Lightweight mirror structures
Borosilicate glass and monolithic core technology for lightweight astronomical mirror construction
Loytty, E. Y.↗
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Protective coating for laser diodes
Coating for GaAs laser diodes should not alter optical and electrical properties. Borosilicate glass coating is easy to apply, breaks evenly when cleaved, and is abrasion and moisture resistant. Its low index of refraction makes thickness less critical when depositing half-wavelength coating.
Ladany, I.↗
Solar cells for solar power satellites
The concept of a solar-cell array for a solar power satellite is developed to permit evaluation of its economic feasibility for generating power for delivery to public utilities on earth. Gallium arsenide solar cells were considered but it could not be assured that the world gallium resources could support constructions of two solar power satellites per year. Therefore, for preliminary design an array blanket made from 5 by 10 cm silicon solar cells, 50 microns thick, and electrostatically bonded between borosilicate glass sheets was adopted. In annealing experiments, a radiated 50 microns thick cell was restored to its initial performance in a 500 C. Solar-cell efficiency effects significantly the solar power satellite mass, which varies from 90,000 metric tons for 20 percent cells to 120,000 metric tons for 12 percent cells. The anticipated cost of delivered power, based on 1977 dollars, varies from 4 cents per kWh with 18 percent cells, to 5 cents per kWh for 12 percent efficient cells.
Oman, H.↗
Secondary Electron Emission Yields
The secondary electron emission (SEE) characteristics for a variety of spacecraft materials were determined under UHV conditions using a commercial double pass CMA which permits sequential Auger electron electron spectroscopic analysis of the surface. The transparent conductive coating indium tin oxide (ITO) was examined on Kapton and borosilicate glass and indium oxide on FED Teflon. The total SEE coefficient ranges from 2.5 to 2.6 on as-received surfaces and from 1.5 to 1.6 on Ar(+) sputtered surfaces with 5 nm removed. A cylindrical sample carousel provides normal incidence of the primary beam as well as a multiple Faraday cup measurement of the approximately nA beam currents. Total and true secondary yields are obtained from target current measurements with biasing of the carousel. A primary beam pulsed mode to reduce electron beam dosage and minimize charging of insulating coatings was applied to Mg/F2 coated solar cell covers. Electron beam effects on ITO were found quite important at the current densities necessary to do Auger studies.
Krainsky, I.↗
Adjustable high emittance gap filler
A flexible, adjustable refractory filler is disclosed for filling gaps between ceramic tiles forming the heat shield of a space shuttle vehicle, to protect its aluminum skin during atmospheric reentry. The easily installed and replaced filler consists essentially of a strip of ceramic cloth coated, at least along both its longitudinal edges with a room temperature vulcanizable silicone rubber compound with a high emittance colored pigment. The filler may have one or more layers as the gap width requires. Preferred materials are basket weave aluminoborosilicate cloth, and a rubber compounded with silicon tetraboride as the emittance agent and finely divided borosilicate glass containing about 7.5% B2O3 as high temperature binder. The filler cloth strip or tape is cut to proper width and length, inserted into the gap, and fastened with previously applied drops of silicone rubber adhesive.
Leiser, D. B.↗
Containerless melting and solidification of materials with an aerodynamic levitation system
A simple aerodynamic system which can heat, melt, cool, and solidify (in a containerless fashion) small, roughly spherical (diameter 1.5-4 mm) samples of materials is described. The principal components of the system are an aerodynamic levitation tube and an elliptical radiant heater. The materials processed, i.e., melted and resolidified, in the system include lead and an alkali borosilicate glass. The processing of a glass bead is described. In addition, the physical phenomena which may generate the levitation force in the tube are briefly discussed.
Oran, W. A.↗
Lessons learned from the development and manufacture of ceramic reusable surface insulation materials for the space shuttle orbiters
Three ceramic, reusable surface insulation materials and two borosilicate glass coatings were used in the fabrication of tiles for the Space Shuttle orbiters. Approximately 77,000 tiles were made from these materials for the first three orbiters, Columbia, Challenger, and Discovery. Lessons learned in the development, scale up to production and manufacturing phases of these materials will benefit future production of ceramic reusable surface insulation materials. Processing of raw materials into tile blanks and coating slurries; programming and machining of tiles using numerical controlled milling machines; preparing and spraying tiles with the two coatings; and controlling material shrinkage during the high temperature (2100-2275 F) coating glazing cycles are among the topics discussed.
