; Deceglie, Michael G.; Sun, Xingshu

2015-06-14

Photovoltaic cells can be damaged by reverse bias stress, which arises during service when a monolithically integrated thin-film module is partially shaded. We introduce a model for describing a module's internal thermal and electrical state, which cannot normally be measured. Using this model and experimental measurements, we present several results with relevance for reliability testing and module engineering: Modules with a small breakdown voltage experience less stress than those with a large breakdown voltage, with some exceptions for modules having light-enhanced reverse breakdown. Masks leaving a small part of the masked cells illuminated can lead to very high temperature andmore » current density compared to masks covering entire cells.« less

A feasible thermal-cycle screening system for cryogenic semiconductor components

NASA Astrophysics Data System (ADS)

Wu, Ligang; Liu, Dafu; Huang, Yimin; Zhu, Sangen; Gong, Haimei

2005-01-01

For the limit of its lifetime, the Stirling cooler is operated on the intermittent mode in satellite in some cases. Thus such cryogenic semiconductor components as HgCdTe mid or long wavelength infrared (IR) detectors are subjected to thousands of repeated thermal cycles from below -173°C to room temperature. Therefore, a series of experiments focused on quality, performance and reliability are essential in order to satisfy the reasonable requirements. Accordingly, a feasible thermal cycle screening system is put forward. And a vast experimental data show that thermal cycle tests play the most effective role in the environment stress screen (ESS). In this paper, we introduce the system to help to study the main failure mechanisms and improve the performance of the semiconductor components. Such main failure mechanisms as solder-ball invalidation encountered commonly in the detector modules, which is due to the large thermal expansion coefficient mismatch among different materials. The thermal cycle system is based on the principle of heat exchange. We expect HgCdTe IR detectors be cooled to lower than -173°C and heated to room temperature in a few minutes. Above all, we simulate the heating and cooling system through finite element method (FEM). As a result, the computations reveal that the IR detectors can be heated and cooled at a higher rate than expected. A consequent design of the entire system is founded on the simulation. At last, we adjust the mechanical structure of heat exchange system to the adaptive state to accomplish the ESS. The thermal cycle screening system includes an autocontrol part and a test part. The autocontrol part is adopted to realize the heat exchange between IR detectors and the environment, and the test one to inspect the temperature and electrical parameters of these detectors. And at least four IR detector samples can be screened at one time.

A heat-pulse flowmeter for measuring minimal discharge rates in boreholes

USGS Publications Warehouse

Hess, A.E.

1982-01-01

The U.S. Geological Survey has tested a borehole-configured heat-pulse flowmeter which has good low-velocity flow-measuring sensitivity. The flowmeter was tested in the laboratory in 51-, 102-, and 152-millimeter-diameter columns using water velocities ranging from 0.35 to 250 millimeters per second. The heat-pulse flowmeter also was tested in a 15-meter-deep granite test pit with controlled water flow, and in a 58-meter-deep borehole in sedimentary materials. The flowmeter's capability to detect and measure naturally occurring, low-velocity, thermally induced convection currents in boreholes was demonstrated. Further improvements to the heat-pulse-flowmeter system are needed to increase its reliability and improve its response through four-conductor logging cable.

Next-generation avionics packaging and cooling 'test results from a prototype system'

NASA Astrophysics Data System (ADS)

Seals, J. D.

The author reports on the design, material characteristics, and test results obtained under the US Air Force's advanced aircraft avionics packaging technologies (AAAPT) program, whose charter is to investigate new designs and technologies for reliable packaging, interconnection, and thermal management. Under this program, AT&T Bell Laboratories has completed the preliminary testing of and is evaluating a number of promising materials and technologies, including conformal encapsulation, liquid flow-through cooling, and a cyanate ester backplane. A fifty-two module system incorporating these and and other technologies has undergone preliminary cooling efficiency, shock, sine and random vibration, and maintenance testing. One of the primary objectives was to evaluate the interaction compatibility of new materials and designs with other components in the system.

Research Staff | Advanced Manufacturing Research | NREL

Science.gov Websites

SYSTEMS CENTER Kevin Bennion leads NREL's Thermal Sciences and Systems research task focused on thermal vehicle thermal management and vehicle systems analysis. He came to NREL from Ford Motor Company, where he focused on thermal management and reliability for power electronics and electric machines for several

Integrated Method for Personal Thermal Comfort Assessment and Optimization through Users' Feedback, IoT and Machine Learning: A Case Study †.

PubMed

Salamone, Francesco; Belussi, Lorenzo; Currò, Cristian; Danza, Ludovico; Ghellere, Matteo; Guazzi, Giulia; Lenzi, Bruno; Megale, Valentino; Meroni, Italo

2018-05-17

Thermal comfort has become a topic issue in building performance assessment as well as energy efficiency. Three methods are mainly recognized for its assessment. Two of them based on standardized methodologies, face the problem by considering the indoor environment in steady-state conditions (PMV and PPD) and users as active subjects whose thermal perception is influenced by outdoor climatic conditions (adaptive approach). The latter method is the starting point to investigate thermal comfort from an overall perspective by considering endogenous variables besides the traditional physical and environmental ones. Following this perspective, the paper describes the results of an in-field investigation of thermal conditions through the use of nearable and wearable solutions, parametric models and machine learning techniques. The aim of the research is the exploration of the reliability of IoT-based solutions combined with advanced algorithms, in order to create a replicable framework for the assessment and improvement of user thermal satisfaction. For this purpose, an experimental test in real offices was carried out involving eight workers. Parametric models are applied for the assessment of thermal comfort; IoT solutions are used to monitor the environmental variables and the users' parameters; the machine learning CART method allows to predict the users' profile and the thermal comfort perception respect to the indoor environment.

Integrated Method for Personal Thermal Comfort Assessment and Optimization through Users’ Feedback, IoT and Machine Learning: A Case Study †

PubMed Central

Currò, Cristian; Danza, Ludovico; Ghellere, Matteo; Guazzi, Giulia; Lenzi, Bruno; Megale, Valentino; Meroni, Italo

2018-01-01

Thermal comfort has become a topic issue in building performance assessment as well as energy efficiency. Three methods are mainly recognized for its assessment. Two of them based on standardized methodologies, face the problem by considering the indoor environment in steady-state conditions (PMV and PPD) and users as active subjects whose thermal perception is influenced by outdoor climatic conditions (adaptive approach). The latter method is the starting point to investigate thermal comfort from an overall perspective by considering endogenous variables besides the traditional physical and environmental ones. Following this perspective, the paper describes the results of an in-field investigation of thermal conditions through the use of nearable and wearable solutions, parametric models and machine learning techniques. The aim of the research is the exploration of the reliability of IoT-based solutions combined with advanced algorithms, in order to create a replicable framework for the assessment and improvement of user thermal satisfaction. For this purpose, an experimental test in real offices was carried out involving eight workers. Parametric models are applied for the assessment of thermal comfort; IoT solutions are used to monitor the environmental variables and the users’ parameters; the machine learning CART method allows to predict the users’ profile and the thermal comfort perception respect to the indoor environment. PMID:29772818

Thermal performance of a multi-evaporator loop heat pipe with thermal masses and thermal electrical coolers

NASA Technical Reports Server (NTRS)

Ku, Jentung; Ottenstein, Laura; Birur, Gajanana

2004-01-01

This paper describes thermal performance of a loop heat pipe (LHP) with two evaporators and two condensers in ambient testing. Each evaporator has an outer diameter of 15mm and a length of 76mm, and has an integral compensation chamber (CC). An aluminum mass of 500 grams is attached to each evaporator to simulate the instrument mass. A thermal electric cooler (TEC) is installed on each CC to provide heating as well as cooling for CC temperature control. A flow regulator is installed in the condenser section to prevent vapor from going back to the evaporators in the event that one of condenser is fully utilized. Ammonia was used ad the working fluid. Tests conducted included start-up, power cycle, heat load sharing, sink temperature cycle, operating temperature control with TECs, and capillary limit tests. Experimental data showed that the loop could start with a heat load of less than 1OW even with added thermal masses. The loop operated stably with even and uneven evaporator heat loads, and even and uneven condenser sink temperatures. The operating temperature could be controlled within +/-0.5K of the set point temperature using either or both TECs, and the required TEC control heater power was less than 2W under most test conditions. Heat load sharing between the two evaporators was also successfully demonstrated. The loop had a heat transport capability of 120W to 140W, and could recover from a dry-out when the heat load was reduced. The 500-gram aluminum mass on each evaporator had a negligible effect on the loop operation. Existing LHPs servicing the orbiting spacecraft have a single evaporator with an outer diameter of about 25mm. Important performance characteristics demonstrated by this LHP included: 1) Operation of an LHP with 15mm diameter evaporators; 2) Robustness and reliability of an LHP with multiple evaporators and multiple condensers under various test conditions; 3) Heat load sharing among LHP evaporators; 4) Effectiveness of TECs in controlling the LHP operating temperature; and 5) Effectiveness of the flow regulator in preventing vapor from going back the evaporators.

Ceramic technology for advanced heat engines project. Semiannual progress report, October 1985-March 1986

DOE Office of Scientific and Technical Information (OSTI.GOV)

Not Available

1986-08-01

Significant accomplishments in fabricating cermaic components for the Department of Energy (DOE), National Aeronautics and Space Administration (NASA), and Department of Defense (DOD) advanced heat engine programs have provided evidence that the operation of ceramic parts in high-temperature engine environments is feasible. However, additional research is needed in materials and processing development, design methodology, and data base and life prediction. An assessment of needs was completed, and a five-year project plan was developed with extensive input from private industry. The objective of the project is to develop the industrial technology base required for reliable ceramics for application in advanced automotivemore » heat engines. The project approach includes determining the mechanisms controlling reliability, improving processes for fabricating existing ceramics, developing new materials with increased reliability, and testing these materials in simulated engine environments to confirm reliability. although this is a generic materials project, the focus is on structural ceramics for advanced gas turbine and diesel engines, ceramic bearings and attachments, and ceramic coatings for thermal barrier and wear applications in these engines.« less

Degradation Physics of High Power LEDs in Outdoor Environment and the Role of Phosphor in the degradation process.

PubMed

Singh, Preetpal; Tan, Cher Ming

2016-04-07

A moisture- electrical - temperature (MET) test is proposed to evaluate the outdoor reliability of high power blue LEDs, with and without phosphor, and to understand the degradation physics of LEDs under the environment of combined humidity, temperature and electrical stresses. The blue LEDs with phosphor will be the high power white LEDs. Scanning acoustic microscopy is used to examine the resulted delamination during this test for the LEDs. The degradation mechanisms of blue LEDs (LEDs without phosphor) and white LEDs (LEDs with phosphor) are found to be different, under both the power on (i.e. with 350 mA through each LED) and power off (i.e. without current supply) conditions. Difference in the coefficient of thermal expansion between the molding part and the lens material as well as the heat generated by the phosphor layer are found to account for the major differences in the degradation mechanisms observed. The findings indicate that the proposed MET test is necessary for the LED industry in evaluating the reliability of LEDs under practical outdoor usage environment.

Thermal management and prototype testing of Compton scattering X-ray beam position monitor for the Advanced Photon Source Upgrade

NASA Astrophysics Data System (ADS)

Lee, S. H.; Yang, B. X.; Collins, J. T.; Ramanathan, M.

2017-02-01

Accurate and stable x-ray beam position monitors (XBPMs) are key elements in obtaining the desired user beam stability in the Advanced Photon Source Upgrade. In the next-generation XBPMs for the canted-undulator front ends, where two undulator beams are separated by 1.0 mrad, the lower beam power (<10 kW) per undulator allows us to explore lower-cost solutions based on Compton scattering from a diamond placed edge-on to the x-ray beam. Because of the high peak power density of the x-ray beams, this diamond experiences high temperatures and has to be clamped to a water-cooled heat spreader using thermal interface materials (TIMs), which play a key role in reducing the temperature of the diamond. To evaluate temperature changes through the interface via thermal simulations, the thermal contact resistance (TCR) of TIMs at an interface between two solid materials under even contact pressure must be known. This paper addresses the TCR measurements of several TIMs, including gold, silver, pyrolytic graphite sheet, and 3D graphene foam. In addition, a prototype of a Compton-scattering XBPM with diamond blades was installed at APS Beamline 24-ID-A in May 2015 and has been tested. This paper presents the design of the Compton-scattering XBPM, and compares thermal simulation results obtained for the diamond blade of this XBPM by the finite element method with in situ empirical measurements obtained by using reliable infrared technology.

Thermal management and prototype testing of Compton scattering X-ray beam position monitor for the Advanced Photon Source Upgrade.

PubMed

Lee, S H; Yang, B X; Collins, J T; Ramanathan, M

2017-02-01

Accurate and stable x-ray beam position monitors (XBPMs) are key elements in obtaining the desired user beam stability in the Advanced Photon Source Upgrade. In the next-generation XBPMs for the canted-undulator front ends, where two undulator beams are separated by 1.0 mrad, the lower beam power (<10 kW) per undulator allows us to explore lower-cost solutions based on Compton scattering from a diamond placed edge-on to the x-ray beam. Because of the high peak power density of the x-ray beams, this diamond experiences high temperatures and has to be clamped to a water-cooled heat spreader using thermal interface materials (TIMs), which play a key role in reducing the temperature of the diamond. To evaluate temperature changes through the interface via thermal simulations, the thermal contact resistance (TCR) of TIMs at an interface between two solid materials under even contact pressure must be known. This paper addresses the TCR measurements of several TIMs, including gold, silver, pyrolytic graphite sheet, and 3D graphene foam. In addition, a prototype of a Compton-scattering XBPM with diamond blades was installed at APS Beamline 24-ID-A in May 2015 and has been tested. This paper presents the design of the Compton-scattering XBPM, and compares thermal simulation results obtained for the diamond blade of this XBPM by the finite element method with in situ empirical measurements obtained by using reliable infrared technology.

Design, fabrication, and implementation of thermally driven outdoor testing devices for building joint sealants.

PubMed

White, C C; Tan, K T; O'Brien, E P; Hunston, D L; Chin, J W; Williams, R S

2011-02-01

The paper describes the development, implementation, and testing of two thermally driven outdoor exposure instruments. These devices are unique in their ability to impose field generated thermally induced strain on sealant specimens while monitoring their resulting load and displacement. The instruments combine a fixed wood and steel supporting frame with a moving polyvinyl chloride frame, and employ differences in the coefficients of thermal expansion between the supporting frame and moving frame to induce strain on the sealant specimens. Two different kinds of instruments have been fabricated, "winter/tension" and "winter/compression" designs. In the winter/tension design, the thermally induced dimensional change is directly transferred to the specimens; while in the winter/compression design, the samples are loaded in an opposite direction with the dimensional change. Both designs are instrumented to monitor load and displacement and are built so that the strain on the specimen does not exceed ±25% over the range of temperatures expected in Gaithersburg, MD. Additionally, a weather station is colocated with the device to record environmental conditions in 1 min intervals. This combination of weather information with mechanical property data enables a direct link between environmental conditions and the corresponding sealant response. The reliability and effectiveness of these instruments are demonstrated with a typical sealant material. The results show that the instruments work according to the design criteria and provide a meaningful quantitative platform to monitor the mechanical response of sealant exposed to outdoor weathering.

Computational logic with square rings of nanomagnets

NASA Astrophysics Data System (ADS)

Arava, Hanu; Derlet, Peter M.; Vijayakumar, Jaianth; Cui, Jizhai; Bingham, Nicholas S.; Kleibert, Armin; Heyderman, Laura J.

2018-06-01

Nanomagnets are a promising low-power alternative to traditional computing. However, the successful implementation of nanomagnets in logic gates has been hindered so far by a lack of reliability. Here, we present a novel design with dipolar-coupled nanomagnets arranged on a square lattice to (i) support transfer of information and (ii) perform logic operations. We introduce a thermal protocol, using thermally active nanomagnets as a means to perform computation. Within this scheme, the nanomagnets are initialized by a global magnetic field and thermally relax on raising the temperature with a resistive heater. We demonstrate error-free transfer of information in chains of up to 19 square rings and we show a high level of reliability with successful gate operations of ∼94% across more than 2000 logic gates. Finally, we present a functionally complete prototype NAND/NOR logic gate that could be implemented for advanced logic operations. Here we support our experiments with simulations of the thermally averaged output and determine the optimal gate parameters. Our approach provides a new pathway to a long standing problem concerning reliability in the use of nanomagnets for computation.

Soil as natural heat resource for very shallow geothermal application: laboratory and test site updates from ITER Project

NASA Astrophysics Data System (ADS)

Di Sipio, Eloisa; Bertermann, David

2017-04-01

Nowadays renewable energy resources for heating/cooling residential and tertiary buildings and agricultural greenhouses are becoming increasingly important. In this framework, a possible, natural and valid alternative for thermal energy supply is represented by soils. In fact, since 1980 soils have been studied and used also as heat reservoir in geothermal applications, acting as a heat source (in winter) or sink (in summer) coupled mainly with heat pumps. Therefore, the knowledge of soil thermal properties and of heat and mass transfer in the soils plays an important role in modeling the performance, reliability and environmental impact in the short and long term of engineering applications. However, the soil thermal behavior varies with soil physical characteristics such as soil texture and water content. The available data are often scattered and incomplete for geothermal applications, especially very shallow geothermal systems (up to 10 m depths), so it is worthy of interest a better comprehension of how the different soil typologies (i.e. sand, loamy sand...) affect and are affected by the heat transfer exchange with very shallow geothermal installations (i.e. horizontal collector systems and special forms). Taking into consideration these premises, the ITER Project (Improving Thermal Efficiency of horizontal ground heat exchangers, http://iter-geo.eu/), funded by European Union, is here presented. An overview of physical-thermal properties variations under different moisture and load conditions for different mixtures of natural material is shown, based on laboratory and field test data. The test site, located in Eltersdorf, near Erlangen (Germany), consists of 5 trenches, filled in each with a different material, where 5 helix have been installed in an horizontal way instead of the traditional vertical option.

Evaluation of accelerated UV and thermal testing for benzene formation in beverages containing benzoate and ascorbic acid.

PubMed

Nyman, Patricia J; Wamer, Wayne G; Begley, Timothy H; Diachenko, Gregory W; Perfetti, Gracia A

2010-04-01

Under certain conditions, benzene can form in beverages containing benzoic and ascorbic acids. The American Beverage Assn. (ABA) has published guidelines to help manufacturers mitigate benzene formation in beverages. These guidelines recommend accelerated testing conditions to test product formulations, because exposure to ultraviolet (UV) light and elevated temperature over the shelf life of the beverage may result in benzene formation in products containing benzoic and ascorbic acids. In this study, the effects of UVA exposure on benzene formation were determined. Benzene formation was examined for samples contained in UV stabilized and non-UV stabilized packaging. Additionally, the usefulness of accelerated thermal testing to simulate end of shelf-life benzene formation was evaluated for samples containing either benzoic or ascorbic acid, or both. The 24 h studies showed that under intense UVA light benzene levels increased by as much as 53% in model solutions stored in non-UV stabilized bottles, whereas the use of UV stabilized polyethylene terephthalate bottles reduced benzene formation by about 13% relative to the non-UV stabilized bottles. Similar trends were observed for the 7 d study. Retail beverages and positive and negative controls were used to study the accelerated thermal testing conditions. The amount of benzene found in the positive controls and cranberry juice suggests that testing at 40 degrees C for 14 d may more reliably simulate end of shelf-life benzene formation in beverages. Except for cranberry juice, retail beverages were not found to contain detectable amounts of benzene (<0.05 ng/g) at the end of their shelf lives.

