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NASA NTRS2024

Contamination Results of MISSE 8 Wake and Nadir Samples After 2 Years of Space Exposure on the International Space Station

Spacecraft in low Earth orbit (LEO) are subjected to harsh environmental conditions, including radiation (cosmic rays, ultraviolet, x-ray and charged particle radiation), micrometeoroids and orbital debris, temperature extremes, thermal cycling, and atomic oxygen. In addition, on-orbit spacecraft contamination is a serious spaceflight issue, with silicone contamination being a particular concern. In an effort to understand on-orbit contamination of Materials International Space Station Experiment 8 (MISSE 8) flight samples and other International Space Station (ISS) payloads, contamination studies were conducted post-flight on retrieved Teflon fluorinated ethylene propylene (FEP) samples flown in the wake and nadir orientations on MISSE 8. The wake sample was Teflon FEP (M8-W11) flown as part of the Glenn MISSE 8 Polymers Experiment on the Optical Reflector Materials Experiment-III Ram/Wake (ORMatE-III R/W) tray and exposed to the LEO wake environment for 2.0 years. The nadir samples were silver-Teflon FEP radiator pieces taken from the MISSE 8 Single Events Upset Xilinx-Sandia Experiment II (SEUXSE II) Power Box and exposed to the LEO nadir environment for 2.14 years. The Teflon FEP flight materials were analyzed for changes in surface morphology and chemistry as compared to pristine control samples. The wake samples were also analyzed for changes in optical properties. There was no evidence of a molecular contamination layer present on the surface of the MISSE 8 wake or nadir facing Teflon FEP flight samples, although both the wake and nadir flight samples contained particulate contamination in some regions. The analyzed nadir particles were primarily zinc rich. The majority of analyzed wake particles were comprised of oxidized aluminum with small amounts of zinc and magnesium. The wake particles appear to have arrived early in the mission (or pre-flight) during a single event. This paper provides details of the MISSE 8 sample contamination analyses.

Erosion↗

NASA NTRSDate not supplied

Thermal Performance of Perovskite-Based Photovoltaics for Operation in Low Earth Orbit

Perovskite-based photovoltaics are attractive for applications in space. The space environment is harsh with extreme temperatures, atomic oxygen, ionizing radiation, UV radiation, and thermal cycling. Here, we evaluate the thermal performance of a perovskite active layer and perovskite photovoltaic devices in low earth orbit. We determine that a 1 µm layer of silicon oxide coupled with a 500 nm zirconia thin film aid in cell thermal management. We model the residual stresses between various layers in the device and prove that thermally induced mechanical failure of the perovskite (t > 460 years) is unlikely during the operating lifetime of a space mission. We identify target power conversion efficiencies to manage operating temperature of a perovskite-based photovoltaic.

Timothy S. Krause↗

NASA NTRS2024

SupportU: Smart UAS Program for the Population by Offering Resources and Tools to the Unhoused

Global warming, challenging economic conditions, the opioid epidemic, and other widespread problems, have impacted people globally, particularly over the past several years. Preventable diseases like the common cold and the effects of heat stroke have become increasingly prevalent due to these issues. It is estimated that 150 million people of the world’s population are unhoused globally, with many dwelling in unsafe and unsanitary conditions while lacking access to basic hygienic items and other essentials. Unsanitary conditions coupled with this lack of access exacerbates and prolongs health problems and harms quality of life. Traditional methods of aid, such as homeless shelters and meal programs, face numerous challenges such as having limited reach and resources. To address these problems, the Smart UAS Program for the Population by Offering Resources and Tools to the Unhoused (SUPPORT U) utilizes Uncrewed Aircraft Systems (UAS) to deliver resources to the unhoused and those in need of basic aid, prior to and during extreme temperature conditions, and after natural disasters in rural, suburban, and urban areas. The UA is envisioned to be an autonomous aircraft capable of efficiently distributing essential supplies, including blankets, water, food, and medicine. The UAS fleet relies on advanced navigation and communication technologies to accurately identify unhoused people and efficiently and safely distribute materials to them. This will be done through a machine learning algorithm. By focusing on identified “homeless clusters”, places where unhoused individuals are concentrated, the UAS network increases access to critical resources, thereby helping to mitigate some of the external risks to the health of unhoused individuals. The UA can also be used during crises, such as by transporting supplies to medical tents that are stationed in difficult-to-reach areas suffering from natural disasters.