Banas, R. P.↗
Steps toward 8 m honeycomb mirror blanks. II - Experiments with waffleplate and honeycomb casting
A technique for fabricating large low-cost light-weight borosilicate-glass mirrors for ground and space-based astronomy is described. This technique involves the remelting of glass into complex molds for vacuum-formed ceramic fiber and is used to cast in one piece either waffleplate or full honeycomb sandwich blanks. The construction of molds and the cycle for melting and annealing are described in detail. A 1.1-m square blank with a 22.4-cm-thick face and 1.6-cm ribs, 15-cm deep on 15-cm squares, has been cast, and a 1.8-m circular blank of full honeycomb construction is scheduled for production. The casting of blanks of up to 8-m in diameter is anticipated, with densities of 200 kg/sq m (like that of the ST mirror) being typical of casting.
Hill, J. M.↗
Electron yields from spacecraft materials
Photoyields and secondary electron emission (SEE) characteristics were determined under UHV conditions for a group of insulating materials used in spacecraft applications. The SEE studies were carried out with a pulsed primary beam while photoyields were obtained with a chopped photon beam from a Kr resonance source with major emission at 123.6 nm. This provides a photon flux close to that of the Lyman alpha in the space environment. Yields per incident photon are obtained relative to those from a freshly evaporated and air oxidized Al surface. Results are presented for Kapton, FEP Teflon, the borosilicate glass covering of a shuttle tile, and spacesuit outer fabric.
Yang, K.↗
Thermal expansion uniformity of materials for large telescope mirrors
Uniformity of thermal expansion has been measured for fused quartz and borosilicate glass. The variation of expansion coefficient for three melts of TO8E was 5 x 10 to the -9th/K over a temperature range of 300 to 100 K and was found to vary linearly with position in the melt. This spatial gradient averaged 3.5 x 10 to the -11th/K-cm. The room-temperature thermal expansivity variation of Duran (Tempax) glass was about 27 x 10 to the -9th/K, while that of E6 glass was about 52 x 10 to the -9th/K.
Jacobs, S. F.↗
Steps toward 8m honeycomb mirrors. VIII - Design and demonstration of a system of thermal control
Directed jets of ambient temperature air are proposed for the maintenance of low internal temperature gradients and conformity with ambient temperatures in honeycomb-structure borosilicate glass telescope mirrors. The use of greater airflow on thicker sections, to match cooling rates, and the cooling or heating of the internal, back, and edge surfaces of the mirror at the same rate established by convection on the front surface, have been tested on a full scale glass thermal model of a single honeycomb cell from an 8-m diameter mirror. The internal thermal gradient (less than 0.1 C) and ambient-temperature-change lag (less than 0.24 C) ensure minimum image degradation.
Cheng, A. Y. S.↗
Nitrogen recombination on high-temperature reusable surface insulation and the analysis of its effect on surface catalysis
The energy transfer catalytic recombination coefficients for nitrogen and oxygen on a borosilicate glass are determined in nitrogen and air hypersonic arc jet streams. These data, obtained from a reacting boundary-layer analysis with first-order surface reaction kinetics, compare well with earlier results from a Goulard frozen boundary-layer model up to 1600 K. The apparent surface recombination rates increase up to 1600 K, then begin to decrease. To illustrate the effects of temperature and nitrogen dissociation on energy transfer to the glass, a diffusional heat-flux is calculated using the present results from 1450 K up to 1850 K. This diffusional heat-flux is the contribution to the total heating rate by atom recombination, and is used to compare the present results with coefficients from three previous studies.
Kolodziej, Paul↗
Raman spectra of adsorbed layers on space shuttle and AOTV thermal protection system surface
Surfaces of interest to space vehicle heat shield design were struck by a 2 W argon ion laser line while subjected to supersonic arc jet flow conditions. Emission spectra were taken at 90 deg to the angle of laser incidence on the test object. Results showed possible weak Raman shifts which could not be directly tied to any particular parameter such as surface temperature or gas composition. The investigation must be considered exploratory in terms of findings. Many undesirable effects were found and corrected as the project progressed. For instance, initial spectra settings led to ghosts which were eliminated by closing the intermediate of filter slit of the Spex from 8 to 3 mm. Further, under certain conditions, plasma lines from the laser were observed. Several materials were also investigated at room temperature for Raman shifts. Results showed Raman shifts for RCC and TEOS coated materials. The HRSI materials showed only weak Raman shifts, however, substantial efforts were made in studying these materials. Baseline materials showed the technique to be sound. The original goal was to find a Raman shift for the High-temperature Reusable Surface Insulation (HRSI) Reaction Cured borosilicate Glass (RCG) coated material and tie the amplitude of this peak to Arc jet conditions. Weak Raman shifts may be present, however, time limitations prevented confirmation.