Alternative Fuels Research Laboratory

NASA Technical Reports Server (NTRS)

Surgenor, Angela D.; Klettlinger, Jennifer L.; Nakley, Leah M.; Yen, Chia H.

2012-01-01

NASA Glenn has invested over $1.5 million in engineering, and infrastructure upgrades to renovate an existing test facility at the NASA Glenn Research Center (GRC), which is now being used as an Alternative Fuels Laboratory. Facility systems have demonstrated reliability and consistency for continuous and safe operations in Fischer-Tropsch (F-T) synthesis and thermal stability testing. This effort is supported by the NASA Fundamental Aeronautics Subsonic Fixed Wing project. The purpose of this test facility is to conduct bench scale F-T catalyst screening experiments. These experiments require the use of a synthesis gas feedstock, which will enable the investigation of F-T reaction kinetics, product yields and hydrocarbon distributions. Currently the facility has the capability of performing three simultaneous reactor screening tests, along with a fourth fixed-bed reactor for catalyst activation studies. Product gas composition and performance data can be continuously obtained with an automated gas sampling system, which directly connects the reactors to a micro-gas chromatograph (micro GC). Liquid and molten product samples are collected intermittently and are analyzed by injecting as a diluted sample into designated gas chromatograph units. The test facility also has the capability of performing thermal stability experiments of alternative aviation fuels with the use of a Hot Liquid Process Simulator (HLPS) (Ref. 1) in accordance to ASTM D 3241 "Thermal Oxidation Stability of Aviation Fuels" (JFTOT method) (Ref. 2). An Ellipsometer will be used to study fuel fouling thicknesses on heated tubes from the HLPS experiments. A detailed overview of the test facility systems and capabilities are described in this paper.

Fiber-optic temperature profiling for thermal protection system heat shields

NASA Astrophysics Data System (ADS)

Black, Richard J.; Costa, Joannes M.; Zarnescu, Livia; Hackney, Drew A.; Moslehi, Behzad; Peters, Kara J.

2016-11-01

To achieve better designs for spacecraft heat shields for missions requiring atmospheric aero-capture or entry/reentry, reliable thermal protection system (TPS) sensors are needed. Such sensors will provide both risk reduction and heat-shield mass minimization, which will facilitate more missions and enable increased payloads and returns. This paper discusses TPS thermal measurements provided by a temperature monitoring system involving lightweight, electromagnetic interference-immune, high-temperature resistant fiber Bragg grating (FBG) sensors with a thermal mass near that of TPS materials together with fast FBG sensor interrogation. Such fiber-optic sensing technology is highly sensitive and accurate, as well as suitable for high-volume production. Multiple sensing FBGs can be fabricated as arrays on a single fiber for simplified design and reduced cost. Experimental results are provided to demonstrate the temperature monitoring system using multisensor FBG arrays embedded in a small-size super-light ablator (SLA) coupon which was thermally loaded to temperatures in the vicinity of the SLA charring temperature. In addition, a high-temperature FBG array was fabricated and tested for 1000°C operation, and the temperature dependence considered over the full range (cryogenic to high temperature) for which silica fiber FBGs have been subjected.

Fracturing And Liquid CONvection

DOE Office of Scientific and Technical Information (OSTI.GOV)

2012-02-29

FALCON has been developed to enable simulation of the tightly coupled fluid-rock behavior in hydrothermal and engineered geothermal system (EGS) reservoirs, targeting the dynamics of fracture stimulation, fluid flow, rock deformation, and heat transport in a single integrated code, with the ultimate goal of providing a tool that can be used to test the viability of EGS in the United States and worldwide. Reliable reservoir performance predictions of EGS systems require accurate and robust modeling for the coupled thermal­hydrological­mechanical processes.

Nondestructive Technique To Assess Embrittlement In Steels

NASA Technical Reports Server (NTRS)

Allison, Sidney G.; Yost, William T.; Cantrell, John H.

1990-01-01

Recent research at NASA Langley Research Center led to identification of nondestructive technique for detection of temper embrittlement in HY80 steel. Measures magnetoacoustic emission associated with reversible motion of domain walls at low magnetic fields. Of interest to engineers responsible for reliability and safety of various dynamically loaded and/or thermally cycled steel parts. Applications include testing of landing gears, naval vessels, and parts subjected to heat, such as those found in steam-pipe fittings, boilers, turbine rotors, and nuclear pressure vessels.

Analytical techniques and instrumentation, a compilation

NASA Technical Reports Server (NTRS)

1974-01-01

Procedures for conducting materials tests and structural analyses of aerospace components are presented as a part of the NASA technology utilization program. Some of the subjects discussed are as follows: (1) failures in cryogenic tank insulation, (2) friction characteristics of graphite and graphite-metal combinations, (3) evaluation of polymeric products in thermal-vacuum environment, (4) erosion of metals by multiple impacts with water, (5) mass loading effects on vibrated ring and shell structures, (6) nonlinear damping in structures, and (7) method for estimating reliability of randomly excited structures.

Comparison of the thermal neutron scattering treatment in MCNP6 and GEANT4 codes

NASA Astrophysics Data System (ADS)

Tran, H. N.; Marchix, A.; Letourneau, A.; Darpentigny, J.; Menelle, A.; Ott, F.; Schwindling, J.; Chauvin, N.

2018-06-01

To ensure the reliability of simulation tools, verification and comparison should be made regularly. This paper describes the work performed in order to compare the neutron transport treatment in MCNP6.1 and GEANT4-10.3 in the thermal energy range. This work focuses on the thermal neutron scattering processes for several potential materials which would be involved in the neutron source designs of Compact Accelerator-based Neutrons Sources (CANS), such as beryllium metal, beryllium oxide, polyethylene, graphite, para-hydrogen, light water, heavy water, aluminium and iron. Both thermal scattering law and free gas model, coming from the evaluated data library ENDF/B-VII, were considered. It was observed that the GEANT4.10.03-patch2 version was not able to account properly the coherent elastic process occurring in crystal lattice. This bug is treated in this work and it should be included in the next release of the code. Cross section sampling and integral tests have been performed for both simulation codes showing a fair agreement between the two codes for most of the materials except for iron and aluminium.

A Flexible 360-Degree Thermal Sound Source Based on Laser Induced Graphene

PubMed Central

Tao, Lu-Qi; Liu, Ying; Ju, Zhen-Yi; Tian, He; Xie, Qian-Yi; Yang, Yi; Ren, Tian-Ling

2016-01-01

A flexible sound source is essential in a whole flexible system. It’s hard to integrate a conventional sound source based on a piezoelectric part into a whole flexible system. Moreover, the sound pressure from the back side of a sound source is usually weaker than that from the front side. With the help of direct laser writing (DLW) technology, the fabrication of a flexible 360-degree thermal sound source becomes possible. A 650-nm low-power laser was used to reduce the graphene oxide (GO). The stripped laser induced graphene thermal sound source was then attached to the surface of a cylindrical bottle so that it could emit sound in a 360-degree direction. The sound pressure level and directivity of the sound source were tested, and the results were in good agreement with the theoretical results. Because of its 360-degree sound field, high flexibility, high efficiency, low cost, and good reliability, the 360-degree thermal acoustic sound source will be widely applied in consumer electronics, multi-media systems, and ultrasonic detection and imaging. PMID:28335239

Characterization and reliability of aluminum gallium nitride/gallium nitride high electron mobility transistors

NASA Astrophysics Data System (ADS)

Douglas, Erica Ann

Compound semiconductor devices, particularly those based on GaN, have found significant use in military and civilian systems for both microwave and optoelectronic applications. Future uses in ultra-high power radar systems will require the use of GaN transistors operated at very high voltages, currents and temperatures. GaN-based high electron mobility transistors (HEMTs) have proven power handling capability that overshadows all other wide band gap semiconductor devices for high frequency and high-power applications. Little conclusive research has been reported in order to determine the dominating degradation mechanisms of the devices that result in failure under standard operating conditions in the field. Therefore, it is imperative that further reliability testing be carried out to determine the failure mechanisms present in GaN HEMTs in order to improve device performance, and thus further the ability for future technologies to be developed. In order to obtain a better understanding of the true reliability of AlGaN/GaN HEMTs and determine the MTTF under standard operating conditions, it is crucial to investigate the interaction effects between thermal and electrical degradation. This research spans device characterization, device reliability, and device simulation in order to obtain an all-encompassing picture of the device physics. Initially, finite element thermal simulations were performed to investigate the effect of device design on self-heating under high power operation. This was then followed by a study of reliability of HEMTs and other tests structures during high power dc operation. Test structures without Schottky contacts showed high stability as compared to HEMTs, indicating that degradation of the gate is the reason for permanent device degradation. High reverse bias of the gate has been shown to induce the inverse piezoelectric effect, resulting in a sharp increase in gate leakage current due to crack formation. The introduction of elevated temperatures during high reverse gate bias indicated that device failure is due to the breakdown of an unintentional gate oxide. RF stress of AlGaN/GaN HEMTs showed comparable critical voltage breakdown regime as that of similar devices stressed under dc conditions. Though RF device characteristics showed stability up to a drain bias of 20 V, Schottky diode characteristics degraded substantially at all voltages investigated. Results from both dc and RF stress conditions, under several bias regimes, confirm that the primary root for stress induced degradation was due to the Schottky contact. (Full text of this dissertation may be available via the University of Florida Libraries web site. Please check http://www.uflib.ufl.edu/etd.html)

Evaluation of ceramics for stator applications: Gas turbine engines interim report. Stator fabrication and evaluation

NASA Technical Reports Server (NTRS)

Arnon, N.; Trela, W.

1983-01-01

The objective was to assess current ceramic materials, fabrication processes, reliability prediction, and stator durability when subjected to simulated automotive gas turbine engine operating conditions. Ceramic one-piece stators were fabricated of two materials, silicon nitride and silicon carbide, using two near-net-shape processes, slip casting and injection molding. Non-destructive evaluation tests were conducted on all stators identifying irregularities which could contribute to failures under durability testing. Development of the test rig and automatic control system for repeatably controlling air flow rate and temperature over a highly transient durability duty cycle is discussed. Durability results are presented for repeated thermal cycle testing of the ceramic one-piece stators. Two duty cycles were used, encompassing the temperature ranges of 704 to 1204 C (1300 to 2200 F) and 871 to 1371 C (1600 to 2500 F). Tests were conducted on 28 stators, accumulating 135,551 cycles in 2441 hours of hot testing. Cyclic durability for the ceramic one-piece stator was demonstrated to be in excess of 500 hours, accumulating over 28,850 thermal cycles. Ceramic interface forces were found to be the significant factor in limiting stator life rather than the scatter in material strength properties or the variation in component defects encountered.

Experimental operation of a sodium heat pipe

NASA Astrophysics Data System (ADS)

Holtz, R. E.; McLennan, G. A.; Koehl, E. R.

1985-05-01

This report documents the operation of a 28 in. long sodium heat pipe in the Heat Pipe Test Facility (HPTF) installed at Argonne National Laboratory. Experimental data were collected to simulate conditions prototypic of both a fluidized bed coal combustor application and a space environment application. Both sets of experiment data show good agreement with the heat pipe analytical model. The heat transfer performance of the heat pipe proved reliable over a substantial period of operation and over much thermal cycling. Additional testing of longer heat pipes under controlled laboratory conditions will be necessary to determine performance limitations and to complete the design code validation.

Ultracompliant Heterogeneous Copper-Tin Nanowire Arrays Making a Supersolder

DOE Office of Scientific and Technical Information (OSTI.GOV)

Narumanchi, Sreekant V; Feng, Xuhui; Major, Joshua

Due to the substantial increase in power density, thermal interface resistance that can constitute more than 50% of the total thermal resistance has generally become a bottleneck for thermal management in electronics. However, conventional thermal interface materials (TIMs) such as solder, epoxy, gel, and grease cannot fulfill the requirements of electronics for high-power and long-term operation. Here, we demonstrate a high-performance TIM consisting of a heterogeneous copper-tin nanowire array, which we term 'supersolder' to emulate the role of conventional solders in bonding various surfaces. The supersolder is ultracompliant with a shear modulus 2-3 orders of magnitude lower than traditional soldersmore » and can reduce the thermal resistance by two times as compared with the state-of-the-art TIMs. This supersolder also exhibits excellent long-term reliability with >1200 thermal cycles over a wide temperature range. By resolving this critical thermal bottleneck, the supersolder enables electronic systems, ranging from microelectronics and portable electronics to massive data centers, to operate at lower temperatures with higher power density and reliability.« less

Impact of Isothermal Aging on Long-Term Reliability of Fine-Pitch Ball Grid Array Packages with Sn-Ag-Cu Solder Interconnects: Surface Finish Effects

NASA Astrophysics Data System (ADS)

Lee, Tae-Kyu; Ma, Hongtao; Liu, Kuo-Chuan; Xue, Jie

2010-12-01

The interaction between isothermal aging and the long-term reliability of fine-pitch ball grid array (BGA) packages with Sn-3.0Ag-0.5Cu (wt.%) solder ball interconnects was investigated. In this study, 0.4-mm fine-pitch packages with 300- μm-diameter Sn-Ag-Cu solder balls were used. Two different package substrate surface finishes were selected to compare their effects on the final solder composition, especially the effect of Ni, during thermal cycling. To study the impact on thermal performance and long-term reliability, samples were isothermally aged and thermally cycled from 0°C to 100°C with 10 min dwell time. Based on Weibull plots for each aging condition, package lifetime was reduced by approximately 44% by aging at 150°C. Aging at 100°C showed a smaller impact but similar trend. The microstructure evolution was observed during thermal aging and thermal cycling with different phase microstructure transformations between electrolytic Ni/Au and organic solderability preservative (OSP) surface finishes, focusing on the microstructure evolution near the package-side interface. Different mechanisms after aging at various conditions were observed, and their impacts on the fatigue lifetime of solder joints are discussed.

Reliability of CCGA and PBGA assemblies

NASA Technical Reports Server (NTRS)

Ghaffarian, Reza

2005-01-01

Area Array Packages (AAPs) with 1.27 mm pitch have been the packages of the choice for commercial applications; they are now started to be implemented for use in military and aerospace applications. Thermal cycling characteristics of plastic BGA (PBGA) and CSP assemblies, because of their wide usage for commercial applications, have been extensively reported in literature. Thermal cycling represents the on-off environmental condition for most electronic products and therefore is a key factor that defines reliability.

Thermally Stabilized Transmit/Receive Modules

NASA Technical Reports Server (NTRS)

Hoffman, James; DelCastillo, Linda; Miller, Jennifer; Birur, Gaj

2011-01-01

RF-hybrid technologies enable smaller packaging and mass reduction in radar instruments, especially for subsystems with dense electronics, such as electronically steered arrays. We are designing thermally stabilized RF-hybrid T/R modules using new materials for improved thermal performance of electronics. We are combining advanced substrate and housing materials with a thermal reservoir material, and develop new packaging techniques to significantly improve thermal-cycling reliability and performance stability over temperature.

Performance and Reliability of Bonded Interfaces for High-Temperature Packaging

DOE Office of Scientific and Technical Information (OSTI.GOV)

DeVoto, Douglas

2016-06-08

This is a technical review of the DOE VTO EDT project EDT063, Performance and Reliability of Bonded Interfaces for High-Temperature Packaging. A procedure for analyzing the reliability of sintered-silver through experimental thermal cycling and crack propagation modeling has been outlined and results have been presented.

High-power UV-LED degradation: Continuous and cycled working condition influence

NASA Astrophysics Data System (ADS)

Arques-Orobon, F. J.; Nuñez, N.; Vazquez, M.; Segura-Antunez, C.; González-Posadas, V.

2015-09-01

High-power (HP) UV-LEDs can replace UV lamps for real-time fluoro-sensing applications by allowing portable and autonomous systems. However, HP UV-LEDs are not a mature technology, and there are still open issues regarding their performance evolution over time. This paper presents a reliability study of 3 W UV-LEDs, with special focus on LED degradation for two working conditions: continuous and cycled (30 s ON and 30 s OFF). Accelerated life tests are developed to evaluate the influence of temperature and electrical working conditions in high-power LEDs degradation, being the predominant failure mechanism the degradation of the package. An analysis that includes dynamic thermal and optical HP UV-LED measurements has been performed. Static thermal and stress simulation analysis with the finite element method (FEM) identifies the causes of package degradation. Accelerated life test results prove that HP UV-LEDs working in cycled condition have a better performance than those working in continuous condition.

Anti-icing Behavior of Thermally Sprayed Polymer Coatings

NASA Astrophysics Data System (ADS)

Koivuluoto, Heli; Stenroos, Christian; Kylmälahti, Mikko; Apostol, Marian; Kiilakoski, Jarkko; Vuoristo, Petri

2017-01-01

Surface engineering shows an increasing potential to provide a sustainable approach to icing problems. Currently, several passive anti-ice properties adoptable to coatings are known, but further research is required to proceed for practical applications. This is due to the fact that icing reduces safety, operational tempo, productivity and reliability of logistics, industry and infrastructure. An icing wind tunnel and a centrifugal ice adhesion test equipment can be used to evaluate and develop anti-icing and icephobic coatings for a potential use in various arctic environments, e.g., in wind power generation, oil drilling, mining and logistic industries. The present study deals with evaluation of icing properties of flame-sprayed polyethylene (PE)-based polymer coatings. In the laboratory-scale icing tests, thermally sprayed polymer coatings showed low ice adhesion compared with metals such as aluminum and stainless steel. The ice adhesion strength of the flame-sprayed PE coating was found to have approximately seven times lower ice adhesion values compared with metallic aluminum, indicating a very promising anti-icing behavior.

Repeatability of a cold stress test to assess cold sensitization.

PubMed

House, C M; Taylor, R J; Oakley, E H N

2015-10-01

Non-freezing cold injury (NFCI) is a syndrome in which damage to peripheral tissues occurs without the tissues freezing following exposure to low ambient temperatures. To assess the test-retest reliability of a cold stress test (CST) used to assess cold sensitization. Volunteers with no self-reported history of NFCI undertook the CST on three occasions. Thermal images were taken of the foot and hand before, immediately after and 5min after immersion of the limb in cold water for 2min. Cold sensitization was graded by the two clinicians and the lead author. Spot temperatures from the toe and finger pads were recorded. There were 30 white and 19 black male participants. The ratings indicated substantial agreement [a Cohen's kappa (κ) value of 0.61-0.8] to within ± one grading category for the hands and feet of the white volunteers and the hands of the black volunteers. Limits of agreement (LoA) analysis for toe and finger pad temperatures indicated high agreement (absolute 95% LoA < 5.5°C). Test-retest reliability for the feet of the black volunteers was not supported by the gradings (κ = 0.38) and toe pad temperatures (absolute 95% LoA = 9.5°C and coefficient of variation = 11%). The test-retest reliability of the CST is considered adequate for the assessment of the cold sensitization of the hands and feet of white and the hands of black healthy non-patients. The study should be repeated with patients who have suffered a NFCI. © Crown copyright 2015.

