Space
Manufacturer testing programmes Component manufacturers which have a strong focus on the space industry are adding optional test programmes to the reliability matrix. These tests confirm the ability of the component to withstand the harsh conditions of a launch and to deliver reliable operation in LEO or in deep space. The flexibility added by additional testing allows customers to use and pay for the testing or screening options that are appropriate for each design. Capacitors can be tested on criteria such as capacitance, dissipation factor, equivalent series resistance (ESR), infrared (IR) and leakage, with the Kemet custom testing programme. This testing can also cover heat and humidity, ageing, and thermal shock, as well as a step surge stress test (SSST) on the dielectric, x-ray testing, and Weibull distribution.
For resistors, the Lot Acceptance Testing (LAT) offered by Exxelia tests for thermal shock, power conditioning, load life and the short-term overload capability. In addition to testing passives, the New Space Electronics programme, from TT Electronics, offers screening tests for discrete semiconductors and multi-chip arrays (MCA). These tests range from a stabilising bake and pre-cap inspection, to validating the component and group testing. Tests are also offered for residual gas analysis, radiography that includes Total Irradiated Dose (TID) and Single Event Upset (SEU).
Each of these programmes adds another level of testing to fill the gaps between the COTS and automotive-grade devices, and fully space-grade components.
The number of actual and forecast launches of nanosats according to
nanosats.eu
The role of distribution Distribution should play a vital role in ensuring that the components which are supplied for use in satellites or spacecraft have the correct level of qualification and traceability.
The majority of distributors focus primarily on higher volume sectors such as consumer,
automotive, energy, communications and the Internet of Things (IoT). For these distributors, space-grade components can be an add-on rather than a core commitment. Unlike the majority of distributors, Charcroft has maintained a core focus on working with OEMs and CEMs in defence, aerospace and other harsh sectors for almost five decades. The difference is that the distribution and manufacturing activities are structured to be quality-led and are all based in the UK.
A key example of this is component traceability. If traceability is lost, there will be great difficulty in tracking the component history in the event of a component failure. A flag on the sales IT system shows the release that is required for each shipment. A designated quality representative can also be named for checking every shipment before being released for delivery. An archive, which was established in 1985, holds a digitised copy of every Certificate of Conformity and Certificate of Compliance (CofC) that has been received from the manufacturer. With this information, there is long-term availability to recall the batch numbers and manufacturing dates of each component.
Solar Orbiter integrates over 16,000 film capacitors (source: ESA/ATG medialab)
www.cieonline.co.uk
The quality-led distribution and custom manufacturing of assemblies, combined with vast experience in defence and aerospace,
enable Charcroft to deliver a viable alternative to using a Coordinated Parts Procurement Agency (CPPA).
Space-grade developments Satellites and spacecraft need space-grade reliability on all of the components in a mission-critical system. For passives, this can be film or ceramic capacitors, or solid and wet tantalum capacitors, with foil and thin-film resistors, inductors and EMI filters. There are also space-grade fuses and ferrite chips as well as thermostats, frequency-tuning components and discrete semiconductors. The developments in space-level components have focused on delivering increased levels of reliability rather than introducing new components. Wet tantalum slugs are now offered with R-level reliability, and film capacitors are manufactured to ESA ESCC 3006 version 3. The QPL surface- mount X7R, C0G, and BP MLCCs, have a high-reliability T rating, or an M level rating with flexible terminations.
To minimise the risks inherent in developing a LEO satellite or spacecraft, designers must ensure that every partner in the supply chain shares the same level of focus and expertise to support the critical space-grade design process.
www.charcroft.com Components in Electronics October 2022 15
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