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Chapter 6: Materials for Spacecraft

The general knowledge in this chapter is intended for a broad variety of spacecraft: manned or unmanned, low Earth to geosynchronous orbit, cis-lunar, lunar, planetary, or deep space exploration. Materials for launch vehicles are covered in chapter 7. Materials used in the fabrication of spacecraft hardware should be selected by considering the operational requirements for the particular application and the design engineering properties of the candidate materials. The information provided in this chapter is not intended to replace an in-depth materials study but rather to make the spacecraft designer aware of the challenges for various types of materials and some lessons learned from more than 50 years of spaceflight. This chapter discusses the damaging effects of the space environment on various materials and what has been successfully used in the past or what may be used for a more robust design. The material categories covered are structural, thermal control for on-orbit and re-entry, shielding against radiation and meteoroid/space debris impact, optics, solar arrays, lubricants, seals, and adhesives. Spacecraft components not directly exposed to space must still meet certain requirements, particularly for manned spacecraft where toxicity and flammability are concerns. Requirements such as fracture control and contamination control are examined, with additional suggestions for manufacturability. It is important to remember that the actual hardware must be tested to understand the real, "as-built" performance, as it could vary from the design intent. Early material trades can overestimate benefits and underestimate costs. An example of this was using graphite/epoxy composite in the International Space Station science racks to save weight. By the time the requirements for vibration isolation, Space Shuttle frequencies, and experiment operations were included, the weight savings had evaporated.

Finckenor, Miria M.↗

US Navy Submarine Sea Trial of NASA developed Multi-Gas Monitor

During a successful 2 year technology demonstration of the tunable diode laser spectroscopy (TDLS) based Multi-Gas Monitor (MGM) on the International Space Station (ISS), we began discussing with the US Navy the possibility of conducting a sea trial of an MGM on a submarine. The sea trial would also include a gas chromatography/differential mobility spectrometer based Air Quality Monitor (AQM), which is used operationally on ISS for select volatile organic compounds. AQM results will be the subject of a separate paper. The Navy’s interest in testing NASA equipment is in a planned update to the environmental monitoring equipment used aboard submarines. NASA’s goal is studying submarines as closed environment analogs to spacecraft. MGM’s core technology was developed by Vista Photonics Inc using Small Business Innovation Research (SBIR) grants and expanded for various applications using NASA program funding. The MGM measures oxygen, carbon dioxide, ammonia and water vapor in ambient air, displays concentrations with temperature and pressure, and stores 30 second moving averages. The sea trial involves colocating the instrument with the Central Air Monitor (CAM) and connecting it to rack power prior to departure, and letting it run during the entire sea trial of a few months duration. All data stored is inside MGM, with no connection to the vessel data bus. Crew intervention is limited to checking MGM periodically to see that it is working and power cycling if the display is OFF. After the trial is over, the unit with its data will be retrieved. Post sea trial calibration check and data analysis are planned and results will be compared with both CAM data and results from MGM’s ISS technology demonstration.