Re-entry simulation chamber for thermo-mechanical characterisation of space materials

NASA Astrophysics Data System (ADS)

Liedtke, Volker

2003-09-01

During re-entry, materials and components are subject to very high thermal and mechanical loads. Any failure may cause loss of mission. Therefore, materials and components have to be tested under most rigid conditions to verify the suitability of the material and to verify the design of the components. The Re-Entry Simulation Chamber (RESiC) at ARC Seibersdorf research (ARCS) allows simulating the high thermal loads as well as complex mechanical load profiles that may occur during a re-entry; additionally, the influence of chemical reactions of materials with gaseous components of the atmosphere can be studied. The high vacuum chamber (better than 1×10-6 mbar) has a diameter of 650 mm and allows a sample height of 500 mm, or 1000 mm with extension flange. The gas dosing system is designed to emulate the increasing atmospheric pressure during the re-entry trajectory of a vehicle. Heating is performed by a 30 kW induction generator that allows a sufficiently rapid heating of larger components; electrically conductive materials such as metals or carbon fibre reinforced ceramics are directly heated, while for electrical insulators, susceptor plates or tubes will be employed. The uniaxial servo-hydraulic testing machine has a maximum load of 70 kN, either static or with a frequency of up to 70 Hz, with any given load profile (sinus, rectangular, triangular, ...). Strain measurements will be done by non-contacting laser speckle system for maximum flexibility and minimum instrumentation time effort (currently under application testing), or by strain gauges. All relevant process parameters are controlled and recorded by microcomputer. The highly sophisticated control software allows a convenient and reliable multi-channel data acquisition, e.g. temperatures at various positions of the test piece, pressure, loads, strains, and any other test data according to customer specifications; the data format is suitable for any further data processing. During the set-up and operation testing, the device has successfully been employed for thermal shock testing, thermal cycling and gas cycling tests, thermomechanical tests and combinations thereof, e.g. sintering or hot-pressing. During the current final test series, the device will be completed, further optimised and shall be fully operational in summer 2003.

Perspective on thermal barrier coatings for industrial gas turbine applications

NASA Technical Reports Server (NTRS)

Mutasim, Z. Z.; Hsu, L. L.; Brentnall, W. D.

1995-01-01

Thermal Barrier Coatings (TBC's) have been used in high thrust aircraft engines for many years, and have proved to be very effective in allowing higher turbine inlet temperatures. TBC life requirements for aircraft engines are typically less than those required in industrial gas turbines. The use of TBC's for industrial gas turbines can increase if durability and longer service life can be successfully demonstrated. This paper will describe current and future applications of TBC's in industrial gas turbine engines. Early testing and applications of TBC's will also be reviewed. This paper focuses on the key factors that are expected to influence utilization of TBC's in advanced industrial gas turbine engines. It is anticipated that reliable, durable and high effective coating systems will be produced that will ultimately improve engine efficiency and performance.

A thermally driven differential mutation approach for the structural optimization of large atomic systems

NASA Astrophysics Data System (ADS)

Biswas, Katja

2017-09-01

A computational method is presented which is capable to obtain low lying energy structures of topological amorphous systems. The method merges a differential mutation genetic algorithm with simulated annealing. This is done by incorporating a thermal selection criterion, which makes it possible to reliably obtain low lying minima with just a small population size and is suitable for multimodal structural optimization. The method is tested on the structural optimization of amorphous graphene from unbiased atomic starting configurations. With just a population size of six systems, energetically very low structures are obtained. While each of the structures represents a distinctly different arrangement of the atoms, their properties, such as energy, distribution of rings, radial distribution function, coordination number, and distribution of bond angles, are very similar.

Form-Stable Phase Change Materials Based on Eutectic Mixture of Tetradecanol and Fatty Acids for Building Energy Storage: Preparation and Performance Analysis

PubMed Central

Huang, Jingyu; Lu, Shilei; Kong, Xiangfei; Liu, Shangbao; li, Yiran

2013-01-01

This paper is focused on preparation and performance analysis of a series of form-stable phase change materials (FSPCMs), based on eutectic mixtures as phase change materials (PCMs) for thermal energy storage and high-density polyethylene (HDPE)-ethylene-vinyl acetate (EVA) polymer as supporting materials. The PCMs were eutectic mixtures of tetradecanol (TD)–capric acid (CA), TD–lauric acid (LA), and TD–myristic acid (MA), which were rarely explored before. Thermal properties of eutectic mixtures and FSPCMs were measured by differential scanning calorimeter (DSC). The onset melting/solidification temperatures of form-stable PCMs were 19.13 °C/13.32 °C (FS TD–CA PCM), 24.53 °C/24.92 °C (FS TD–LA PCM), and 33.15 °C/30.72 °C (FS TD–MA PCM), respectively, and latent heats were almost greater than 90 J/g. The surface morphologies and chemical stability of form-stable PCM were surveyed by scanning electron microscopy (SEM) and Fourier-transform infrared (FT-IR) spectroscopy, respectively. The thermal cycling test revealed that the thermal reliability of these three form-stable PCMs was good. Thermal storage/release experiment indicated melting/solidification time was shortened by introducing 10 wt % aluminum powder (AP). It is concluded that these FSPCMs can act as potential building thermal storage materials in terms of their satisfactory thermal properties. PMID:28788358

Form-Stable Phase Change Materials Based on Eutectic Mixture of Tetradecanol and Fatty Acids for Building Energy Storage: Preparation and Performance Analysis.

PubMed

Huang, Jingyu; Lu, Shilei; Kong, Xiangfei; Liu, Shangbao; Li, Yiran

2013-10-22

This paper is focused on preparation and performance analysis of a series of form-stable phase change materials (FSPCMs), based on eutectic mixtures as phase change materials (PCMs) for thermal energy storage and high-density polyethylene (HDPE)-ethylene-vinyl acetate (EVA) polymer as supporting materials. The PCMs were eutectic mixtures of tetradecanol (TD)-capric acid (CA), TD-lauric acid (LA), and TD-myristic acid (MA), which were rarely explored before. Thermal properties of eutectic mixtures and FSPCMs were measured by differential scanning calorimeter (DSC). The onset melting/solidification temperatures of form-stable PCMs were 19.13 °C/13.32 °C (FS TD-CA PCM), 24.53 °C/24.92 °C (FS TD-LA PCM), and 33.15 °C/30.72 °C (FS TD-MA PCM), respectively, and latent heats were almost greater than 90 J/g. The surface morphologies and chemical stability of form-stable PCM were surveyed by scanning electron microscopy (SEM) and Fourier-transform infrared (FT-IR) spectroscopy, respectively. The thermal cycling test revealed that the thermal reliability of these three form-stable PCMs was good. Thermal storage/release experiment indicated melting/solidification time was shortened by introducing 10 wt % aluminum powder (AP). It is concluded that these FSPCMs can act as potential building thermal storage materials in terms of their satisfactory thermal properties.

COTS Ceramic Chip Capacitors: An Evaluation of the Parts and Assurance Methodologies

NASA Technical Reports Server (NTRS)

Brusse, Jay A.; Sampson, Michael J.

2004-01-01

Commercial-Off-The-Shelf (COTS) multilayer ceramic chip capacitors (MLCCs) are continually evolving to reduce physical size and increase volumetric efficiency. Designers of high reliability aerospace and military systems are attracted to these attributes of COTS MLCCs and would like to take advantage of them while maintaining the high standards for long-term reliable operation they are accustomed io when selecting military qualified established reliability (MIL-ER) MLCCs. However, MIL-ER MLCCs are not available in the full range of small chip sizes with high capacitance as found in today's COTS MLCCs. The objectives for this evaluation were to assess the long-term performance of small case size COTS MLCCs and to identify effective, lower-cost product assurance methodologies. Fifteen (15) lots of COTS X7R dielectric MLCCs from four (4) different manufacturers and two (2) MIL-ER BX dielectric MLCCs from two (2) of the same manufacturers were evaluated. Both 0805 and 0402 chip sizes were included. Several voltage ratings were tested ranging from a high of 50 volts to a low of 6.3 volts. The evaluation consisted of a comprehensive screening and qualification test program based upon MIL-PRF-55681 (i.e., voltage conditioning, thermal shock, moisture resistance, 2000-hour life test, etc.). In addition, several lot characterization tests were performed including Destructive Physical Analysis (DPA), Highly Accelerated Life Test (HALT) and Dielectric Voltage Breakdown Strength. The data analysis included a comparison of the 2000-hour life test results (used as a metric for long-term performance) relative to the screening and characterization test results. Results of this analysis indicate that the long-term life performance of COTS MLCCs is variable -- some lots perform well, some lots perform poorly. DPA and HALT were found to be promising lot characterization tests to identify substandard COTS MLCC lots prior to conducting more expensive screening and qualification tests. The results indicate that lot- specific screening and qualification are still recommended for high reliability applications. One significant and concerning observation is that MIL- type voltage conditioning (100 hours at twice rated voltage, 125 C) was not an effective screen in removing infant mortality parts for the particular lots of COTS MLCCs evaluated.

Design and Manufacture of a Highly Reliable, Miniaturized and Low Mass Shutter Mechanism

NASA Technical Reports Server (NTRS)

Manhart, M.; Zeh, T.; Preibler, G.; Hurni, A.; Walter, I.; Helbert, J.; Hiesinger, H.

2010-01-01

This paper describes the development, manufacturing and testing of a lightweight shutter mechanism made of titanium for the MERTIS Instrument. MERTIS is a thermal infrared imaging spectrometer onboard ESA's future BepiColombo mission to Mercury. The mechanism is built as a parallelogram arrangement of flexible hinges, actuated by a voice coil. In a first test run, it was shown that the selected EDM processing led to the generation of titanium oxides and an oxygen-enriched surface layer on the substrate (so called alpha-case layer). In the revised version of the shutter, it was possible to manufacture the complex geometry by micro-milling and an adjacent pickling procedure. The adequacy of this approach was verified by lifetime and vibration testing.

Assembly processes comparison for a miniaturized laser used for the Exomars European Space Agency mission

NASA Astrophysics Data System (ADS)

Ribes-Pleguezuelo, Pol; Inza, Andoni Moral; Basset, Marta Gilaberte; Rodríguez, Pablo; Rodríguez, Gemma; Laudisio, Marco; Galan, Miguel; Hornaff, Marcel; Beckert, Erik; Eberhardt, Ramona; Tünnermann, Andreas

2016-11-01

A miniaturized diode-pumped solid-state laser (DPSSL) designed as part of the Raman laser spectrometer (RLS) instrument for the European Space Agency (ESA) Exomars mission 2020 is assembled and tested for the mission purpose and requirements. Two different processes were tried for the laser assembling: one based on adhesives, following traditional laser manufacturing processes; another based on a low-stress and organic-free soldering technique called solderjet bumping technology. The manufactured devices were tested for the processes validation by passing mechanical, thermal cycles, radiation, and optical functional tests. The comparison analysis showed a device improvement in terms of reliability of the optical performances from the soldered to the assembled by adhesive-based means.

Comparing optical test methods for a lightweight primary mirror of a space-borne Cassegrain telescope

NASA Astrophysics Data System (ADS)

Lin, Wei-Cheng; Chang, Shenq-Tsong; Yu, Zong-Ru; Lin, Yu-Chuan; Ho, Cheng-Fong; Huang, Ting-Ming; Chen, Cheng-Huan

2014-09-01

A Cassegrain telescope with a 450 mm clear aperture was developed for use in a spaceborne optical remote-sensing instrument. Self-weight deformation and thermal distortion were considered: to this end, Zerodur was used to manufacture the primary mirror. The lightweight scheme adopted a hexagonal cell structure yielding a lightweight ratio of 50%. In general, optical testing on a lightweight mirror is a critical technique during both the manufacturing and assembly processes. To prevent unexpected measurement errors that cause erroneous judgment, this paper proposes a novel and reliable analytical method for optical testing, called the bench test. The proposed algorithm was used to distinguish the manufacturing form error from surface deformation caused by the mounting, supporter and gravity effects for the optical testing. The performance of the proposed bench test was compared with a conventional vertical setup for optical testing during the manufacturing process of the lightweight mirror.

Noninteractive macroscopic reliability model for whisker-reinforced ceramic composites

NASA Technical Reports Server (NTRS)

Duffy, Stephen F.; Arnold, Steven M.

1990-01-01

Considerable research is underway in the field of material science focusing on incorporating silicon carbide whiskers into silicon nitride and alumina matrices. These composites show the requisite thermal stability and thermal shock resistance necessary for use as components in advanced gas turbines and heat exchangers. This paper presents a macroscopic noninteractive reliability model for whisker-reinforced ceramic composites. The theory is multiaxial and is applicable to composites that can be characterized as transversely isotropic. Enough processing data exists to suggest this idealization encompasses a significantly large class of fabricated components. A qualitative assessment of the model is made by presenting reliability surfaces in several different stress spaces and for different values of model parameters.

Development of a non-explosive release actuator using shape memory alloy wire.

PubMed

Yoo, Young Ik; Jeong, Ju Won; Lim, Jae Hyuk; Kim, Kyung-Won; Hwang, Do-Soon; Lee, Jung Ju

2013-01-01

We have developed a newly designed non-explosive release actuator that can replace currently used release devices. The release mechanism is based on a separation mechanism, which relies on segmented nuts and a shape memory alloy (SMA) wire trigger. A quite fast and simple trigger operation is made possible through the use of SMA wire. This actuator is designed to allow a high preload with low levels of shock for the solar arrays of medium-size satellites. After actuation, the proposed device can be easily and instantly reset. Neither replacement, nor refurbishment of any components is necessary. According to the results of a performance test, the release time, preload capacity, and maximum shock level are 50 ms, 15 kN, and 350 G, respectively. In order to increase the reliability of the actuator, more than ten sets of performance tests are conducted. In addition, the proposed release actuator is tested under thermal vacuum and extreme vibration environments. No degradation or damage was observed during the two environment tests, and the release actuator was able to operate successfully. Considering the test results as a whole, we conclude that the proposed non-explosive release actuator can be applied reliably to intermediate-size satellites to replace existing release systems.

Multi-Mission Earth Vehicle Subsonic Dynamic Stability Testing and Analyses

NASA Technical Reports Server (NTRS)

Glaab, Louis J.; Fremaux, C. Michael

2013-01-01

Multi-Mission Earth Entry Vehicles (MMEEVs) are blunt-body vehicles designed with the purpose of transporting payloads from outer space to the surface of the Earth. To achieve high-reliability and minimum weight, MMEEVs avoid use of limited-reliability systems, such as parachutes, retro-rockets, and reaction control systems and rely on the natural aerodynamic stability of the vehicle throughout the Entry, Descent, and Landing (EDL) phase of flight. The Multi-Mission Systems Analysis for Planetary Entry (M-SAPE) parametric design tool is used to facilitate the design of MMEEVs for an array of missions and develop and visualize the trade space. Testing in NASA Langley?s Vertical Spin Tunnel (VST) was conducted to significantly improve M-SAPE?s subsonic aerodynamic models. Vehicle size and shape can be driven by entry flight path angle and speed, thermal protection system performance, terminal velocity limitations, payload mass and density, among other design parameters. The objectives of the VST testing were to define usable subsonic center of gravity limits, and aerodynamic parameters for 6-degree-of-freedom (6-DOF) simulations, for a range of MMEEV designs. The range of MMEEVs tested was from 1.8m down to 1.2m diameter. A backshell extender provided the ability to test a design with a much larger payload for the 1.2m MMEEV.

Thermal Adaptation Methods of Urban Plaza Users in Asia's Hot-Humid Regions: A Taiwan Case Study.

PubMed

Wu, Chen-Fa; Hsieh, Yen-Fen; Ou, Sheng-Jung

2015-10-27

Thermal adaptation studies provide researchers great insight to help understand how people respond to thermal discomfort. This research aims to assess outdoor urban plaza conditions in hot and humid regions of Asia by conducting an evaluation of thermal adaptation. We also propose that questionnaire items are appropriate for determining thermal adaptation strategies adopted by urban plaza users. A literature review was conducted and first hand data collected by field observations and interviews used to collect information on thermal adaptation strategies. Item analysis--Exploratory Factor Analysis (EFA) and Confirmatory Factor Analysis (CFA)--were applied to refine the questionnaire items and determine the reliability of the questionnaire evaluation procedure. The reliability and validity of items and constructing process were also analyzed. Then, researchers facilitated an evaluation procedure for assessing the thermal adaptation strategies of urban plaza users in hot and humid regions of Asia and formulated a questionnaire survey that was distributed in Taichung's Municipal Plaza in Taiwan. Results showed that most users responded with behavioral adaptation when experiencing thermal discomfort. However, if the thermal discomfort could not be alleviated, they then adopted psychological strategies. In conclusion, the evaluation procedure for assessing thermal adaptation strategies and the questionnaire developed in this study can be applied to future research on thermal adaptation strategies adopted by urban plaza users in hot and humid regions of Asia.

Thermal Adaptation Methods of Urban Plaza Users in Asia’s Hot-Humid Regions: A Taiwan Case Study

PubMed Central

Wu, Chen-Fa; Hsieh, Yen-Fen; Ou, Sheng-Jung

2015-01-01

Thermal adaptation studies provide researchers great insight to help understand how people respond to thermal discomfort. This research aims to assess outdoor urban plaza conditions in hot and humid regions of Asia by conducting an evaluation of thermal adaptation. We also propose that questionnaire items are appropriate for determining thermal adaptation strategies adopted by urban plaza users. A literature review was conducted and first hand data collected by field observations and interviews used to collect information on thermal adaptation strategies. Item analysis—Exploratory Factor Analysis (EFA) and Confirmatory Factor Analysis (CFA)—were applied to refine the questionnaire items and determine the reliability of the questionnaire evaluation procedure. The reliability and validity of items and constructing process were also analyzed. Then, researchers facilitated an evaluation procedure for assessing the thermal adaptation strategies of urban plaza users in hot and humid regions of Asia and formulated a questionnaire survey that was distributed in Taichung’s Municipal Plaza in Taiwan. Results showed that most users responded with behavioral adaptation when experiencing thermal discomfort. However, if the thermal discomfort could not be alleviated, they then adopted psychological strategies. In conclusion, the evaluation procedure for assessing thermal adaptation strategies and the questionnaire developed in this study can be applied to future research on thermal adaptation strategies adopted by urban plaza users in hot and humid regions of Asia. PMID:26516881

Modeling and experimental study on characterization of micromachined thermal gas inertial sensors.

PubMed

Zhu, Rong; Ding, Henggao; Su, Yan; Yang, Yongjun

2010-01-01

Micromachined thermal gas inertial sensors based on heat convection are novel devices that compared with conventional micromachined inertial sensors offer the advantages of simple structures, easy fabrication, high shock resistance and good reliability by virtue of using a gaseous medium instead of a mechanical proof mass as key moving and sensing elements. This paper presents an analytical modeling for a micromachined thermal gas gyroscope integrated with signal conditioning. A simplified spring-damping model is utilized to characterize the behavior of the sensor. The model relies on the use of the fluid mechanics and heat transfer fundamentals and is validated using experimental data obtained from a test-device and simulation. Furthermore, the nonideal issues of the sensor are addressed from both the theoretical and experimental points of view. The nonlinear behavior demonstrated in experimental measurements is analyzed based on the model. It is concluded that the sources of nonlinearity are mainly attributable to the variable stiffness of the sensor system and the structural asymmetry due to nonideal fabrication.