Samuel Beard↗

NASA NTRS2024

Enhancing the Payload Development Process for Lunar Gateway and Lunar Surface Science & Exploration: Space Biology Beyond Low-Earth-Orbit Instrumentation and Science Series (BLISS) Science Working Group 2023-2024 Annual Report

Space biology BLEO research is inherently driven by the differences between the LEO and BLEO environments, which can be broadly characterized by the five-hazard “RIDGE” paradigm (Radiation, Isolation, Distance, Gravity, Environment, e.g., similar to Figure 2 in (1)). Thus, the envisioned goals over the next decade will include using the cislunar and lunar surface environments to (A) characterize deep-space environments including biological effects of radiation and other stressors, (B) gain experience from isolation of very small groups in very small enclosures, (C) learn to compensate for distance from Earth via in situ resource utilization (ISRU) and bioregenerative life support, (D) gain assurance that all aspects of deep-space exploration can proceed in altered or artificial gravity environments, (E) develop essential adaptation scenarios for the built (e.g., low pressure) and external (e.g., temperature extremes, dust) environments.

Biology↗

NASA NTRSDate not supplied

Maturation of In-space Welding in Reduced Gravity and Reduced Pressure Environments Through Progression to Suborbital Flight Experiments

Development of in-space welding (ISW) is a key and enabling manufacturing technology as welding is currently involved in producing approximately 90% of durable goods, and this trend is expected to hold for in-space manufacturing as well. ISW is critical to a sustainable space economy. To mature in-space welding, numerous gaps must be closed since NASA has not made a weld in space in 50 years. Advancing laser beam welding (LBW) towards a suborbital flight demonstration will help mature the process for in-space assembly & manufacturing (ISAM) through demonstration in relevant environments and achieving technology readiness milestones. LBW technologies and science improved by this work will benefit in-space manufacturing, long-term sustainability of space structures & operations, and the overall space economy. Ground-based welding of aerospace hardware requires an Edisonian approach to qualify a welding process; however, this approach is infeasible for ISW qualification due to mass, volume, logistic, and cost challenges inherent to the space environment. To address this challenge, we are conducting ground and suborbital tests with partners performing parabolic flights to gather data on LBW processes and infuse them into NASA & partner missions. This progression from ground to flight experiments will elucidate relevant physics during LBW: 1) reduced gravity, 2) reduced pressure, and 3) extreme temperature. Data from post-flight evaluation and in situ instrumentation will feed integrated computational materials engineering (ICME) tools to reduce the burden of ISW infusion by establishing a link between space and terrestrial environments, ultimately accelerating the qualification of LBW in space.

in-space welding↗

NASA NTRSDate not supplied

Establishing an in-Space Joining Ecosystem at NASA Marshall via Laser Beam Welding

NASA Marshall is establishing an ISAM technology development ecosystem leveraging investments in laser beam processing to enable in-space joining via laser beam welding. A number of ground and flight experiments are being performed to develop laser beam welding as a mature process for use in space. These experiments access varied combinations of reduced gravity, reduced atmospheric pressure, and extreme temperatures to simulate relevant space environments. The associated instrumentation needed to exquisitely understand fundamental mechanisms during laser beam welding and to provide adequate validation datasets for computational models is also being developed and/or integrated.

thermal vacuum↗

NASA NTRSDate not supplied

Establishing an In-Space Joining Ecosystem at NASA Marshall via Laser Beam Welding

thermal vacuum↗

NASA NTRSDate not supplied

Engineering the Interface: Advanced Surface Technologies for Lunar Dust Management and Equipment Longevity