Willey, Ronald J.↗
Deposition of vanadium oxide films by direct-current magnetron reactive sputtering
It is demonstrated here that thin films of vanadium oxide can be deposited at modest substrate temperatures by dc reactive sputtering from a vanadium target in an O2-Ar working gas using a planar magnetron source. Resistivity ratios of about 5000 are found between a semiconductor phase with a resistivity of about 5 Ohm cm and a metallic phase with a resistivity of about 0.001 Ohm cm for films deposited onto borosilicate glass substrates at about 400 C. X-ray diffraction shows the films to be single-phase VO2 with a monoclinic structure. The VO2 films are obtained for a narrow range of O2 injection rates which correspond to conditions where cathode poisoning is just starting to occur.
Kusano, E.↗
Mechanical behavior of a ceramic matrix composite material
Monolithic ceramic materials have been used in industry for hundreds of years. These materials have proven their usefulness in many applications, yet, their potential for critical structural applications is limited. The existence of an imperfection in a monolithic ceramic on the order of several microns in size may be critical, resulting in catastrophic failure. To overcome this extreme sensitivity to small material imperfections, reinforced ceramic materials were developed. A ceramic matrix which has been reinforced with continuous fibers is not only less sensitive to microscopic flaws, but is also able to sustain significant damage without suffering catastrophic failure. A borosilicate glass reinforced with several layers of plain weave silicon carbide cloth (Nicalon) was studied. The mechanical testing which was performed included both flexural and tensile loading configurations. This testing was done not only to determine the material properties, but also to initiate a controlled amount of damage within each specimen. Several nondestructive testing techniques, including acousto-ultrasonics (AU), were performed on the specimens periodically during testing. The AU signals were monitored through the use of an IBM compatible personal computer with a high speed data acquisition board. Software was written which manipulates the AU signals in both the time and frequency domains, resulting in quantitative measures of the mechanical response of the material. The measured AU parameters are compared to both the mechanical test results and data from other nondestructive methods including ultrasonic C-scans and penetrant enhanced x ray radiography.
Grosskopf, Paul P.↗
Toughened uni-piece fibrous insulation
A porous body of fibrous, low density silica-based insulation material is at least in part impregnated with a reactive boron oxide containing borosilicate glass frit, a silicon tetraboride fluxing agent and a molybdenum silicide emittance agent. The glass frit, fluxing agent and emittance agent are separately milled to reduce their particle size, then mixed together to produce a slurry in ethanol. The slurry is then applied to the insulation material and sintered to produce the porous body.
Leiser, Daniel B↗
Effect of thermal convection on the shape of a solid-liquid interface
The effect of thermal convection on the shape of solid-liquid interface was investigated in experiments conducted in a transparent Bridgman-type directional solidification furnace. The relationship was numerically modeled using a standard 2D finite-difference approach, with the solid-liquid deformable interface approximated by a blocking-off technique. The directional solidification furnace was used with pure succinonitrile (which is also transparent) contained in a long square ampoule made of borosilicate glass. With the furnace in the vertical configuration, a flat interface was observed, in agreement with the model. On the other hand, a highly distorted interface was obtained in the horizontal configuration; the numerical results showed a strong recirculating cell in front of the interface due to natural thermal convection. The results indicate that thermal convection is responsible for the interface distortion.
Mennetrier, C.↗
Thermal certification tests of Orbiter Thermal Protection System tiles coated with KSC coating slurries
Thermal tests of Orbiter thermal protection system (TPS) tiles, which were coated with borosilicate glass slurries fabricated at Kennedy Space Center (KSC), were performed in the Radiant Heat Test Facility and the Atmospheric Reentry Materials & Structures Evaluation Facility at Johnson Space Center to verify tile coating integrity after exposure to multiple entry simulation cycles in both radiant and convective heating environments. Eight high temperature reusable surface insulation (HRSI) tiles and six low temperature reusable surface insulation (LRSI) tiles were subjected to 25 cycles of radiant heat at peaked surface temperatures of 2300 F and 1200 F, respectively. For the LRSI tiles, an additional cycle at peaked surface temperature of 2100 F was performed. There was no coating crack on any of the HRSI specimens. However, there were eight small coating cracks (less than 2 inches long) on two of the six LRSI tiles on the 26th cycle. There was practically no change on the surface reflectivity, physical dimensions, or weight of any of the test specimens. There was no observable thermal-chemical degradation of the coating either. For the convective heat test, eight HRSI tiles were tested for five cycles at a surface temperature of 2300 F. There was no thermal-induced coating crack on any of the test specimens, almost no change on the surface reflectivity, and no observable thermal-chemical degradation with an exception of minor slumping of the coating under painted TPS identification numbers. The tests demonstrated that KSC's TPS slurries and coating processes meet the Orbiter's thermal specification requirements.
Milhoan, James D.↗