Solar thermal technology evaluation, fiscal year 1982. Volume 2: Technical

NASA Technical Reports Server (NTRS)

1983-01-01

The technology base of solar thermal energy is investigated. The materials, components, subsystems, and processes capable of meeting specific energy cost targets are emphasized, as are system efficiency and reliability.

Performance and Reliability of Bonded Interfaces for High-Temperature Packaging (Presentation)

DOE Office of Scientific and Technical Information (OSTI.GOV)

Devoto, D.

2014-11-01

The thermal performance and reliability of sintered-silver is being evaluated for power electronics packaging applications. This will be experimentally accomplished by the synthesis of large-area bonded interfaces between metalized substrates that will be subsequently subjected to thermal cycles. A finite element model of crack initiation and propagation in these bonded interfaces will allow for the interpretation of degradation rates by a crack-velocity (V)-stress intensity factor (K) analysis. The experiment is outlined, and the modeling approach is discussed.

Study of thermal management for space platform applications

NASA Technical Reports Server (NTRS)

Oren, J. A.

1980-01-01

Techniques for the management of the thermal energy of large space platforms using many hundreds of kilowatts over a 10 year life span were evaluated. Concepts for heat rejection, heat transport within the vehicle, and interfacing were analyzed and compared. The heat rejection systems were parametrically weight optimized over conditions for heat pipe and pumped fluid approaches. Two approaches to achieve reliability were compared for: performance, weight, volume, projected area, reliability, cost, and operational characteristics. Technology needs are assessed and technology advancement recommendations are made.

Advanced Flip Chips in Extreme Temperature Environments

NASA Technical Reports Server (NTRS)

Ramesham, Rajeshuni

2010-01-01

The use of underfill materials is necessary with flip-chip interconnect technology to redistribute stresses due to mismatching coefficients of thermal expansion (CTEs) between dissimilar materials in the overall assembly. Underfills are formulated using organic polymers and possibly inorganic filler materials. There are a few ways to apply the underfills with flip-chip technology. Traditional capillary-flow underfill materials now possess high flow speed and reduced time to cure, but they still require additional processing steps beyond the typical surface-mount technology (SMT) assembly process. Studies were conducted using underfills in a temperature range of -190 to 85 C, which resulted in an increase of reliability by one to two orders of magnitude. Thermal shock of the flip-chip test articles was designed to induce failures at the interconnect sites (-40 to 100 C). The study on the reliability of flip chips using underfills in the extreme temperature region is of significant value for space applications. This technology is considered as an enabling technology for future space missions. Flip-chip interconnect technology is an advanced electrical interconnection approach where the silicon die or chip is electrically connected, face down, to the substrate by reflowing solder bumps on area-array metallized terminals on the die to matching footprints of solder-wettable pads on the chosen substrate. This advanced flip-chip interconnect technology will significantly improve the performance of high-speed systems, productivity enhancement over manual wire bonding, self-alignment during die joining, low lead inductances, and reduced need for attachment of precious metals. The use of commercially developed no-flow fluxing underfills provides a means of reducing the processing steps employed in the traditional capillary flow methods to enhance SMT compatibility. Reliability of flip chips may be significantly increased by matching/tailoring the CTEs of the substrate material and the silicon die or chip, and also the underfill materials. Advanced packaging interconnects technology such as flip-chip interconnect test boards have been subjected to various extreme temperature ranges that cover military specifications and extreme Mars and asteroid environments. The eventual goal of each process step and the entire process is to produce components with 100 percent interconnect and satisfy the reliability requirements. Underfill materials, in general, may possibly meet demanding end use requirements such as low warpage, low stress, fine pitch, high reliability, and high adhesion.

High Reliability R-10 Windows Using Vacuum Insulating Glass Units

DOE Office of Scientific and Technical Information (OSTI.GOV)

Stark, David

2012-08-16

The objective of this effort was for EverSealed Windows (“EverSealed” or “ESW”) to design, assemble, thermally and environmentally test and demonstrate a Vacuum Insulating Glass Unit (“VIGU” or “VIG”) that would enable a whole window to meet or exceed the an R-10 insulating value (U-factor ≤ 0.1). To produce a VIGU that could withstand any North American environment, ESW believed it needed to design, produce and use a flexible edge seal system. This is because a rigid edge seal, used by all other know VIG producers and developers, limits the size and/or thermal environment of the VIG to where themore » unit is not practical for typical IG sizes and cannot withstand severe outdoor environments. The rigid-sealed VIG’s use would be limited to mild climates where it would not have a reasonable economic payback when compared to traditional double-pane or triple-pane IGs. ESW’s goals, in addition to achieving a sufficiently high R-value to enable a whole window to achieve R-10, included creating a VIG design that could be produced for a cost equal to or lower than a traditional triple-pane IG (low-e, argon filled). ESW achieved these goals. EverSealed produced, tested and demonstrated a flexible edge-seal VIG that had an R-13 insulating value and the edge-seal system durability to operate reliably for at least 40 years in the harshest climates of North America.« less

Flexible Chip Scale Package and Interconnect for Implantable MEMS Movable Microelectrodes for the Brain.

PubMed

Jackson, Nathan; Muthuswamy, Jit

2009-04-01

We report here a novel approach called MEMS microflex interconnect (MMFI) technology for packaging a new generation of Bio-MEMS devices that involve movable microelectrodes implanted in brain tissue. MMFI addresses the need for (i) operating space for movable parts and (ii) flexible interconnects for mechanical isolation. We fabricated a thin polyimide substrate with embedded bond-pads, vias, and conducting traces for the interconnect with a backside dry etch, so that the flexible substrate can act as a thin-film cap for the MEMS package. A double gold stud bump rivet bonding mechanism was used to form electrical connections to the chip and also to provide a spacing of approximately 15-20 µm for the movable parts. The MMFI approach achieved a chip scale package (CSP) that is lightweight, biocompatible, having flexible interconnects, without an underfill. Reliability tests demonstrated minimal increases of 0.35 mΩ, 0.23 mΩ and 0.15 mΩ in mean contact resistances under high humidity, thermal cycling, and thermal shock conditions respectively. High temperature tests resulted in an increase in resistance of > 90 mΩ when aluminum bond pads were used, but an increase of ~ 4.2 mΩ with gold bond pads. The mean-time-to-failure (MTTF) was estimated to be at least one year under physiological conditions. We conclude that MMFI technology is a feasible and reliable approach for packaging and interconnecting Bio-MEMS devices.

Advanced Liquid Cooling for a Traction Drive Inverter Using Jet Impingement and Microfinned Enhanced Surfaces: Preprint

DOE Office of Scientific and Technical Information (OSTI.GOV)

Waye, S. K.; Narumanchi, S.; Mihalic, M.

2014-08-01

Jet impingement on plain and micro-finned enhanced surfaces was compared to a traditional channel flow configuration. The jets provide localized cooling to areas heated by the insulated-gate bipolar transistor and diode devices. Enhanced microfinned surfaces increase surface area and thermal performance. Using lighter materials and designing the fluid path to manage pressure losses increases overall performance while reducing weight, volume, and cost. Powering four diodes in the center power module of the inverter and computational fluid dynamics (CFD) modeling was used to characterize the baseline as well as jet-impingement-based heat exchangers. CFD modeling showed the thermal performance improvements should holdmore » for a fully powered inverter. Increased thermal performance was observed for the jet-impingement configurations when tested at full inverter power (40 to 100 kW output power) on a dynamometer. The reliability of the jets and enhanced surfaces over time was also investigated. Experimentally, the junction-to- coolant thermal resistance was reduced by up to 12.5% for jet impingement on enhanced surfaces s compared to the baseline channel flow configuration. Base plate-to-coolant (convective) resistance was reduced by up to 37.0% for the jet-based configuration compared to the baseline, suggesting that while improvements to the cooling side reduce overall resistance, reducing the passive stack resistance may contribute to lowering overall junction-to-coolant resistance. Full inverter power testing showed reduced thermal resistance from the middle of the module baseplate to coolant of up to 16.5%. Between the improvement in thermal performance and pumping power, the coefficient of performance improved by up to 13% for the jet-based configuration.« less

Performance and Reliability of Bonded Interfaces for High-Temperature Packaging; NREL (National Renewable Energy Laboratory)

DOE Office of Scientific and Technical Information (OSTI.GOV)

DeVoto, Douglas

2015-06-10

This is a technical review of the DOE VTO EDT project EDT063, Performance and Reliability of Bonded Interfaces for High-Temperature Packaging. A procedure for analyzing the reliability of sintered-silver through experimental thermal cycling and crack propagation modeling has been outlined and results have been presented.

Development of the Lens Antenna Deployment Demonstration (LADD) shuttle-attached flight experiment

NASA Technical Reports Server (NTRS)

Hill, H.; Johnston, D.; Frauenberger, H.

1986-01-01

The primary objective of the LADD Program is to develop a technology demonstration test article that can be used for both ground and flight tests to demonstrate the structural and mechanical feasibility and reliability of the single-axis roll-out space based radar (SBR) approach. As designed, the LADD will essentially be a generic strucutural experiment which incorporates all critical technology elements of the operational satellite and is applicable to a number of future antenna systems. However, to fully determine its design integrity for meeting the lens flatness and constant geometry requirements in a zero g environment under extreme thermal conditions, the LADD must be space flight tested. By accurately surveying the structure under varying conditions the membrane tolerance-holding capabilities of the structure will be demonstrated. The flight test will provide data to verify analytical tools used to predict thermal and structural behavior. Most important, the experiment will provide an initial indication of structural damping in a zero g vacuum environment. The recently completed Solar Array Flight Experiment (SAFE) showed orbital damping greater than that experienced during ground testing. From the experience and the information obtained from LADD it is hoped that designs can be confidently extrapolated to operational satellites with apertures in the 20 m by 60 m size range.

Thermal Management and Thermal Protection Systems

NASA Technical Reports Server (NTRS)

Hasnain, Aqib

2016-01-01

During my internship in the Thermal Design Branch (ES3), I contributed to two main projects: i) novel passive thermal management system for future human exploration, ii) AVCOAT undercut thermal analysis. i) As NASA prepares to further expand human and robotic presence in space, it is well known that spacecraft architectures will be challenged with unprecedented thermal environments. Future exploration activities will have the need of thermal management systems that can provide higher reliability, mass and power reduction and increased performance. In an effort to start addressing the current technical gaps the NASA Johnson Space Center Passive Thermal Discipline has engaged in technology development activities. One of these activities was done through an in-house Passive Thermal Management System (PTMS) design for a lunar lander. The proposed PTMS, functional in both microgravity and gravity environments, consists of three main components: a heat spreader, a novel hybrid wick Variable Conductance Heat Pipe (VCHP), and a radiator. The aim of this PTMS is to keep electronics on a vehicle within their temperature limits (0 and 50 C for the current design) during all mission phases including multiple lunar day/night cycles. The VCHP was tested to verify its thermal performance. I created a thermal math model using Thermal Desktop (TD) and analyzed it to predict the PTMS performance. After testing, the test data provided a means to correlate the thermal math model. This correlation took into account conduction and convection heat transfer, representing the actual benchtop test. Since this PTMS is proposed for space missions, a vacuum test will be taking place to provide confidence that the system is functional in space environments. Therefore, the model was modified to include a vacuum chamber with a liquid nitrogen shroud while taking into account conduction and radiation heat transfer. Infrared Lamps were modelled and introduced into the model to simulate the sun's rays directly impinging on the system. Heating rate of the lamps were calculated by knowing fraction of emitted energy in a wavelength interval and the filament temperature. This version of the model can be used to predict performance of the system under vacuum with extreme cold or hot conditions. Initial testing of the PTMS showed promise, and the thermal math model predicts even better performance in thermal vacuum testing. ii) Thermal Protection Systems (TPS) are required for vehicles which enter earth's atmosphere to protect from aerodynamic heating caused by the friction between the vehicle and atmospheric gases. Orion's heat shield design has two aspects which needed to be analyzed thermally: i) a small excess of adhesive used to bond the outer AVCOAT layer to the inner composite structure tends to seep from under the AVCOAT and form a small bead in between two bricks of AVCOAT, ii) a silicone rubber with different thermophysical properties than AVCOAT fills the gap between two bricks of AVCOAT. I created a thermal model using TD to determine temperature differences that are caused by these two features. To prevent false results, all TD models must be verified against something known. In this case, the TD model was correlated to CHAR, an ablation modelling software used to analyze TPS. Analyzing a node far from the concerning features, we saw that the TD model data match CHAR data, verifying the TD model. Next, the temperature of the silicone rubber as well as the bead of adhesive were analyzed to determine if they exceeded allowable temperatures. It was determined that these two features do not have a significant effect on the max temperature of the heat shield. This model can be modified to check temperatures at various locations of the heat shield where the composite thickness varies.

Lifetime Reliability Prediction of Ceramic Structures Under Transient Thermomechanical Loads

NASA Technical Reports Server (NTRS)

Nemeth, Noel N.; Jadaan, Osama J.; Gyekenyesi, John P.

2005-01-01

An analytical methodology is developed to predict the probability of survival (reliability) of ceramic components subjected to harsh thermomechanical loads that can vary with time (transient reliability analysis). This capability enables more accurate prediction of ceramic component integrity against fracture in situations such as turbine startup and shutdown, operational vibrations, atmospheric reentry, or other rapid heating or cooling situations (thermal shock). The transient reliability analysis methodology developed herein incorporates the following features: fast-fracture transient analysis (reliability analysis without slow crack growth, SCG); transient analysis with SCG (reliability analysis with time-dependent damage due to SCG); a computationally efficient algorithm to compute the reliability for components subjected to repeated transient loading (block loading); cyclic fatigue modeling using a combined SCG and Walker fatigue law; proof testing for transient loads; and Weibull and fatigue parameters that are allowed to vary with temperature or time. Component-to-component variation in strength (stochastic strength response) is accounted for with the Weibull distribution, and either the principle of independent action or the Batdorf theory is used to predict the effect of multiaxial stresses on reliability. The reliability analysis can be performed either as a function of the component surface (for surface-distributed flaws) or component volume (for volume-distributed flaws). The transient reliability analysis capability has been added to the NASA CARES/ Life (Ceramic Analysis and Reliability Evaluation of Structures/Life) code. CARES/Life was also updated to interface with commercially available finite element analysis software, such as ANSYS, when used to model the effects of transient load histories. Examples are provided to demonstrate the features of the methodology as implemented in the CARES/Life program.

A review of passive thermal management of LED module

NASA Astrophysics Data System (ADS)

Huaiyu, Ye; Koh, Sau; van Zeijl, Henk; Gielen, A. W. J.; Guoqi, Zhang

2011-01-01

Recently, the high-brightness LEDs have begun to be designed for illumination application. The increased electrical currents used to drive LEDs lead to thermal issues. Thermal management for LED module is a key design parameter as high operation temperature directly affects their maximum light output, quality, reliability and life time. In this review, only passive thermal solutions used on LED module will be studied. Moreover, new thermal interface materials and passive thermal solutions applied on electronic equipments are discussed which have high potential to enhance the thermal performance of LED Module.

Early-Stage Research & Development | Transportation Research | NREL

Science.gov Websites

thermal conductivity of packed copper wire used in electric-drive vehicle motor applications provides a research on thermal management in copper-wound electric motors is helping to improve the performance and reliability of electric-drive vehicles. Photo by Kevin Bennion, NREL. Anisotropic Thermal Measurement Study

Spatial and Temporal Control of Hyperthermia Using Real Time Ultrasonic Thermal Strain Imaging with Motion Compensation, Phantom Study

PubMed Central

Foiret, Josquin; Ferrara, Katherine W.

2015-01-01

Mild hyperthermia has been successfully employed to induce reversible physiological changes that can directly treat cancer and enhance local drug delivery. In this approach, temperature monitoring is essential to avoid undesirable biological effects that result from thermal damage. For thermal therapies, Magnetic Resonance Imaging (MRI) has been employed to control real-time Focused Ultrasound (FUS) therapies. However, combined ultrasound imaging and therapy systems offer the benefits of simple, low-cost devices that can be broadly applied. To facilitate such technology, ultrasound thermometry has potential to reliably monitor temperature. Control of mild hyperthermia was previously achieved using a proportional-integral-derivative (PID) controller based on thermocouple measurements. Despite accurate temporal control of heating, this method is limited by the single position at which the temperature is measured. Ultrasound thermometry techniques based on exploiting the thermal dependence of acoustic parameters (such as longitudinal velocity) can be extended to create thermal maps and allow an accurate monitoring of temperature with good spatial resolution. However, in vivo applications of this technique have not been fully developed due to the high sensitivity to tissue motion. Here, we propose a motion compensation method based on the acquisition of multiple reference frames prior to treatment. The technique was tested in the presence of 2-D and 3-D physiological-scale motion and was found to provide effective real-time temperature monitoring. PID control of mild hyperthermia in presence of motion was then tested with ultrasound thermometry as feedback and temperature was maintained within 0.3°C of the requested value. PMID:26244783

Thermal management and prototype testing of Compton scattering X-ray beam position monitor for the Advanced Photon Source Upgrade

DOE PAGES

Lee, S. H.; Yang, B. X.; Collins, J. T.; ...

2017-02-07

Accurate and stable x-ray beam position monitors (XBPMs) are key elements in obtaining the desired user beam stability in the Advanced Photon Source Upgrade. In the next-generation XBPMs for the canted-undulator front ends, where two undulator beams are separated by 1.0 mrad, the lower beam power (<10 kW) per undulator allows us to explore lower-cost solutions based on Compton scattering from a diamond placed edge-on to the x-ray beam. Because of the high peak power density of the x-ray beams, this diamond experiences high temperatures and has to be clamped to a water-cooled heat spreader using thermal interface materials (TIMs),more » which play a key role in reducing the temperature of the diamond. To evaluate temperature changes through the interface via thermal simulations, the thermal contact resistance (TCR) of TIMs at an interface between two solid materials under even contact pressure must be known. This paper addresses the TCR measurements of several TIMs, including gold, silver, pyrolytic graphite sheet, and 3D graphene foam. In addition, a prototype of a Compton-scattering XBPM with diamond blades was installed at APS Beamline 24-ID-A in May 2015 and has been tested. This study presents the design of the Compton-scattering XBPM, and compares thermal simulation results obtained for the diamond blade of this XBPM by the finite element method with in situ empirical measurements obtained by using reliable infrared technology.« less

Effects of aging temperature on microstructural evolution at dissimilar metal weld interfaces

NASA Astrophysics Data System (ADS)

Choi, Kyoung Joon; Yoo, Seung Chang; Kim, Taeho; Bahn, Chi Bum; Kim, Ji Hyun

2015-07-01

From the earlier study which characterized the region of a fusion boundary between a low-alloy steel (LAS) and a Ni-based weld metal of as-welded and aged samples at 450 °C for a 30-y-equivalent time, it was observed in the microstructure that the aging treatment induced the formation and growth of Cr precipitates in the fusion boundary region because of the thermodynamic driving force. Now, this research extends the text matrix and continues the previous study by compiling all the test data, with an additional aging heat treatment conducted at 400 °C for 15- and 30-y-equivalent times (6450 and 12,911 h, respectively). The results for the extended test matrix primarily represent the common features of and disparities in the effects of thermal aging on the aged samples at two different heat-treatment temperatures (400 and 450 °C). Although no difference was expected between the samples, because the heat treatment conditions simulate thermal aging effects during the same service time of 30 y, the sample aged at 450 °C exhibited slightly more severe effects of thermal aging than the sample aged at 400 °C. Nevertheless, the trends for these effects are similar and the simulation of thermal aging effects for a light-water reactor appears to be reliable. However, according to a simulation of the same degree of thermal aging effects, it appears that the activation energy for Cr diffusion should be larger than the numerical value used in this study.