Through the Artemis program, NASA intends to develop a sustainable human foothold on the Moon, ultimately paving the way for crewed exploration of Mars. The Moon's hostile environment poses numerous obstacles, including exposure to radiation, temperature extremes, micrometeoroid threats, and particularly the persistent problem of lunar dust. Lunar dust impacts nearly every aspect of surface operations through adhesion and abrasion mechanisms, with contamination from anthropogenic activities (landing, rovers) far outweighing natural phenomena. Multiple adhesion pathways contribute to surface contamination in the lunar environment, including van der Waals forces, electrostatic forces, chemical reaction, and magnetic forces from elemental iron deposits. Sharp asperities from micrometeoroid bombardment and atmospheric absence increase interaction potential and enable mechanical interlocking. Low cohesion between dust particles exacerbates these challenges, as minimal interaction potential between dust and nearby surfaces overcomes particle cohesion, causing contamination. Lunar dust adhesion mitigation technologies can be categorized as either active, requiring external energy, or passive, relying on intrinsic material properties. Ultrasonic and electrodynamic technologies have been developed to the highest technology readiness level for active approaches. Passive strategies primarily focus on surface chemistry and topography modifications. At NASA Langley Research Center, approaches include surface migration agents to reduce surface energy, topographical modification using laser ablation patterning, and tailored surface conductivity to reduce intrinsic adhesion force. Performance has been evaluated using custom-built ultrasonic and centrifuge instruments. Plume-surface interactions from lunar landers can propel micrometer-sized particles at velocities up to 1000 m s-1.8 These particles pose risks to landers, habitats and infrastructure, leading to erosion, degradation, and reduced component lifespan. A panel recovered from Surveyor III was determined to have been severely abraded because of lunar dust displaced from the Apollo 12 lunar module that landed 160 m away. The performance of metallic surfaces has been evaluated via high velocity single particle impact using the laser-induced project impact test (LIPIT) facility at the University of Utah. Peridynamics modeling, a form of continuum mechanics that uses a nonlocal approach enabling greater simulation capabilities of crack initiation and fracture, has also been utilized to gain greater insight into material response during impact events. Lunar dust contamination challenges extend to power generation systems and moving equipment. Cables, rotation stages, and other mechanisms may experience limited range of motion and reduced lifetime due to dust infiltration. NASA Langley Research Center has evaluated traditional aerospace alloys, softgoods, wear resistant ceramics, and several polymer and polymer composite materials. Test methods have included traditional techniques like Taber abrasion testing, as well as designed test configurations developed in the DUSTE (dust, ultraviolet radiation, and space thermal environmental) chamber that reproduce mechanism functions in operational environment. Beyond laboratory experiments, several flight experiments have been conducted. Materials were exposed to the low Earth orbit environment on the Materials International Space Station Experiment (MISSE) and to the lunar surface environment through the Aegis Aerospace Regolith Adherence Characterization (RAC) payload and the Honeybee Robotics PlanetVac payload. Determining lunar dust's impact on surface exploration and habitation requires comprehensive experimental and computational capabilities combined with lessons learned from initial lunar activities. Identifying the greatest environmental challenges and developing mitigation technologies provides the clearest path toward successfully, expeditiously, and efficaciously completing NASA's mission. This presentation will discuss ongoing efforts at NASA Langley Research Center and collaborator contributions to these critical objectives.

Surface Engineering↗

NASA NTRSDate not supplied

Laser Beam Welding Benchmark Experiments Performed in Reduced Gravity and Vacuum

Laser beam welding (LBW) is affected by the extreme temperatures, reduced pressure, and reduced gravity present in space environments. Gravity and pressure especially influence its melt pool and solidification dynamics. A compact, modular vacuum chamber adaptable to flight platforms from parabolic to orbital currently hosts an experiment to investigate the combined influence of reduced gravity and pressure on LBW. A swappable cartridge contains a rotating platen on which customizable workpieces can be welded under vacuum, greatly increasing experimental throughput. Instrumentation includes weld and thermal cameras observing the process, thermocouples placed on workpieces, accelerometers, and vacuum sensors. Experimental data gathered during the welding process will be combined with post-flight nondestructive evaluation, metallography, and mechanical testing to provide validation datasets for computational modeling. Phase I of this effort involves a parabolic flight campaign in low gravity while an anticipated Phase II would proceed to in-space demonstration to access extended duration microgravity.

in-space welding↗

NASA NTRS2026

Radiation-Conditioned Ti–hBN Coatings for Space Mechanisms: Bridging Tribology and Irradiation Effects from Laboratory to Low-Earth Orbit

The longevity of tribological components in extraterrestrial environments is challenged by abrasive regolith, extreme temperatures, and ionizing radiation. This study evaluates the performance of vacuum plasma sprayed (VPS) Ti-2vol.% hexagonal boron nitride (hBN) coatings applied to joint mechanisms such as rod and slot, ball and socket, and hinge assemblies, fabricated from Al6061 and Ti6Al4V for planetary structures. Coated and uncoated samples were tested under vacuum with lunar regolith simulant (JSC-1A), followed by environmental exposures including electron radiation and thermal cycling. Results show that coated samples consistently outperformed uncoated counterparts across all configurations. Wear depth in coated components was reduced by over 80%, as confirmed by 3D profilometry and surface imaging. SEM analysis revealed severe abrasion and localized plastic deformation in uncoated surfaces, while coated samples retained structural integrity due to synergy of hard protective phases formed during deposition and retained hBN providing solid lubrication in the sliding surface. Coated and exposed samples exhibited smoother actuation profiles and reduced friction, indicating a beneficial "conditioning" effect from environmental exposure. The coatings-maintained performance even on complex geometries with minimal delamination. These findings demonstrate the potential of VPS Ti-hBN coatings to extend the operational life of lunar mechanisms, bridging laboratory-scale tribology with flight-relevant mechanical applications.

tribology↗

NASA NTRS2026

Raising TRL of Your Lunar Payload

Preparing payloads for the lunar surface requires rigorous testing that accurately captures the extreme environmental and operational conditions. This presentation provides an overview of the lunar relevant test capabilities at NASA JSC’s Astromaterials Research and Exploration Science (ARES) laboratories as well as the Energy System Test Area (ESTA) Lunar Development and Test Facility. These facilities allow teams to assess hardware performance in dusty vacuum environments, characterize interactions with high fidelity lunar regolith simulants, evaluate mechanical and thermal durability, and understand the effects of micrometeoroid and orbital debris impacts—critical factors for certifying payloads that will operate on the lunar surface or in orbit. While Lunar power challenges such as variable illumination, extreme temperatures, and dust driven degradation will be briefly summarized, the focus of this talk is on how JSC’s test infrastructure enables developers to validate designs, reduce mission risk, and ensure compatibility with CLPS and Artemis objectives. NASA JSC’s expertise and experience help industry, academic, and government teams prepare robust hardware ready for successful delivery and operation on the surface of the Moon.

Lunar Regolith Simulant↗

NASA NTRS2026

Raising TRL of Your Lunar Payload

Laboratories↗

NASA NTRS2025

A Review of Direct Ink Writing of Polymer Derived Ceramics

With the growing demand for materials capable of withstanding extreme temperatures and pressures, ceramic components with exceptional corrosion resistance and reliable mechanical properties have experienced a significant surge in demand. However, traditional ceramic forming methods involve high-temperatures and energy-intensive processes that often struggle to produce complex parts or composites efficiently. Polymer-Derived Ceramics (PDCs) offer a transformative solution by using polymeric precursors that can be converted into a wide variety of silicon-based and non-silicon-based ceramics through heat treatment. The polymeric nature of PDC precursors enables the fabrication of geometrically intricate components using conventional polymer-forming techniques at significantly lower processing temperatures. Furthermore, PDCs are well-suited for additive manufacturing (AM), allowing the production of complex structural and functional components through cost-effective, low-temperature processes. By leveraging the diverse properties of PDC materials – each with unique advantages and limitations – manufacturers can optimise performance for specific applications. This review provides an overview of the types of PDCs developed to date and their broad range of applications. Specifically, it delves into the Direct Ink Writing (DIW) process, exploring its rheological requirements and the critical role of fillers in tailoring the rheological properties of polymeric precursors to meet the specific demands of DIW.