Evaluation of Microbolometer-Based Thermography for Gossamer Space Structures

NASA Technical Reports Server (NTRS)

Miles, Jonathan J.; Blandino, Joseph R.; Jenkins, Christopher H.; Pappa, Richard S.; Banik, Jeremy; Brown, Hunter; McEvoy, Kiley

2005-01-01

In August 2003, NASA's In-Space Propulsion Program contracted with our team to develop a prototype on-board Optical Diagnostics System (ODS) for solar sail flight tests. The ODS is intended to monitor sail deployment as well as structural and thermal behavior, and to validate computational models for use in designing future solar sail missions. This paper focuses on the thermography aspects of the ODS. A thermal model was developed to predict local sail temperature variations as a function of sail tilt to the sun, billow depth, and spectral optical properties of front and back sail surfaces. Temperature variations as small as 0.5 C can induce significant thermal strains that compare in magnitude to mechanical strains. These thermally induced strains may result in changes in shape and dynamics. The model also gave insight into the range and sensitivity required for in-flight thermal measurements and supported the development of an ABAQUS-coupled thermo-structural model. The paper also discusses three kinds of tests conducted to 1) determine the optical properties of candidate materials; 2) evaluate uncooled microbolometer-type infrared imagers; and 3) operate a prototype imager with the ODS baseline configuration. (Uncooled bolometers are less sensitive than cooled ones, but may be necessary because of restrictive ODS mass and power limits.) The team measured the spectral properties of several coated polymer samples at various angles of incidence. Two commercially available uncooled microbolometer imagers were compared, and it was found that reliable temperature measurements are feasible for both coated and uncoated sides of typical sail membrane materials.

International Space Station Active Thermal Control Sub-System On-Orbit Pump Performance and Reliability Using Liquid Ammonia as a Coolant

NASA Technical Reports Server (NTRS)

Morton, Richard D.; Jurick, Matthew; Roman, Ruben; Adamson, Gary; Bui, Chinh T.; Laliberte, Yvon J.

2011-01-01

The International Space Station (ISS) contains two Active Thermal Control Sub-systems (ATCS) that function by using a liquid ammonia cooling system collecting waste heat and rejecting it using radiators. These subsystems consist of a number of heat exchangers, cold plates, radiators, the Pump and Flow Control Subassembly (PFCS), and the Pump Module (PM), all of which are Orbital Replaceable Units (ORU's). The PFCS provides the motive force to circulate the ammonia coolant in the Photovoltaic Thermal Control Subsystem (PVTCS) and has been in operation since December, 2000. The Pump Module (PM) circulates liquid ammonia coolant within the External Active Thermal Control Subsystem (EATCS) cooling the ISS internal coolant (water) loops collecting waste heat and rejecting it through the ISS radiators. These PM loops have been in operation since December, 2006. This paper will discuss the original reliability analysis approach of the PFCS and Pump Module, comparing them against the current operational performance data for the ISS External Thermal Control Loops.

Performance Evaluation of Pressure Transducers for Water Impacts

NASA Technical Reports Server (NTRS)

Vassilakos, Gregory J.; Stegall, David E.; Treadway, Sean

2012-01-01

The Orion Multi-Purpose Crew Vehicle is being designed for water landings. In order to benchmark the ability of engineering tools to predict water landing loads, test programs are underway for scale model and full-scale water impacts. These test programs are predicated on the reliable measurement of impact pressure histories. Tests have been performed with a variety of pressure transducers from various manufacturers. Both piezoelectric and piezoresistive devices have been tested. Effects such as thermal shock, pinching of the transducer head, and flushness of the transducer mounting have been studied. Data acquisition issues such as sampling rate and anti-aliasing filtering also have been studied. The response of pressure transducers have been compared side-by-side on an impulse test rig and on a 20-inch diameter hemisphere dropped into a pool of water. The results have identified a range of viable configurations for pressure measurement dependent on the objectives of the test program.

Development of a prototype thermoelectric space cooling system using phase change material to improve the performance

NASA Astrophysics Data System (ADS)

Zhao, Dongliang

The thermoelectric cooling system has advantages over conventional vapor compression cooling devices, including compact in size, light in weight, high reliability, no mechanical moving parts, no refrigerant, being powered by direct current, and easily switching between cooling and heating modes. However, it has been long suffering from its relatively high cost and low energy efficiency, which has restricted its usage to niche applications, such as space missions, portable cooling devices, scientific and medical equipment, where coefficient of performance (COP) is not as important as reliability, energy availability, and quiet operation environment. Enhancement of thermoelectric cooling system performance generally relies on two methods: improving thermoelectric material efficiency and through thermoelectric cooling system thermal design. This research has been focused on the latter one. A prototype thermoelectric cooling system integrated with phase change material (PCM) thermal energy storage unit for space cooling has been developed. The PCM thermal storage unit used for cold storage at night, functions as the thermoelectric cooling system's heat sink during daytime's cooling period and provides relatively lower hot side temperature for the thermoelectric cooling system. The experimental test of the prototype system in a reduced-scale chamber has realized an average cooling COP of 0.87, with the maximum value of 1.22. Another comparison test for efficacy of PCM thermal storage unit shows that 35.3% electrical energy has been saved from using PCM for the thermoelectric cooling system. In general, PCM faces difficulty of poor thermal conductivity at both solid and liquid phases. This system implemented a finned inner tube to increase heat transfer during PCM charging (melting) process that directly impacts thermoelectric system's performance. A simulation tool for the entire system has been developed including mathematical models for a single thermoelectric module, for the thermoelectric cooling unit, for the PCM thermal storage unit, and for the outdoor air-water heat exchanger. When modeling PCM thermal storage unit, the enthalpy method has been adopted. Since natural convection has been observed in experiments playing a key effect on heat transfer in PCM, a staged effective thermal conductivity (ke) concept and modified Rayleigh (Ra) number formula have been developed to better capture natural convection's variable effects during the PCM charging process. Therefore, a modeling-based design procedure for thermoelectric cooling system integrating with PCM has been proposed. A case study has been completed for a model office room to demonstrate the qualitative and quantitative evaluations to the major system components. Results of this research can be extended to other applications in relevant areas. For instance, the proposed PCM thermal storage unit can be applied to integration with water-cooled conventional air-conditioning devices. Instead of using water cooling, a case study of using the proposed PCM unit for a water-cooled air-conditioner shows a COP increase of more than 25.6%.

Development of Thermal Barriers for Solid Rocket Motor Nozzle Joints

NASA Technical Reports Server (NTRS)

Steinetz, Bruce M.; Dunlap, Patrick H., Jr.

1999-01-01

The Space Shuttle solid rocket motor case assembly joints are sealed using conventional 0-ring seals. The 5500+F combustion gases are kept a safe distance away from the seals by thick layers of insulation. Special joint-fill compounds are used to fill the joints in the insulation to prevent a direct flowpath to the seals. On a number of occasions. NASA has observed in several of the rocket nozzle assembly joints hot gas penetration through defects in the joint- fill compound. The current nozzle-to-case joint design incorporates primary, secondary and wiper (inner-most) 0-rings and polysulfide joint-fill compound. In the current design, 1 out of 7 motors experience hot gas to the wiper 0-ring. Though the condition does not threaten motor safety, evidence of hot gas to the wiper 0-ring results in extensive reviews before resuming flight. NASA and solid rocket motor manufacturer Thiokol are working to improve the nozzle-to-case joint design by implementing a more reliable J-leg design and a thermal barrier, This paper presents burn-resistance, temperature drop, flow and resiliency test results for several types of NASA braided carbon-fiber thermal barriers. Burn tests were performed to determine the time to burn through each of the thermal barriers when exposed to the flame of an oxy-acetylene torch (5500 F), representative of the 5500 F solid rocket motor combustion temperatures. Thermal barriers braided out of carbon fibers endured the flame for over 6 minutes, three times longer than solid rocket motor burn time. Tests were performed on two thermal barrier braid architectures, denoted Carbon-3 and Carbon-6, to measure the temperature drop across and along the barrier in a compressed state when subjected to the flame of an oxyacetylene torch. Carbon-3 and Carbon-6 thermal barriers were excellent insulators causing temperature drops through their diameter of up to a 2800 and 2560 F. respectively. Gas temperature 1/4" downstream of the thermal barrier were within the downstream Viton 0-ring temperature limit of 600 F. Carbon-6 performed extremely well in subscale rocket "char" motor tests when subjected to hot gas at 3200 F for an 11 second rocket firing, simulating the maximum downstream joint cavity fill time. The thermal barrier reduced the incoming hot gas temperature by 2200 F in an intentionally oversized gap defect, spread the incoming jet flow, and blocked hot slag, thereby offering protection to the downstream 0-rings.

Computational Modeling Develops Ultra-Hard Steel

NASA Technical Reports Server (NTRS)

2007-01-01

Glenn Research Center's Mechanical Components Branch developed a spiral bevel or face gear test rig for testing thermal behavior, surface fatigue, strain, vibration, and noise; a full-scale, 500-horsepower helicopter main-rotor transmission testing stand; a gear rig that allows fundamental studies of the dynamic behavior of gear systems and gear noise; and a high-speed helical gear test for analyzing thermal behavior for rotorcraft. The test rig provides accelerated fatigue life testing for standard spur gears at speeds of up to 10,000 rotations per minute. The test rig enables engineers to investigate the effects of materials, heat treat, shot peen, lubricants, and other factors on the gear's performance. QuesTek Innovations LLC, based in Evanston, Illinois, recently developed a carburized, martensitic gear steel with an ultra-hard case using its computational design methodology, but needed to verify surface fatigue, lifecycle performance, and overall reliability. The Battelle Memorial Institute introduced the company to researchers at Glenn's Mechanical Components Branch and facilitated a partnership allowing researchers at the NASA Center to conduct spur gear fatigue testing for the company. Testing revealed that QuesTek's gear steel outperforms the current state-of-the-art alloys used for aviation gears in contact fatigue by almost 300 percent. With the confidence and credibility provided by the NASA testing, QuesTek is commercializing two new steel alloys. Uses for this new class of steel are limitless in areas that demand exceptional strength for high throughput applications.

Drought and Heat Wave Impacts on Electricity Grid Reliability in Illinois

NASA Astrophysics Data System (ADS)

Stillwell, A. S.; Lubega, W. N.

2016-12-01

A large proportion of thermal power plants in the United States use cooling systems that discharge large volumes of heated water into rivers and cooling ponds. To minimize thermal pollution from these discharges, restrictions are placed on temperatures at the edge of defined mixing zones in the receiving waters. However, during extended hydrological droughts and heat waves, power plants are often granted thermal variances permitting them to exceed these temperature restrictions. These thermal variances are often deemed necessary for maintaining electricity reliability, particularly as heat waves cause increased electricity demand. Current practice, however, lacks tools for the development of grid-scale operational policies specifying generator output levels that ensure reliable electricity supply while minimizing thermal variances. Such policies must take into consideration characteristics of individual power plants, topology and characteristics of the electricity grid, and locations of power plants within the river basin. In this work, we develop a methodology for the development of these operational policies that captures necessary factors. We develop optimal rules for different hydrological and meteorological conditions, serving as rule curves for thermal power plants. The rules are conditioned on leading modes of the ambient hydrological and meteorological conditions at the different power plant locations, as the locations are geographically close and hydrologically connected. Heat dissipation in the rivers and cooling ponds is modeled using the equilibrium temperature concept. Optimal rules are determined through a Monte Carlo sampling optimization framework. The methodology is applied to a case study of eight power plants in Illinois that were granted thermal variances in the summer of 2012, with a representative electricity grid model used in place of the actual electricity grid.

Reliability Analysis of Brittle Material Structures - Including MEMS(?) - With the CARES/Life Program

NASA Technical Reports Server (NTRS)

Nemeth, Noel N.

2002-01-01

Brittle materials are being used, or considered, for a wide variety of high tech applications that operate in harsh environments, including static and rotating turbine parts. thermal protection systems, dental prosthetics, fuel cells, oxygen transport membranes, radomes, and MEMS. Designing components to sustain repeated load without fracturing while using the minimum amount of material requires the use of a probabilistic design methodology. The CARES/Life code provides a general-purpose analysis tool that predicts the probability of failure of a ceramic component as a function of its time in service. For this presentation an interview of the CARES/Life program will be provided. Emphasis will be placed on describing the latest enhancements to the code for reliability analysis with time varying loads and temperatures (fully transient reliability analysis). Also, early efforts in investigating the validity of using Weibull statistics, the basis of the CARES/Life program, to characterize the strength of MEMS structures will be described as as well as the version of CARES/Life for MEMS (CARES/MEMS) being prepared which incorporates single crystal and edge flaw reliability analysis capability. It is hoped this talk will open a dialog for potential collaboration in the area of MEMS testing and life prediction.

Supporting Technology at GRC to Mitigate Risk as Stirling Power Conversion Transitions to Flight

NASA Technical Reports Server (NTRS)

Schreiber, Jeffrey G.; Thieme, Lanny G.; Wong, Wayne A.

2009-01-01

Stirling power conversion technology has been reaching more advanced levels of maturity during its development for space power applications. The current effort is in support of the Advanced Stirling Radioisotope Generator (ASRG), which is being developed by the U.S. Department of Energy (DOE), Lockheed Martin Space Systems Company (LMSSC), Sunpower Inc., and the NASA Glenn Research Center (GRC). This generator would use two high-efficiency Advanced Stirling Convertors (ASCs) to convert thermal energy from a radioisotope heat source into electricity. Of paramount importance is the reliability of the power system and as a part of this, the Stirling power convertors. GRC has established a supporting technology effort with tasks in the areas of reliability, convertor testing, high-temperature materials, structures, advanced analysis, organics, and permanent magnets. The project utilizes the matrix system at GRC to make use of resident experts in each of the aforementioned fields. Each task is intended to reduce risk and enhance reliability of the convertor as this technology transitions toward flight status. This paper will provide an overview of each task, outline the recent efforts and accomplishments, and show how they mitigate risk and impact the reliability of the ASC s and ultimately, the ASRG.

Supporting Technology at GRC to Mitigate Risk as Stirling Power Conversion Transitions to Flight

NASA Technical Reports Server (NTRS)

Schreiber, Jeffrey G.; Thieme, Lanny G.; Wong, Wayne A.

2008-01-01

Stirling power conversion technology has been reaching more advanced levels of maturity during its development for space power applications. The current effort is in support of the Advanced Stirling Radioisotope Generator (ASRG), which is being developed by the U.S. Department of Energy (DOE), Lockheed Martin Space Systems Company (LMSSC), Sunpower Inc., and the NASA Glenn Research Center (GRC). This generator would use two high-efficiency Advanced Stirling Convertors (ASCs) to convert thermal energy from a radioisotope heat source into electricity. Of paramount importance is the reliability of the power system and as a part of this, the Stirling power convertors. GRC has established a supporting technology effort with tasks in the areas of reliability, convertor testing, high-temperature materials, structures, advanced analysis, organics, and permanent magnets. The project utilizes the matrix system at GRC to make use of resident experts in each of the aforementioned fields. Each task is intended to reduce risk and enhance reliability of the convertor as this technology transitions toward flight status. This paper will provide an overview of each task, outline the recent efforts and accomplishments, and show how they mitigate risk and impact the reliability of the ASC s and ultimately, the ASRG.

AGUACLARA: CLEAN WATER FOR SMALL COMMUNITIES

EPA Science Inventory

We will systematically evaluate commercially available solar thermal collectors and thermal storage systems for use in residential scale co-generative heat and electrical power systems. Currently, reliable data is unavailable over the range of conditions and installations thes...

Delamination-Indicating Thermal Barrier Coatings

NASA Technical Reports Server (NTRS)

Eldridge, Jeffrey I.

2007-01-01

The risk of premature failure of thermal barrier coatings (TBCs), typically composed of yttria-stabilized zirconia (YSZ), compromises the reliability of TBCs used to provide thermal protection for turbine engine components. Unfortunately, TBC delamination proceeds well beneath the TBC surface and cannot be monitored by visible inspection. Nondestructive diagnostic tools that could reliably probe the subsurface damage state of TBCs would alleviate the risk of TBC premature failure by indicating when the TBC needs to be replaced before the level of TBC damage threatens engine performance or safety. To meet this need, a new coating design for thermal barrier coatings (TBCs) that are self-indicating for delamination has been successfully implemented by incorporating a europium-doped luminescent sublayer at the base of a TBC composed of YSZ. The luminescent sublayer has the same YSZ composition as the rest of the TBC except for the addition of low-level europium doping and therefore does not alter TBC performance.

The application of probabilistic design theory to high temperature low cycle fatigue

NASA Technical Reports Server (NTRS)

Wirsching, P. H.

1981-01-01

Metal fatigue under stress and thermal cycling is a principal mode of failure in gas turbine engine hot section components such as turbine blades and disks and combustor liners. Designing for fatigue is subject to considerable uncertainty, e.g., scatter in cycles to failure, available fatigue test data and operating environment data, uncertainties in the models used to predict stresses, etc. Methods of analyzing fatigue test data for probabilistic design purposes are summarized. The general strain life as well as homo- and hetero-scedastic models are considered. Modern probabilistic design theory is reviewed and examples are presented which illustrate application to reliability analysis of gas turbine engine components.

Reliability of Next Generation Power Electronics Packaging Under Concurrent Vibration, Thermal and High Power Loads

DTIC Science & Technology

2008-02-01

combined thermal g effect and initial current field. The model is implemented using Abaqus user element subroutine and verified against the experimental...Finite Element Formulation The proposed model is implemented with ABAQUS general purpose finite element program using thermal -displacement analysis...option. ABAQUS and other commercially available finite element codes do not have the capability to solve general electromigration problem directly. Thermal

{sup 6}LiF oleic acid capped nanoparticles entrapment in siloxanes for thermal neutron detection

DOE Office of Scientific and Technical Information (OSTI.GOV)

Carturan, S., E-mail: sara.carturan@lnl.infn.it; Maggioni, G., E-mail: Gianluigi.maggioni@lnl.infn.it; INFN, Laboratori Nazionali di Legnaro, Viale dell’Università 2, 35020 Legnaro

2016-07-07

The good light output of siloxane based scintillators as displayed under γ-rays and α particles has been exploited here to obtain clear and reliable response toward thermal neutrons. Sensitization towards thermal neutrons has been pursued by adding {sup 6}LiF, in form of nanoparticles. Aiming at the enhancement of compatibility between the inorganic nanoparticles and the low polarity, siloxane based surrounding medium, oleic acid-capped {sup 6}LiF nanoparticles have been synthesized by thermal decomposition of Li trifluoroacetate. Thin pellets siloxane scintillator maintained their optical transmittance up to weight load of 2% of {sup 6}Li. Thin samples with increasing {sup 6}Li concentration andmore » thicker ones with fixed {sup 6}Li amount have been prepared and tested with several sources (α, γ-rays, moderated neutrons). Light output as high as 80% of EJ212 under α irradiation was measured with thin samples, and negligible changes have been observed as a result of {sup 6}LiF addition. In case of thick samples, severe light loss has been observed, as induced by opacity. Nevertheless, thermal neutrons detection has been assessed and the data have been compared with GS20, based on Li glass, taken as a reference material.« less

Mission definition study for Stanford relativity satellite. Volume 3: Appendices

NASA Technical Reports Server (NTRS)

1971-01-01

An analysis is presented for the cost of the mission as a function of the following variables: amount of redundancy in the spacecraft, amount of care taken in building the spacecraft (functional and environmental tests, screening of components, quality control, etc), and the number of flights necessary to accomplish the mission. Thermal analysis and mathematical models for the experimental components are presented. The results of computer structural and stress analyses for support and cylinders are discussed. Reliability, quality control, and control system simulation by computer are also considered.

885-nm laser diode array pumped ceramic Nd:YAG master oscillator power amplifier system

NASA Astrophysics Data System (ADS)

Yu, Anthony W.; Li, Steven X.; Stephen, Mark A.; Seas, Antonios; Troupaki, Elisavet; Vasilyev, Aleksey; Conley, Heather; Filemyr, Tim; Kirchner, Cynthia; Rosanova, Alberto

2010-04-01

The objective of this effort is to develop more reliable, higher efficiency diode pumped Nd:YAG laser systems for space applications by leveraging technology investments from the DoD and other commercial industries. Our goal is to design, build, test and demonstrate the effectiveness of combining 885 nm laser pump diodes and the use of ceramic Nd:YAG for future flight missions. The significant reduction in thermal loading on the gain medium by the use of 885 nm pump lasers will improve system efficiency.

Structural design and analysis for an ultra low CTE optical bench for the Hubble Space Telescope corrective optics

NASA Technical Reports Server (NTRS)

Neam, Douglas C.; Gerber, John D.

1992-01-01

The stringent stability requirements of the Corrective Optics Space Telescope Axial Replacement (COSTAR) necessitates a Deployable Optical Bench (DOB) with both a low CTE and high resonant frequency. The DOB design consists of a monocoque thin shell structure which marries metallic machined parts with graphite epoxy formed structure. Structural analysis of the DOB has been integrated into the laminate design and optimization process. Also, the structural analytical results are compared with vibration and thermal test data to assess the reliability of the analysis.

Castellated tiles as the beam-facing components for the diagnostic calorimeter of the negative ion source SPIDER

DOE Office of Scientific and Technical Information (OSTI.GOV)

Peruzzo, S., E-mail: simone.peruzzo@igi.cnr.it; Cervaro, V.; Dalla Palma, M.

2016-02-15

This paper presents the results of numerical simulations and experimental tests carried out to assess the feasibility and suitability of graphite castellated tiles as beam-facing component in the diagnostic calorimeter of the negative ion source SPIDER (Source for Production of Ions of Deuterium Extracted from Radio frequency plasma). The results indicate that this concept could be a reliable, although less performing, alternative for the present design based on carbon fiber composite tiles, as it provides thermal measurements on the required spatial scale.

Castellated tiles as the beam-facing components for the diagnostic calorimeter of the negative ion source SPIDER

NASA Astrophysics Data System (ADS)

Peruzzo, S.; Cervaro, V.; Dalla Palma, M.; Delogu, R.; De Muri, M.; Fasolo, D.; Franchin, L.; Pasqualotto, R.; Pimazzoni, A.; Rizzolo, A.; Tollin, M.; Zampieri, L.; Serianni, G.

2016-02-01

This paper presents the results of numerical simulations and experimental tests carried out to assess the feasibility and suitability of graphite castellated tiles as beam-facing component in the diagnostic calorimeter of the negative ion source SPIDER (Source for Production of Ions of Deuterium Extracted from Radio frequency plasma). The results indicate that this concept could be a reliable, although less performing, alternative for the present design based on carbon fiber composite tiles, as it provides thermal measurements on the required spatial scale.

Structural design considerations for micromachined solid-oxide fuel cells

NASA Astrophysics Data System (ADS)

Srikar, V. T.; Turner, Kevin T.; Andrew Ie, Tze Yung; Spearing, S. Mark

Micromachined solid-oxide fuel cells (μSOFCs) are among a class of devices being investigated for portable power generation. Optimization of the performance and reliability of such devices requires robust, scale-dependent, design methodologies. In this first analysis, we consider the structural design of planar, electrolyte-supported, μSOFCs from the viewpoints of electrochemical performance, mechanical stability and reliability, and thermal behavior. The effect of electrolyte thickness on fuel cell performance is evaluated using a simple analytical model. Design diagrams that account explicitly for thermal and intrinsic residual stresses are presented to identify geometries that are resistant to fracture and buckling. Analysis of energy loss due to in-plane heat conduction highlights the importance of efficient thermal isolation in microscale fuel cell design.

Toward a mechanistic understanding of the damage evolution of SnAgCu solder joints in accelerated thermal cycling test

NASA Astrophysics Data System (ADS)

Mahin Shirazi, Sam

Accelerated thermal cycling (ATC) tests are the most commonly used tests for the thermo-mechanical performance assessment of microelectronics assemblies. Currently used reliability models have failed to incorporate the microstructural dependency of lead free solder joint behavior and its microstructure evolution during cycling. Thus, it is essential to have a mechanistic understanding of the effect of cycling parameters on damage evolution and failure of lead free solder joints in ATC. Recrystallization has been identified as the damage rate controlling mechanism in ATC. Usually it takes 1/3 of life for completion of recrystallization regardless of cycling parameters. Thus, the life of the solder joints can be predicted by estimating global recrystallization. The objective of the first part of the study was to examine whether the damage scenario applies in service is the same as the harsh thermal cycling tests (i.e. 0/100 °C and -40/125 °C) commonly used in industry. Microstructure analysis results on a variety of lead free solder SnAgCu assemblies subjected to the both harsh (0/100 °C) and mild (20/80 °C) ATC confirmed similar failure mechanism under the both testing conditions. Sn grain morphology (interlaced versus beach ball) has a significant effect on the thermo-mechanical performance (and thus the model) of the lead free solder joints. The longer thermal cycling lifetime observed in the interlaced solder joints subjected to the ATC compared to the beach ball structure was correlated to the different initial microstructure and the microstructure evolution during cycling. For the modeling proposes, the present study was focused on Sn-Ag-Cu solder joints with either a single Sn grain or beach ball structure. Microstructural analysis results of the simulated thermal cycling experiment revealed that, the life can be approximated as determined by the accumulation of a certain amount of work during the high temperature dwells. Finally the effect of precipitates spacing on acceleration factor was investigated. Results indicated that a smaller initial precipitate spacing would tend to result in a longer life in mild thermal cycling/service (where there is lower stresses). Accordingly, it is essential to incorporate the dependence of damage rate (i.e. recrystallization) on precipitate coarsening in any predictions.

Testing of a Wireless Sensor System for Instrumented Thermal Protection Systems

NASA Technical Reports Server (NTRS)

Kummer, Allen T.; Weir, Erik D.; Morris, Trey J.; Friedenberger, Corey W.; Singh, Aseem; Capuro, Robert M.; Bilen, Sven G.; Fu, Johnny; Swanson, Gregory T.; Hash, David B.

2011-01-01

Funded by NASA's Constellation Universities Institutes Project (CUIP), we have been developing and testing a system to wirelessly power and collect data from sensors on space platforms in general and, in particular, the harsh environment of spacecraft re-entry. The elimination of wires and associated failures such as chafing, sparking, ageing, and connector issues can increase reliability and design flexibility while reducing costs. These factors present an appealing case for the pursuit of wireless solutions for harsh environments, particularly for their use in space and on spacecraft. We have designed and built a prototype wireless sensor system. The system, with capabilities similar to that of a wired sensor system, was tested in NASA Ames Research Center s Aerodynamic Heating Facility and Interaction Heating Facility. This paper discusses the overall development effort, testing results, as well as future directions.

Design, fabrication, and operation of a test rig for high-speed tapered-roller bearings

NASA Technical Reports Server (NTRS)

Signer, H. R.

1974-01-01

A tapered-roller bearing test machine was designed, fabricated and successfully operated at speeds to 20,000 rpm. Infinitely variable radial loads to 26,690 N (6,000 lbs.) and thrust loads to 53,380 N (12,000 lbs.) can be applied to test bearings. The machine instrumentation proved to have the accuracy and reliability required for parametric bearing performance testing and has the capability of monitoring all programmed test parameters at continuous operation during life testing. This system automatically shuts down a test if any important test parameter deviates from the programmed conditions, or if a bearing failure occurs. A lubrication system was developed as an integral part of the machine, capable of lubricating test bearings by external jets and by means of passages feeding through the spindle and bearing rings into the critical internal bearing surfaces. In addition, provisions were made for controlled oil cooling of inner and outer rings to effect the type of bearing thermal management that is required when testing at high speeds.

Self-Cleaning Anticondensing Glass via Supersonic Spraying of Silver Nanowires, Silica, and Polystyrene Nanoparticles.

PubMed

Lee, Jong-Gun; An, Seongpil; Kim, Tae-Gun; Kim, Min-Woo; Jo, Hong-Seok; Swihart, Mark T; Yarin, Alexander L; Yoon, Sam S

2017-10-11

We have sequentially deposited layers of silver nanowires (AgNWs), silicon dioxide (SiO 2 ) nanoparticles, and polystyrene (PS) nanoparticles on uncoated glass by a rapid low-cost supersonic spraying method to create antifrosting, anticondensation, and self-cleaning glass. The conductive silver nanowire network embedded in the coating allows electrical heating of the glass surface. Supersonic spraying is a single-step coating technique that does not require vacuum. The fabricated multifunctional glass was characterized by X-ray diffraction analysis (XRD), scanning electron microscopy (SEM), atomic force microscopy (AFM), ultraviolet-visible spectroscopy, and transmission electron microscopy (TEM). The thermal insulation and antifrosting performance were demonstrated using infrared thermal imaging. The reliability of the electrical heating function was tested through extensive cycling. This transparent multifunctional coating holds great promise for use in various smart window designs.

Evaluation of Different Techniques of Active Thermography for Quantification of Artificial Defects in Fiber-Reinforced Composites Using Thermal and Phase Contrast Data Analysis

NASA Astrophysics Data System (ADS)

Maierhofer, Christiane; Röllig, Mathias; Gower, Michael; Lodeiro, Maria; Baker, Graham; Monte, Christian; Adibekyan, Albert; Gutschwager, Berndt; Knazowicka, Lenka; Blahut, Ales

2018-05-01

For assuring the safety and reliability of components and constructions in energy applications made of fiber-reinforced polymers (e.g., blades of wind turbines and tidal power plants, engine chassis, flexible oil and gas pipelines) innovative non-destructive testing methods are required. Within the European project VITCEA complementary methods (shearography, microwave, ultrasonics and thermography) have been further developed and validated. Together with partners from the industry, test specimens have been constructed and selected on-site containing different artificial and natural defect artefacts. As base materials, carbon and glass fibers in different orientations and layering embedded in different matrix materials (epoxy, polyamide) have been considered. In this contribution, the validation of flash and lock-in thermography to these testing problems is presented. Data analysis is based on thermal contrasts and phase evaluation techniques. Experimental data are compared to analytical and numerical models. Among others, the influence of two different types of artificial defects (flat bottom holes and delaminations) with varying diameters and depths and of two different materials (CFRP and GFRP) with unidirectional and quasi-isotropic fiber alignment is discussed.

Coolant effectiveness in dental cutting with air-turbine handpieces.

PubMed

Leung, Brian T W; Dyson, John E; Darvell, Brian W

2012-03-01

To establish a strategy for evaluating coolant effectiveness and to compare typical cooling conditions used in dental cutting. A test system comprising a resistive heat source and an array of four type K thermocouples was used to compare the cooling effectiveness of air alone, water stream alone, and an air-water spray, as delivered by representative air-turbine handpieces. Mean temperature change at the four sites was recorded for a range of water flow rates in the range 10 to 90 mL min(-1), with and without air, and with and without the turbine running. The thermal resistance of the system, R, was calculated as the temperature change per watt (KW(-1)). For wet cooling (water stream and air-water spray), R was 5.1 to 11.5 KW(-1), whereas for air coolant alone the range was 18.5 to 30.7 KW(-1). R for air-water spray was lower than for water stream cooling at the same flow rate. The thermal resistivity approach is a viable means of comparative testing of cooling efficacy in simulated dental cutting. It may provide a reliable means of testing handpiece nozzle design, thus enabling the development of more efficient cooling.

Kinetic Monte Carlo simulations for transient thermal fields: Computational methodology and application to the submicrosecond laser processes in implanted silicon.

PubMed

Fisicaro, G; Pelaz, L; Lopez, P; La Magna, A

2012-09-01

Pulsed laser irradiation of damaged solids promotes ultrafast nonequilibrium kinetics, on the submicrosecond scale, leading to microscopic modifications of the material state. Reliable theoretical predictions of this evolution can be achieved only by simulating particle interactions in the presence of large and transient gradients of the thermal field. We propose a kinetic Monte Carlo (KMC) method for the simulation of damaged systems in the extremely far-from-equilibrium conditions caused by the laser irradiation. The reference systems are nonideal crystals containing point defect excesses, an order of magnitude larger than the equilibrium density, due to a preirradiation ion implantation process. The thermal and, eventual, melting problem is solved within the phase-field methodology, and the numerical solutions for the space- and time-dependent thermal field were then dynamically coupled to the KMC code. The formalism, implementation, and related tests of our computational code are discussed in detail. As an application example we analyze the evolution of the defect system caused by P ion implantation in Si under nanosecond pulsed irradiation. The simulation results suggest a significant annihilation of the implantation damage which can be well controlled by the laser fluence.

Evaluation of miniature single-wire sheathed thermocouples for turbine blade temperature measurement

NASA Technical Reports Server (NTRS)

Hollanda, R.

1979-01-01

Chromel Alumel thermocouples were used, with sheath diameters of 0.15 and 0.25 mm. Tests were conducted at temperatures ranging from 750 to 1250 K. Both steady state and thermal cycling tests were performed for times up to 200 hours. Initial testing was performed in a low velocity gas stream for long time periods using a Meker-type burner. Additional testing was done in a high velocity gas stream for short time periods using a hot gas tunnel and also in a J75 jet engine. A total of eleven 0.15 mm diameter thermocouples and six 0.25 mm diameter thermocouples were tested. Drift rates up to 2.5% in 10 hours were observed. Photomicrographs show that this design is near the limit of miniaturization based on present manufacturing capabilities. Results indicate that the effects of miniaturization on reliability and accuracy must be considered when choosing thermocouples for a particular application.

The impact of hydrogenation on the thermal transport of silicene

NASA Astrophysics Data System (ADS)

Liu, Zeyu; Wu, Xufei; Luo, Tengfei

2017-06-01

Silicene, the silicon counterpart of graphene, has been identified as a promising 2D material for electronics applications. The reported very low thermal conductivity of silicene can potentially pose challenges on the thermal management of such nanoelectronics, which can in turn influence the device performance and reliability. Although the thermal conductivity of silicene has been studied, the impact of hydrogenation of silicene, which can happen spontaneously due to the resultant lower energy state, on its thermal transport ability is not clear. In this paper, we use first-principles calculations and iterative solution of phonon Boltzmann transport equation (BTE) to investigate and compare the thermal transport property of silicene and hydrogenated silicene. Surprisingly, we predict that the hydrogenation can lead to a large increase in thermal conductivity (from 22.5 W m-1 K-1 for silicene to 78.0 W m-1 K-1 for hydrogenated silicene at 300 K). We also find that the main contributor for such an improvement is the transverse acoustic phonon modes, and the reasons are the reduced anharmonicity as well as the reduced three-phonon scattering phase space after hydrogenation. This research may help better understand thermal transport in functionalized 2D materials and inspire new strategies to manipulate their thermal properties, which is of critical importance for designing high performance and reliable nanoelectronic devices.

Cyclic and low temperature effects on microcircuits

NASA Technical Reports Server (NTRS)

Weissflug, V. A.; Sisul, E. V.

1977-01-01

Cyclic temperature and low temperature operating life tests, and pre-/post-life device evaluations were used to determine the degrading effects of thermal environments on microcircuit reliability. Low power transistor-transistor-logic gates and linear devices were included in each test group. Device metallization systems included aluminum metallization/aluminum wire, aluminum metallization/gold wire, and gold metallization/gold wire. Fewer than 2% electrical failures were observed during the cyclic and low temperature life tests and the post-life evaluations revealed approximately 2% bond pull failures. Reconstruction of aluminum die metallization was observed in all devices and the severity of the reconstruction appeared to be directly related to the magnitude of the temperature excursion. All types of bonds except the gold/gold bonds were weakened by exposure to repeated cyclic temperature stress.