Victoria Bishop↗

DOE OSTI2021

Planned Steady State Irradiation of Characterized Instruments for Nuclear Thermal Rockets Using In-Pile Experiment Apparatus

The development of nuclear rocket technology is critical for the further exploration of extraterrestrial bodies. Nuclear rockets are capable of providing various advantages over current chemical rockets. However, the harsh environment provides a number of challenges regarding instrument performance. Temperature extremes, radiation (reactor and space), and the inability to conduct traditional maintenance activities can lead to a severe degradation in instrument performance. To better understand the effects of radiation on instrumentation, an irradiation campaign has been designed to test a set of instruments provided by a collaborator in the aerospace industry. Details concerning pre-irradiation performance are provided for a future comparison to the irradiated performance. Additionally, the design of the irradiation test is described in detail.

Floyd, Dan↗

DOE OSTI2023

The Qualification of Sealability and Creep Relaxation of Additively Manufactured Zytel Gaskets for PEM Fuel Cells

The purpose of this thesis is to study the feasibility of low-cost additive manufacturing of gaskets for proton exchange membrane fuel cells exposed to extreme temperature conditions ranging from -55°C to 100°C. With the growing popularity and decreasing costs of additive manufacturing technologies, specifically Material Extrusion (ME), research is being conducted to determine the feasibility of ME components. Thermally cycled PEMFCs may exhibit accelerated gasket deterioration, therefore, the mechanical stability of material extruded gaskets following a harsh thermal cycle must be assessed. The feasibility of the material extruded gaskets will be proven by manufacturing optimization and mechanical testing. The target material for this study is Zytel by DuPont Chemical. The mechanical stability will be assessed via sealability and creep relaxation testing according to ASTM F37B and ASTM F38B respectively. Because the capabilities to conduct sealability testing at temperature were not available, each specimen was thermally soaked and allowed to return to room temperature prior to testing. As a result of sealability experiments, the 100°C-soaked specimens resulted in lower leak rates with a higher precision when compared to specimens soaked at -55°C and 22°C at across all compressive loads. It was observed from results from creep relaxation testing that there is thermal contraction and expansion occurring at 55°C and 100°C respectively, which can be observed by the resultant graphs. The recoverability of thermally cycled specimens are better than those that just experienced a high temperature hold. After the seven-day thermal cycle, the samples stabilized and maintained their structure.

Lazarin, Robert↗

DOE OSTI2023

Resilience Assessment Framework For Electric Distribution Systems Performance Under Extreme Conditions

The devastating impact of extreme weather-related events is increasingly evident on power grids, especially on distribution grids. The severity of their potential impact calls for 1) developing a suitable resilience assessment framework to capture the system performance and 2) assessing relevant mitigative strategies to lessen the impact of such events. This paper proposes a framework to identify grid vulnerabilities using the energy-at-risk concept to select, disconnect and isolate grid portions due to a resilience event. The proposed framework mainly consists of two steps; i) processing the utility's available infrastructure, i.e., a network model, possible switching combinations, and outage information for those combinations, as a graph-based database, and ii) implementing a novel optimal switching algorithm leveraging database and grid simulated metrics. These switching actions are generated to implement load curtailment in a rolling manner during anticipated grid scarcity conditions. In this study, a test case is created using two taxonomy feeders and is simulated against an extreme temperature event, e.g., a long, relatively cold, and prolonged freeze peak, thereby creating stress on the grid. It is demonstrated that the proposed framework allows utilities to predict the energy-at-risk during such resilience events and design suitable outage management strategies.