Strategic need for a multi-purpose thermal hydraulic loop for support of advanced reactor technologies

DOE Office of Scientific and Technical Information (OSTI.GOV)

O'Brien, James E.; Sabharwall, Piyush; Yoon, Su -Jong

2014-09-01

This report presents a conceptual design for a new high-temperature multi fluid, multi loop test facility for the INL to support thermal hydraulic, materials, and thermal energy storage research for nuclear and nuclear-hybrid applications. In its initial configuration, the facility will include a high-temperature helium loop, a liquid salt loop, and a hot water/steam loop. The three loops will be thermally coupled through an intermediate heat exchanger (IHX) and a secondary heat exchanger (SHX). Research topics to be addressed with this facility include the characterization and performance evaluation of candidate compact heat exchangers such as printed circuit heat exchangers (PCHEs)more » at prototypical operating conditions, flow and heat transfer issues related to core thermal hydraulics in advanced helium-cooled and salt-cooled reactors, and evaluation of corrosion behavior of new cladding materials and accident-tolerant fuels for LWRs at prototypical conditions. Based on its relevance to advanced reactor systems, the new facility has been named the Advanced Reactor Technology Integral System Test (ARTIST) facility. Research performed in this facility will advance the state of the art and technology readiness level of high temperature intermediate heat exchangers (IHXs) for nuclear applications while establishing the INL as a center of excellence for the development and certification of this technology. The thermal energy storage capability will support research and demonstration activities related to process heat delivery for a variety of hybrid energy systems and grid stabilization strategies. Experimental results obtained from this research will assist in development of reliable predictive models for thermal hydraulic design and safety codes over the range of expected advanced reactor operating conditions. Proposed/existing IHX heat transfer and friction correlations and criteria will be assessed with information on materials compatibility and instrumentation needs. The experimental database will guide development of appropriate predictive methods and be available for code verification and validation (V&V) related to these systems.« less

HALT to qualify electronic packages: a proof of concept

NASA Astrophysics Data System (ADS)

Ramesham, Rajeshuni

2014-03-01

A proof of concept of the Highly Accelerated Life Testing (HALT) technique was explored to assess and optimize electronic packaging designs for long duration deep space missions in a wide temperature range (-150°C to +125°C). HALT is a custom hybrid package suite of testing techniques using environments such as extreme temperatures and dynamic shock step processing from 0g up to 50g of acceleration. HALT testing used in this study implemented repetitive shock on the test vehicle components at various temperatures to precipitate workmanship and/or manufacturing defects to show the weak links of the designs. The purpose is to reduce the product development cycle time for improvements to the packaging design qualification. A test article was built using advanced electronic package designs and surface mount technology processes, which are considered useful for a variety of JPL and NASA projects, i.e. (surface mount packages such as ball grid arrays (BGA), plastic ball grid arrays (PBGA), very thin chip array ball grid array (CVBGA), quad flat-pack (QFP), micro-lead-frame (MLF) packages, several passive components, etc.). These packages were daisy-chained and independently monitored during the HALT test. The HALT technique was then implemented to predict reliability and assess survivability of these advanced packaging techniques for long duration deep space missions in much shorter test durations. Test articles were built using advanced electronic package designs that are considered useful in various NASA projects. All the advanced electronic packages were daisychained independently to monitor the continuity of the individual electronic packages. Continuity of the daisy chain packages was monitored during the HALT testing using a data logging system. We were able to test the boards up to 40g to 50g shock levels at temperatures ranging from +125°C to -150°C. The HALT system can deliver 50g shock levels at room temperature. Several tests were performed by subjecting the test boards to various g levels ranging from 5g to 50g, test durations of 10 minutes to 60 minutes, hot temperatures of up to +125°C and cold temperatures down to -150°C. During the HALT test, electrical continuity measurements of the PBGA package showed an open-circuit, whereas the BGA, MLF, and QFPs showed signs of small variations of electrical continuity measurements. The electrical continuity anomaly of the PBGA occurred in the test board within 12 hours of commencing the accelerated test. Similar test boards were assembled, thermal cycled independently from -150°C to +125°C and monitored for electrical continuity through each package design. The PBGA package on the test board showed an anomalous electrical continuity behavior after 959 thermal cycles. Each thermal cycle took around 2.33 hours, so that a total test time to failure of the PBGA was 2,237 hours (or ~3.1 months) due to thermal cycling alone. The accelerated technique (thermal cycling + shock) required only 12 hours to cause a failure in the PBGA electronic package. Compared to the thermal cycle only test, this was an acceleration of ~186 times (more than 2 orders of magnitude). This acceleration process can save significant time and resources for predicting the life of a package component in a given environment, assuming the failure mechanisms are similar in both the tests. Further studies are in progress to make systematic evaluations of the HALT technique on various other advanced electronic packaging components on the test board. With this information one will be able to estimate the number of mission thermal cycles to failure with a much shorter test program. Further studies are in progress to make systematic study of various components, constant temperature range for both the tests. Therefore, one can estimate the number of hours to fail in a given thermal and shock levels for a given test board physical properties.

Operation of a New Half-Bridge Gate Driver for Enhancement - Mode GaN FETs, Type LM5113, Over a Wide Temperature Range

NASA Technical Reports Server (NTRS)

Patterson, Richard; Hammoud, Ahmad

2011-01-01

A new commercial-off-the-shelf (COTS) gate driver designed to drive both the high-side and the low-side enhancement-mode GaN FETs, National Semiconductor's type LM5113, was evaluated for operation at temperatures beyond its recommended specified limits of -40 C to +125 C. The effects of limited thermal cycling under the extended test temperature, which ranged from -194 C to +150 C, on the operation of this chip as well as restart capability at the extreme cryogenic and hot temperatures were also investigated. The driver circuit was able to maintain good operation throughout the entire test regime between -194 C and +150 C without undergoing any major changes in its outputs signals and characteristics. The limited thermal cycling performed on the device also had no effect on its performance, and the driver chip was able to successfully restart at each of the extreme temperatures of -194 C and +150 C. The plastic packaging of this device was also not affected by either the short extreme temperature exposure or the limited thermal cycling. These preliminary results indicate that this new commercial-off-the-shelf (COTS) halfbridge eGaN FET driver integrated circuit has the potential for use in space exploration missions under extreme temperature environments. Further testing is planned under long-term cycling to assess the reliability of these parts and to determine their suitability for extended use in the harsh environments of space.

Three-dimensional and thermal surface imaging produces reliable measures of joint shape and temperature: a potential tool for quantifying arthritis

PubMed Central

Spalding, Steven J; Kwoh, C Kent; Boudreau, Robert; Enama, Joseph; Lunich, Julie; Huber, Daniel; Denes, Louis; Hirsch, Raphael

2008-01-01

Introduction The assessment of joints with active arthritis is a core component of widely used outcome measures. However, substantial variability exists within and across examiners in assessment of these active joint counts. Swelling and temperature changes, two qualities estimated during active joint counts, are amenable to quantification using noncontact digital imaging technologies. We sought to explore the ability of three dimensional (3D) and thermal imaging to reliably measure joint shape and temperature. Methods A Minolta 910 Vivid non-contact 3D laser scanner and a Meditherm med2000 Pro Infrared camera were used to create digital representations of wrist and metacarpalphalangeal (MCP) joints. Specialized software generated 3 quantitative measures for each joint region: 1) Volume; 2) Surface Distribution Index (SDI), a marker of joint shape representing the standard deviation of vertical distances from points on the skin surface to a fixed reference plane; 3) Heat Distribution Index (HDI), representing the standard error of temperatures. Seven wrists and 6 MCP regions from 5 subjects with arthritis were used to develop and validate 3D image acquisition and processing techniques. HDI values from 18 wrist and 9 MCP regions were obtained from 17 patients with active arthritis and compared to data from 10 wrist and MCP regions from 5 controls. Standard deviation (SD), coefficient of variation (CV), and intraclass correlation coefficients (ICC) were calculated for each quantitative measure to establish their reliability. CVs for volume and SDI were <1.3% and ICCs were greater than 0.99. Results Thermal measures were less reliable than 3D measures. However, significant differences were observed between control and arthritis HDI values. Two case studies of arthritic joints demonstrated quantifiable changes in swelling and temperature corresponding with changes in symptoms and physical exam findings. Conclusion 3D and thermal imaging provide reliable measures of joint volume, shape, and thermal patterns. Further refinement may lead to the use of these technologies to improve the assessment of disease activity in arthritis. PMID:18215307

Toward automated face detection in thermal and polarimetric thermal imagery

NASA Astrophysics Data System (ADS)

Gordon, Christopher; Acosta, Mark; Short, Nathan; Hu, Shuowen; Chan, Alex L.

2016-05-01

Visible spectrum face detection algorithms perform pretty reliably under controlled lighting conditions. However, variations in illumination and application of cosmetics can distort the features used by common face detectors, thereby degrade their detection performance. Thermal and polarimetric thermal facial imaging are relatively invariant to illumination and robust to the application of makeup, due to their measurement of emitted radiation instead of reflected light signals. The objective of this work is to evaluate a government off-the-shelf wavelet based naïve-Bayes face detection algorithm and a commercial off-the-shelf Viola-Jones cascade face detection algorithm on face imagery acquired in different spectral bands. New classifiers were trained using the Viola-Jones cascade object detection framework with preprocessed facial imagery. Preprocessing using Difference of Gaussians (DoG) filtering reduces the modality gap between facial signatures across the different spectral bands, thus enabling more correlated histogram of oriented gradients (HOG) features to be extracted from the preprocessed thermal and visible face images. Since the availability of training data is much more limited in the thermal spectrum than in the visible spectrum, it is not feasible to train a robust multi-modal face detector using thermal imagery alone. A large training dataset was constituted with DoG filtered visible and thermal imagery, which was subsequently used to generate a custom trained Viola-Jones detector. A 40% increase in face detection rate was achieved on a testing dataset, as compared to the performance of a pre-trained/baseline face detector. Insights gained in this research are valuable in the development of more robust multi-modal face detectors.

Electrothermal Action of the Pulse of the Current of a Short Artificial-Lightning Stroke on Test Specimens of Wires and Cables of Electric Power Objects

NASA Astrophysics Data System (ADS)

Baranov, M. I.; Rudakov, S. V.

2018-03-01

The authors have given results of investigations of the electrothermal action of aperiodic pulses of temporal shape 10/350 μs of the current of a short artificial-lightning stroke on test specimens of electric wires and cables with copper and aluminum cores and sheaths with polyvinylchloride and polyethylene insulations of power circuits of industrial electric power objects. It has been shown that the thermal stability of such wires and cables is determined by the action integral of the indicated current pulse. The authors have found the maximum permissible and critical densities of this pulse in copper and aluminum current-carrying parts of the wires and cables. High-current experiments conducted under high-voltage laboratory conditions on a unique generator of 10/350 μs pulses of an artificial-lightning current with amplitude-time parameters normalized according to the existing requirements of international and national standards and with tolerances on them have confirmed the reliability of the proposed calculated estimate for thermal lightning resistance of cabling and wiring products.

Passive Two-Phase Cooling for Automotive Power Electronics

DOE Office of Scientific and Technical Information (OSTI.GOV)

Moreno, G.; Jeffers, J. R.; Narumanchi, S.

2014-01-01

Experiments were conducted to evaluate the use of a passive two-phase cooling strategy as a means of cooling automotive power electronics. The proposed cooling approach utilizes an indirect cooling configuration to alleviate some reliability concerns and to allow the use of conventional power modules. An inverter-scale proof-of-concept cooling system was fabricated and tested using the refrigerants hydrofluoroolefin HFO-1234yf and hydrofluorocarbon HFC-245 fa. Results demonstrated that the system can dissipate at least 3.5 kW of heat with 250 cm3 of HFC-245fa. An advanced evaporator concept that incorporates features to improve performance and reduce its size was designed. Simulation results indicate themore » concept's thermal resistance can be 58% to 65% lower than automotive dual-side-cooled power modules. Tests were also conducted to measure the thermal performance of two air-cooled condensers-plain and rifled finned tube designs. The results combined with some analysis were then used to estimate the required condenser size per operating conditions and maximum allowable system (i.e., vapor and liquid) temperatures.« less

Passive Two-Phase Cooling of Automotive Power Electronics: Preprint

DOE Office of Scientific and Technical Information (OSTI.GOV)

Moreno, G.; Jeffers, J. R.; Narumanchi, S.

2014-08-01

Experiments were conducted to evaluate the use of a passive two-phase cooling strategy as a means of cooling automotive power electronics. The proposed cooling approach utilizes an indirect cooling configuration to alleviate some reliability concerns and to allow the use of conventional power modules. An inverter-scale proof-of-concept cooling system was fabricated, and tests were conducted using the refrigerants hydrofluoroolefin HFO-1234yf and hydrofluorocarbon HFC-245fa. Results demonstrated that the system can dissipate at least 3.5 kW of heat with 250 cm3 of HFC-245fa. An advanced evaporator design that incorporates features to improve performance and reduce size was conceived. Simulation results indicate itsmore » thermal resistance can be 37% to 48% lower than automotive dual side cooled power modules. Tests were also conducted to measure the thermal performance of two air-cooled condensers--plain and rifled finned tube designs. The results combined with some analysis were then used to estimate the required condenser size per operating conditions and maximum allowable system (i.e., vapor and liquid) temperatures.« less

Electrothermal Action of the Pulse of the Current of a Short Artificial-Lightning Stroke on Test Specimens of Wires and Cables of Electric Power Objects

NASA Astrophysics Data System (ADS)

Baranov, M. I.; Rudakov, S. V.

2018-05-01

The authors have given results of investigations of the electrothermal action of aperiodic pulses of temporal shape 10/350 μs of the current of a short artificial-lightning stroke on test specimens of electric wires and cables with copper and aluminum cores and sheaths with polyvinylchloride and polyethylene insulations of power circuits of industrial electric power objects. It has been shown that the thermal stability of such wires and cables is determined by the action integral of the indicated current pulse. The authors have found the maximum permissible and critical densities of this pulse in copper and aluminum current-carrying parts of the wires and cables. High-current experiments conducted under high-voltage laboratory conditions on a unique generator of 10/350 μs pulses of an artificial-lightning current with amplitude-time parameters normalized according to the existing requirements of international and national standards and with tolerances on them have confirmed the reliability of the proposed calculated estimate for thermal lightning resistance of cabling and wiring products.

Thermal dye double indicator dilution measurement of lung water in man: comparison with gravimetric measurements.

PubMed Central

Mihm, F G; Feeley, T W; Jamieson, S W

1987-01-01

The thermal dye double indicator dilution technique for estimating lung water was compared with gravimetric analyses in nine human subjects who were organ donors. As observed in animal studies, the thermal dye measurement of extravascular thermal volume (EVTV) consistently overestimated gravimetric extravascular lung water (EVLW), the mean (SEM) difference being 3.43 (0.59) ml/kg. In eight of the nine subjects the EVTV -3.43 ml/kg would yield an estimate of EVLW that would be from 3.23 ml/kg under to 3.37 ml/kg over the actual value EVLW at the 95% confidence limits. Reproducibility, assessed with the standard error of the mean percentage, suggested that a 15% change in EVTV can be reliably detected with repeated measurements. One subject was excluded from analysis because the EVTV measurement grossly underestimated its actual EVLW. This error was associated with regional injury observed on gross examination of the lung. Experimental and clinical evidence suggest that the thermal dye measurement provides a reliable estimate of lung water in diffuse pulmonary oedema states. PMID:3616974

Manufacture of a UO2-Based Nuclear Fuel with Improved Thermal Conductivity with the Addition of BeO

NASA Astrophysics Data System (ADS)

Garcia, Chad B.; Brito, Ryan A.; Ortega, Luis H.; Malone, James P.; McDeavitt, Sean M.

2017-12-01

The low thermal conductivity of oxide nuclear fuels is a performance-limiting parameter. Enhancing this property may provide a contribution toward establishing accident-tolerant fuel forms. In this study, the thermal conductivity of UO2 was increased through the fabrication of ceramic-ceramic composite forms with UO2 containing a continuous BeO matrix. Fuel with a higher thermal conductivity will have reduced thermal gradients and lower centerline temperatures in the fuel pin. Lower operational temperatures will reduce fission gas release and reduce fuel restructuring. Additions of BeO were made to UO2 fuel pellets in 2.5, 5, 7.5, and 10 vol pct concentrations with the goals of establishing reliable lab-scale processing procedures, minimizing porosity, and maximizing thermal conductivity. The microstructure was characterized with electron probe microanalysis, and the thermal properties were assessed by light flash analysis and differential scanning calorimetry. Reliable, high-density samples were prepared using compaction pressure between 200 and 225 MPa and sintering times between 4 and 6 hours. It was found that the thermal conductivity of UO2 improved approximately 10 pct for each 1 vol pct BeO added over the measured temperature range 298.15 K to 523.15 K (25 °C to 250 °C) with the maximum observed improvement being ˜ 100 pct, or doubled, at 10 vol pct BeO.

PERFORMANCE OF SOLAR HOT WATER COLLECTORS FOR ELECTRICITY PRODUCTION AND CLIMATE CONTROL

EPA Science Inventory

We will systematically evaluate commercially available solar thermal collectors and thermal storage systems for use in residential scale co-generative heat and electrical power systems. Currently, reliable data is unavailable over the range of conditions and installations thes...

A high-temperature furnace for applications in microgravity

NASA Technical Reports Server (NTRS)

1991-01-01

Technology in the area of material processing and crystal growth has been greatly furthered by research in microgravity environments. The role of efficient, lightweight furnaces with reliable performance is crucial in these experiments. A need exists for the development of a readily duplicated, high-temperature furnace satisfying stringent weight, volume, and power constraints. A furnace was designed and is referred to as the UAH SHIELD. Stringent physical and operating characteristics for the system were specified, including a maximum weight of 20 kg, a maximum power requirement of 60 W, and a volume of the furnace assembly, excluding the batteries, limited to half a Get-Away-Special canister. The UAH SHIELD furnace uses radiation shield and vacuum technology applied in the form of a series of concentric cylinders enclosed on either end with disks. Thermal testing of a furnace prototype was performed in addition to some thermal and structural analysis. Results indicate the need for spacing of the shields to accommodate the thermal expansion during furnace operation. In addition, a power dissipation of approximately 100 W and system weight of approximately 30 kg was found for the current design.

Environmental testing of a diode-laser-pumped Nd:YAG laser and a set of diode-laser-arrays

NASA Technical Reports Server (NTRS)

Hemmati, H.; Lesh, J. R.

1989-01-01

Results of the environmental test of a compact, rigid and lightweight diode-laser-pumped Nd:YAG laser module are discussed. All optical elements are bonded onto the module using space applicable epoxy, and two 200 mW diode laser arrays for pump sources are used to achieve 126 mW of CW output with about 7 percent electrical-to-optical conversion efficiency. This laser assembly and a set of 20 semiconductor diode laser arrays were environmentally tested by being subjected to vibrational and thermal conditions similar to those experienced during launch of the Space Shuttle, and both performed well. Nevertheless, some damage to the laser front facet in diode lasers was observed. Significant degradation was observed only on lasers which performed poorly in the life test. Improvements in the reliability of the Nd:YAG laser are suggested.

Fire extinguishing tests -80 with methyl alcohol gasoline

NASA Astrophysics Data System (ADS)

Holmstedt, G.; Ryderman, A.; Carlsson, B.; Lennmalm, B.

1980-10-01

Large scale tests and laboratory experiments were carried out for estimating the extinguishing effectiveness of three alcohol resistant aqueous film forming foams (AFFF), two alcohol resistant fluoroprotein foams and two detergent foams in various poolfires: gasoline, isopropyl alcohol, acetone, methyl-ethyl ketone, methyl alcohol and M15 (a gasoline, methyl alcohol, isobutene mixture). The scaling down of large scale tests for developing a reliable laboratory method was especially examined. The tests were performed with semidirect foam application, in pools of 50, 11, 4, 0.6, and 0.25 sq m. Burning time, temperature distribution in the liquid, and thermal radiation were determined. An M15 fire can be extinguished with a detergent foam, but it is impossible to extinguish fires in polar solvents, such as methyl alcohol, acetone, and isopropyl alcohol with detergent foams, AFFF give the best results; and performances with small pools can hardly be correlated with results from large scale fires.

DOE Office of Scientific and Technical Information (OSTI.GOV)

Katz, Jessica; Denholm, Paul; Pless, Jacquelyn

Wind and solar are inherently more variable and uncertain than the traditional dispatchable thermal and hydro generators that have historically provided a majority of grid-supplied electricity. The unique characteristics of variable renewable energy (VRE) resources have resulted in many misperceptions regarding their contribution to a low-cost and reliable power grid. Common areas of concern include: 1) The potential need for increased operating reserves, 2) The impact of variability and uncertainty on operating costs and pollutant emissions of thermal plants, and 3) The technical limits of VRE penetration rates to maintain grid stability and reliability. This fact sheet corrects misperceptions inmore » these areas.« less

Flexible ferroelectric element based on van der Waals heteroepitaxy.

PubMed

Jiang, Jie; Bitla, Yugandhar; Huang, Chun-Wei; Do, Thi Hien; Liu, Heng-Jui; Hsieh, Ying-Hui; Ma, Chun-Hao; Jang, Chi-Yuan; Lai, Yu-Hong; Chiu, Po-Wen; Wu, Wen-Wei; Chen, Yi-Chun; Zhou, Yi-Chun; Chu, Ying-Hao

2017-06-01

We present a promising technology for nonvolatile flexible electronic devices: A direct fabrication of epitaxial lead zirconium titanate (PZT) on flexible mica substrate via van der Waals epitaxy. These single-crystalline flexible ferroelectric PZT films not only retain their performance, reliability, and thermal stability comparable to those on rigid counterparts in tests of nonvolatile memory elements but also exhibit remarkable mechanical properties with robust operation in bent states (bending radii down to 2.5 mm) and cycling tests (1000 times). This study marks the technological advancement toward realizing much-awaited flexible yet single-crystalline nonvolatile electronic devices for the design and development of flexible, lightweight, and next-generation smart devices with potential applications in electronics, robotics, automotive, health care, industrial, and military systems.

Flexible ferroelectric element based on van der Waals heteroepitaxy

PubMed Central

Jiang, Jie; Bitla, Yugandhar; Huang, Chun-Wei; Do, Thi Hien; Liu, Heng-Jui; Hsieh, Ying-Hui; Ma, Chun-Hao; Jang, Chi-Yuan; Lai, Yu-Hong; Chiu, Po-Wen; Wu, Wen-Wei; Chen, Yi-Chun; Zhou, Yi-Chun; Chu, Ying-Hao

2017-01-01

We present a promising technology for nonvolatile flexible electronic devices: A direct fabrication of epitaxial lead zirconium titanate (PZT) on flexible mica substrate via van der Waals epitaxy. These single-crystalline flexible ferroelectric PZT films not only retain their performance, reliability, and thermal stability comparable to those on rigid counterparts in tests of nonvolatile memory elements but also exhibit remarkable mechanical properties with robust operation in bent states (bending radii down to 2.5 mm) and cycling tests (1000 times). This study marks the technological advancement toward realizing much-awaited flexible yet single-crystalline nonvolatile electronic devices for the design and development of flexible, lightweight, and next-generation smart devices with potential applications in electronics, robotics, automotive, health care, industrial, and military systems. PMID:28630922

Long-life mission reliability for outer planet atmospheric entry probes

NASA Technical Reports Server (NTRS)

Mccall, M. T.; Rouch, L.; Maycock, J. N.

1976-01-01

The results of a literature analysis on the effects of prolonged exposure to deep space environment on the properties of outer planet atmospheric entry probe components are presented. Materials considered included elastomers and plastics, pyrotechnic devices, thermal control components, metal springs and electronic components. The rates of degradation of each component were determined and extrapolation techniques were used to predict the effects of exposure for up to eight years to deep space. Pyrotechnic devices were aged under accelerated conditions to an equivalent of eight years in space and functionally tested. Results of the literature analysis of the selected components and testing of the devices indicated that no severe degradation should be expected during an eight year space mission.

Evaluation of Temperature-Dependent Effective Material Properties and Performance of a Thermoelectric Module

NASA Astrophysics Data System (ADS)

Chien, Heng-Chieh; Chu, En-Ting; Hsieh, Huey-Lin; Huang, Jing-Yi; Wu, Sheng-Tsai; Dai, Ming-Ji; Liu, Chun-Kai; Yao, Da-Jeng

2013-07-01

We devised a novel method to evaluate the temperature-dependent effective properties of a thermoelectric module (TEM): Seebeck coefficient ( S m), internal electrical resistance ( R m), and thermal conductance ( K m). After calculation, the effective properties of the module are converted to the average material properties of a p- n thermoelectric pillar pair inside the module: Seebeck coefficient ( S TE), electrical resistivity ( ρ TE), and thermal conductivity ( k TE). For a commercial thermoelectric module (Altec 1091) chosen to verify the novel method, the measured S TE has a maximum value at bath temperature of 110°C; ρ TE shows a positive linear trend dependent on the bath temperature, and k TE increases slightly with increasing bath temperature. The results show the method to have satisfactory measurement performance in terms of practicability and reliability; the data for tests near 23°C agree with published values.

Analytical modeling of intumescent coating thermal protection system in a JP-5 fuel fire environment

NASA Technical Reports Server (NTRS)

Clark, K. J.; Shimizu, A. B.; Suchsland, K. E.; Moyer, C. B.

1974-01-01

The thermochemical response of Coating 313 when exposed to a fuel fire environment was studied to provide a tool for predicting the reaction time. The existing Aerotherm Charring Material Thermal Response and Ablation (CMA) computer program was modified to treat swelling materials. The modified code is now designated Aerotherm Transient Response of Intumescing Materials (TRIM) code. In addition, thermophysical property data for Coating 313 were analyzed and reduced for use in the TRIM code. An input data sensitivity study was performed, and performance tests of Coating 313/steel substrate models were carried out. The end product is a reliable computational model, the TRIM code, which was thoroughly validated for Coating 313. The tasks reported include: generation of input data, development of swell model and implementation in TRIM code, sensitivity study, acquisition of experimental data, comparisons of predictions with data, and predictions with intermediate insulation.

Numerical simulation on behaviour of timber-concrete composite beams in fire

NASA Astrophysics Data System (ADS)

Du, Hao; Hu, Xiamin; Zhang, Bing; Minli, Yao

2017-08-01

This paper established sequentially coupled thermal-mechanical models of timber--concrete composite (TCC) beams by finite element software ANSYS to investigate the fire resistance of TCC beam. Existing experimental results were used to verify the coupled thermal-mechanical model. The influencing parameters consisted of the width of timber beam, the thickness of the concrete slab and the timber board. Based on the numerical results, the effects of these parameters on fire resistance of TCC beams were investigated in detail. The results showed that modeling results agreed well with test results, and verified the reliability of the finite element model. The width of the timber beam had a significant influence on the fire resistance of TCC beams. The fire resistance of TCC beams would be enhanced by increasing the width of timber beam, the thickness of concrete slab and the timber board.

Space Qualification Issues in Acousto-optic and Electro-optic Devices

NASA Technical Reports Server (NTRS)

Prasad, Narasimha S.; Taylor, Edward W.; Trivedi, Sudhir; Kutcher, Sue; Soos, Jolanta

2007-01-01

Satellite and space-based applications of photonic devices and systems require operational reliability in the harsh environment of space for extended periods of time. This in turn requires every component of the systems and their packaging to meet space qualifications. Acousto- and electro-optical devices form the major components of many current space based optical systems, which is the focus of this paper. The major space qualification issues are related to: mechanical stability, thermal effects and operation of the devices in the naturally occurring space radiation environment. This paper will discuss acousto- and electro-optic materials and devices with respect to their stability against mechanical vibrations, thermal cycling in operating and non-operating conditions and device responses to space ionizing and displacement radiation effects. Selection of suitable materials and packaging to meet space qualification criteria will also be discussed. Finally, a general roadmap for production and testing of acousto- and electro-optic devices will be discussed.

Gyrocopter-Based Remote Sensing Platform

NASA Astrophysics Data System (ADS)

Weber, I.; Jenal, A.; Kneer, C.; Bongartz, J.

2015-04-01

In this paper the development of a lightweight and highly modularized airborne sensor platform for remote sensing applications utilizing a gyrocopter as a carrier platform is described. The current sensor configuration consists of a high resolution DSLR camera for VIS-RGB recordings. As a second sensor modality, a snapshot hyperspectral camera was integrated in the aircraft. Moreover a custom-developed thermal imaging system composed of a VIS-PAN camera and a LWIR-camera is used for aerial recordings in the thermal infrared range. Furthermore another custom-developed highly flexible imaging system for high resolution multispectral image acquisition with up to six spectral bands in the VIS-NIR range is presented. The performance of the overall system was tested during several flights with all sensor modalities and the precalculated demands with respect to spatial resolution and reliability were validated. The collected data sets were georeferenced, georectified, orthorectified and then stitched to mosaics.

The linear Boltzmann equation in slab geometry - Development and verification of a reliable and efficient solution

NASA Technical Reports Server (NTRS)

Stamnes, K.; Lie-Svendsen, O.; Rees, M. H.

1991-01-01

The linear Boltzmann equation can be cast in a form mathematically identical to the radiation-transport equation. A multigroup procedure is used to reduce the energy (or velocity) dependence of the transport equation to a series of one-speed problems. Each of these one-speed problems is equivalent to the monochromatic radiative-transfer problem, and existing software is used to solve this problem in slab geometry. The numerical code conserves particles in elastic collisions. Generic examples are provided to illustrate the applicability of this approach. Although this formalism can, in principle, be applied to a variety of test particle or linearized gas dynamics problems, it is particularly well-suited to study the thermalization of suprathermal particles interacting with a background medium when the thermal motion of the background cannot be ignored. Extensions of the formalism to include external forces and spherical geometry are also feasible.

Passive Thermal Management of Foil Bearings

NASA Technical Reports Server (NTRS)

Bruckner, Robert J. (Inventor)

2015-01-01

Systems and methods for passive thermal management of foil bearing systems are disclosed herein. The flow of the hydrodynamic film across the surface of bearing compliant foils may be disrupted to provide passive cooling and to improve the performance and reliability of the foil bearing system.

DOE Office of Scientific and Technical Information (OSTI.GOV)

Narumanchi, Sreekant

Increasing the number of electric-drive vehicles (EDVs) on America's roads has been identified as a strategy with near-term potential for dramatically decreasing the nation's dependence on oil - by the U.S. Department of Energy, the federal cross-agency EV-Everywhere Challenge, and the automotive industry. Mass-market deployment will rely on meeting aggressive technical targets, including improved efficiency and reduced size, weight, and cost. Many of these advances will depend on optimization of thermal management. Effective thermal management is critical to improving the performance and ensuring the reliability of EDVs. Efficient heat removal makes higher power densities and lower operating temperatures possible, andmore » in turn enables cost and size reductions. The National Renewable Energy Laboratory (NREL), along with DOE and industry partners is working to develop cost-effective thermal management solutions to increase device and component power densities. In this presentation, the activities in recent years related to thermal management and reliability of automotive power electronics and electric machines are presented.« less

DOE Office of Scientific and Technical Information (OSTI.GOV)

Narumanchi, Sreekant

Increasing the number of electric-drive vehicles (EDVs) on America's roads has been identified as a strategy with near-term potential for dramatically decreasing the nation's dependence on oil -- by the U.S. Department of Energy, the federal cross-agency EV-Everywhere Challenge, and the automotive industry. Mass-market deployment will rely on meeting aggressive technical targets, including improved efficiency and reduced size, weight, and cost. Many of these advances will depend on optimization of thermal management. Effective thermal management is critical to improving the performance and ensuring the reliability of EDVs. Efficient heat removal makes higher power densities and lower operating temperatures possible, andmore » in turn enables cost and size reductions. The National Renewable Energy Laboratory (NREL), along with DOE and industry partners is working to develop cost-effective thermal management solutions to increase device and component power densities. In this presentation, the activities in recent years related to thermal management and reliability of automotive power electronics and electric machines will be presented.« less

Predicting the Reliability of Brittle Material Structures Subjected to Transient Proof Test and Service Loading

NASA Astrophysics Data System (ADS)

Nemeth, Noel N.; Jadaan, Osama M.; Palfi, Tamas; Baker, Eric H.

Brittle materials today are being used, or considered, for a wide variety of high tech applications that operate in harsh environments, including static and rotating turbine parts, thermal protection systems, dental prosthetics, fuel cells, oxygen transport membranes, radomes, and MEMS. Designing brittle material components to sustain repeated load without fracturing while using the minimum amount of material requires the use of a probabilistic design methodology. The NASA CARES/Life 1 (Ceramic Analysis and Reliability Evaluation of Structure/Life) code provides a general-purpose analysis tool that predicts the probability of failure of a ceramic component as a function of its time in service. This capability includes predicting the time-dependent failure probability of ceramic components against catastrophic rupture when subjected to transient thermomechanical loads (including cyclic loads). The developed methodology allows for changes in material response that can occur with temperature or time (i.e. changing fatigue and Weibull parameters with temperature or time). For this article an overview of the transient reliability methodology and how this methodology is extended to account for proof testing is described. The CARES/Life code has been modified to have the ability to interface with commercially available finite element analysis (FEA) codes executed for transient load histories. Examples are provided to demonstrate the features of the methodology as implemented in the CARES/Life program.

Syn-Fuel reciprocating charge pump improvement program. Quarterly technical project report, April-June 1984

DOE Office of Scientific and Technical Information (OSTI.GOV)

Not Available

1984-01-01

Major accomplishments during the second quarter of 1984 were completion of the Diaphragm Separation Seal clear liquid testing, and initiation of Phase III Field Testing. Diaphragm operational testing was conducted on a clear water test loop. The test goals were to ensure; mechanical reliability of the Diaphragm Seal, safe operation with simulated component failure, and proper operation of the Diaphragm Buffer Volume Control System. This latter system is essential in controlling the phasing of the diaphragm with its driving plunger. These tests were completed successfully. All operational problems were solved. However, it must be emphasized that the Diaphragm Seal wouldmore » be damaged by allowing the pump to operate in a cavitating condition for an extended period of time. A change in the Field Test phase of the program was made regarding choice of field test site. There is no operating Syn-Fuel pilot plant capable of inexpensively producing the slurry stream required for the reciprocating pump testing. The Field Tests will now be conducted by first testing the prototype pump and separation seals in an ambient temperature sand water slurry. This will determine resistence to abrasive wear and determine any operation problems at pressure over a lengthy period of time. After successful conclusion of these tests the pump and seals will be operated with a high temperature oil, but without solids, to identify any problems associated with thermal gradients, thermal shock and differential growth. After successful completion of the high temperature clean oil tests the pump will be deemed ready for in-line installation at a designated Syn-Fuel pilot plant. The above approach avoids the expense and complications of a separate hot slurry test loop. It also reduces risk of operational problems while in-line at the pilot plant. 5 figs.« less

Preparation and Thermal Properties of Molecular-Bridged Expanded Graphite/Polyethylene Glycol Composite Phase Change Materials for Building Energy Conservation.

PubMed

Zhang, Dong; Chen, Meizhu; Liu, Quantao; Wan, Jiuming; Hu, Jinxuan

2018-05-16

Using phase change materials (PCMs) in building envelopes became a reliable method to improve indoor comfort and reduce buildings' energy consumption. This research developed molecular-bridged expanded graphite (EG)/polyethylene glycol (PEG) composite PCMs (m-EPs) to conserve energy in buildings. The m-EPs were prepared through a vacuum absorption technique, and a titanate coupling agent was used to build a molecular bridge between EG and PEG. SEM, mercury intrusion porosimetry (MIP), the leakage test, microcalorimetry, X-ray photoelectron spectroscopy (XPS), and Fourier transform infrared spectroscopy (FT-IR) were conducted to characterize the morphology, pore structure, absorbability, and modifying effects of the m-EPs. The phase change temperature, latent heat, thermal stability, and thermal conductivity of the m-EPs were determined by a differential scanning calorimeter (DSC), TGA, and a thermal constants analyzer. Results showed that the maximum mass ratio of PEG to EG without leakage was 1:7, and a stable connection was established in the m-EPs after modification. Compared with the unmodified EPs, the supercooling degree of the m-EPs reduced by about 3 °C, but the latent heats and initial decomposition temperatures increased by approximately 10% and 20 °C, respectively, which indicated an improvement in the thermal energy storage efficiency. The thermal conductivities of the m-EPs were 10 times higher than those of the pristine PEGs, which ensured a rapid responding to building temperature fluctuations.

Preparation and Thermal Properties of Molecular-Bridged Expanded Graphite/Polyethylene Glycol Composite Phase Change Materials for Building Energy Conservation

PubMed Central

Zhang, Dong; Chen, Meizhu; Liu, Quantao; Hu, Jinxuan

2018-01-01

Using phase change materials (PCMs) in building envelopes became a reliable method to improve indoor comfort and reduce buildings’ energy consumption. This research developed molecular-bridged expanded graphite (EG)/polyethylene glycol (PEG) composite PCMs (m-EPs) to conserve energy in buildings. The m-EPs were prepared through a vacuum absorption technique, and a titanate coupling agent was used to build a molecular bridge between EG and PEG. SEM, mercury intrusion porosimetry (MIP), the leakage test, microcalorimetry, X-ray photoelectron spectroscopy (XPS), and Fourier transform infrared spectroscopy (FT-IR) were conducted to characterize the morphology, pore structure, absorbability, and modifying effects of the m-EPs. The phase change temperature, latent heat, thermal stability, and thermal conductivity of the m-EPs were determined by a differential scanning calorimeter (DSC), TGA, and a thermal constants analyzer. Results showed that the maximum mass ratio of PEG to EG without leakage was 1:7, and a stable connection was established in the m-EPs after modification. Compared with the unmodified EPs, the supercooling degree of the m-EPs reduced by about 3 °C, but the latent heats and initial decomposition temperatures increased by approximately 10% and 20 °C, respectively, which indicated an improvement in the thermal energy storage efficiency. The thermal conductivities of the m-EPs were 10 times higher than those of the pristine PEGs, which ensured a rapid responding to building temperature fluctuations. PMID:29772728

Design of a heatpipe-cooled Mars-surface fission reactor

NASA Astrophysics Data System (ADS)

Poston, David I.; Kapernick, Richard J.; Guffee, Ray M.; Reid, Robert S.; Lipinski, Ronald J.; Wright, Steven A.; Talandis, Regina A.

2002-01-01

The next generation of robotic missions to Mars will most likely require robust power sources in the range of 3 to 20 kWe. Fission systems are well suited to provide safe, reliable, and economic power within this range. The goal of this study is to design a compact, low-mass fission system that meets Mars-surface power requirements, while maintaining a high level of safety and reliability at a relatively low cost. The Heatpipe Power System (HPS) is one possible approach for producing near-term, low-cost, space fission power. The goal of the HPS project is to devise an attractive space fission system that can be developed quickly and affordably. The primary ways of doing this are by using existing technology and by designing the system for inexpensive testing. If the system can be designed to allow highly prototypic testing with electrical heating, then an exhaustive test program can be carried out quickly and inexpensively, and thorough testing of the actual flight unit can be performed-which is a major benefit to reliability. Over the past 4 years, three small HPS proof-of-concept technology demonstrations have been conducted, and each has been highly successful. The Heatpipe-Operated Mars Exploration Reactor (HOMER) is a derivative of the HPS designed especially for producing power on the surface of Mars. The HOMER-15 is a 15-kWt reactor that couples with a 3-kWe Stirling engine power system. The reactor contains stainless-steel (SS)-clad uranium nitride (UN) fuel pins that are structurally and thermally bonded to SS/sodium heatpipes. Fission energy is conducted from the fuel pins to the heatpipes, which then carry the heat to the Stirling engine. This paper describes the attributes, specifications, and performance of a 15-kWt HOMER reactor. .