Poudel, Shiva↗

DOE OSTI2023

Muon-Catalyzed Fusion

Fusion holds great promise as a clean and abundant energy source. However, traditional thermonuclear fusion encounters significant challenges due to the extreme temperatures required to overcome the coulomb barrier for two nuclei to fuse. In contrast, muon-catalyzed fusion presents an alternative approach that can surmount this barrier at significantly lower temperatures. Muons, with properties resembling those of electrons but 200 times heavier, can effectively reduce the atomic orbital radius, enabling central nuclei to overcome the coulomb force through the strong force. By introducing muons into a mixture of deuterium and tritium (two hydrogen isotopes), fusion is facilitated, releasing a 3.5MeV alpha particle and a 14.1MeV neutron. In the majority of cases, the muon is liberated and can initiate further fusions. However, approximately 0.8% of the time, it adheres to the alpha particle and remains bound until it either decays or undergoes reactivation through collisional ionization. To maximize the number of fusions per muon, it is crucial to enhance the cycling rate and reactivation fraction. Theoretical predictions and experimental data both suggest that the sticking rate decreases with increasing density. However, there exists a discrepancy between experimental observations and theoretical estimations regarding the extent of this decrease. To address these disparities, this experiment aims to investigate the cycling rate and sticking fraction under higher temperatures and pressures than previously explored.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

DOE OSTI2020

Modeling Efforts to Gain Insight into Historical Leak Events from the Single-Shell Tank A-105 in the Hanford 241-A Tank Farm - 20113

The 241-A Tank Farm is a single-shell tank (SST) farm constructed to store process waste from Hanford nuclear operations. Millions of gallons of nuclear waste were stored in the 241-A Tank Farm SSTs and some of the SSTs leaked in the past. In addition, spills and pipeline leaks during transfers and storage and intentional discharges to cribs and trenches resulted in releasing waste to the ground. Tank liner leaks are referred to as 'leaks' and all other discharges to the soil are referred to as 'releases.' Liquid waste that could be removed by pumping has been removed from all of the SSTs to reduce the potential for future leaks. The most significant historical leak event in 241-A Tank Farm occurred in 1965 when tank A-105 experienced a pressurized steam event. This event resulted in damage to the inner steel liner flooring of A-105, which was separated from the sidewalls over part of its circumference and buckled up to 2.5 m, vertically. During this event up to 7,570 L of contaminated liquid may have leaked to the adjacent soil. This leak occurred under extreme temperature and pressure conditions. Modeling efforts to better understand the nature and extent of historical leaks from subsurface SSTs that were used to store highly radioactive, self-boiling liquid wastes at 241-A Tank Farm have recently been undertaken. These efforts have compiled the available historical information to support a preliminary non-isothermal, multiphase flow and chemical transport modeling effort to re-create the conditions under which the leaks occurred and to formulate a conceptual model as to the extent and distribution of leaked radioactive contaminants in the adjacent soil material. The focus of this work was on developing an understanding of the key features, processes and bounding conditions related to tank A-105 leak events that occurred in the 1960's. The activities include estimation of leak composition, non-isothermal multiphase flow and transport modeling, and geochemical modeling. The STOMP{sup C} Water-Air-Energy modeling code was utilized to implement the three-dimensional representation of the subsurface tank and the surrounding flow field. Once constructed, the model was used to evaluate the conceptual understanding of leaks originating from different parts of the tank under the elevated temperature boundary conditions that were imposed by surrounding tanks at the time of the historical leaks. The chemical evolution of the liquid waste was also evaluated as it leaked from the tank under transient pressure and temperature gradients. The results of the preliminary evaluation suggested the presence of a heat-pipe effect beneath tank A-105 in which water vapor at an elevated temperature is driven away from the base of the tank to a position where water vapor cools, condenses and is then drawn back toward the tank by the strong capillary attraction of the dry soil. A non-sorbing contaminant (Tc-99) was introduced into this flow field to better understand the potential distribution patterns of leaked contaminants that may have occurred during the historical leak events. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