Mudgett, Paul D.↗

A Dose of Reality: Radiation Analysis for Realistic Human Spacecraft

INTRODUCTION As with most computational analyses, a tradeoff exists between problem complexity, resource availability and response accuracy when modeling radiation transport from the source to a detector. The largest amount of analyst time for setting up an analysis is often spent ensuring that any simplifications made have minimal impact on the results. The vehicle shield geometry of interest is typically simplified from the original CAD design in order to reduce computation time, but this simplification requires the analyst to "re-draw" the geometry with a limited set of volumes in order to accommodate a specific radiation transport software package. The resulting low-fidelity geometry model cannot be shared with or compared to other radiation transport software packages, and the process can be error prone with increased model complexity. The work presented here demonstrates the use of the DAGMC (Direct Accelerated Geometry for Monte Carlo) Toolkit from the University of Wisconsin, to model the impacts of several space radiation sources on a CAD drawing of the US Lab module. METHODS The DAGMC toolkit workflow begins with the export of an existing CAD geometry from the native CAD to the ACIS format. The ACIS format file is then cleaned using SpaceClaim to remove small holes and component overlaps. Metadata is then assigned to the cleaned geometry file using CUBIT/Trelis from csimsoft (Registered Trademark). The DAGMC plugin script removes duplicate shared surfaces, facets the geometry to a specified tolerance, and ensures that the faceted geometry is water tight. This step also writes the material and scoring information to a standard input file format that the analyst can alter as desired prior to running the radiation transport program. The scoring results can be transformed, via python script, into a 3D format that is viewable in a standard graphics program. RESULTS The CAD model of the US Lab module of the International Space Station, inclusive of all the racks and components, was simplified to remove holes and volume overlaps. Problematic features within the drawing were also removed or repaired to prevent runtime issues. The cleaned drawing was then run through the DAGMC workflow to prepare for analysis. Pilot tests modeling transport of 1GeV proton and 800MeV/A oxygen sources show that reasonable results are converged upon in an acceptable amount of overall computation time from drawing preparation to data analysis. The FLUKA radiation transport code will next be used to model both a GCR and a trapped radiation source. These results will then be compared with measurements that have been made by the radiation instrumentation deployed inside the US Lab module. DISCUSSION Early analyses have indicated that the DAGMC workflow is a promising toolkit for running vehicle geometries of interest to NASA through multiple radiation transport codes. In addition, recent work has shown that a realistic human phantom, provided via a subcontract with the University of Florida, can be placed inside any vehicle geometry for a combinatorial analysis. This added functionality gives the user the ability to score various parameters at the organ level, and the results can then be used as input for cancer risk models.

Barzilla, J. E.↗

Behavioral Assessment of Spaceflight Effects on Neurocognitive Performance: Extent and Longevity

Exposure to the microgravity environment during spaceflight missions impacts crewmembers' sensorimotor function. Bock et al. [1] studied the cognitive demands of human sensorimotor performance and dual tasking during long duration missions and concluded that both stress and scarcity of cognitive resources required for sensorimotor adaptation may be responsible for these deficits during spaceflight. Therefore, in consideration of the health and performance of crewmembers in- and post-flight, we are conducting this study to investigate the effects of spaceflight on the extent, longevity and neural bases of sensorimotor, cognitive, and neural changes. The data presented will focus on the behavioral measures that were collected pre-, in- and post-flight including spatial cognition, processing speed, bimanual coordination, functional mobility, computerized dynamic posturography (CDP), and vibrotactile induced vestibular evoked myogenic potential (VEMP). To date, data were collected over the course of two pre-flight sessions and four post-flight sessions on five crewmembers (n=13) using the protocol described in Koppelmans et al. [2]. Balance control was assessed using CDP, with eyes closed and a sway-referenced base of support (Sensory Organization Test 5), with and without head movements in the pitch plane. Spatial working memory was assessed using Thurston's Card Rotation Test and a Mental Rotation Test. The Rod and Frame Test was performed to test visual dependence. The Digit Symbol Substitution Test was performed to evaluate processing speed, and the Purdue Pegboard Task was performed to test bimanual coordination. Vestibular function was assessed by eliciting ocular VEMP via a hand held striker on the side of the head as subjects lay supine on a gurney. Subjects also performed the Functional Mobility Test of walking through an obstacle course to assess rate of early motor learning. Data were also collected on the same crewmembers during three in-flight sessions on the International Space Station (ISS). In-flight, spatial working memory was assessed using the Mental Rotation Test, adaptation to visuo-motor transformation in manual control was assessed using the Sensorimotor Adaptation Test, and multi-tasking ability was assessed using the Dual Task Test. These three tests were performed in a strapped-in configuration mimicking a seated position - waist bungees pulled the crewmember toward the "floor" with feet secured in foot loops. The Mental Rotation Test was also performed in a free-floating configuration while the crewmember floated while holding on to the gamepad controller used to provide input that was secured to the equipment rack on the ISS. Preliminary findings from data collected to date, will be included in the presentation. Eventual comparison to results from supporting bed rest and longitudinal studies will enable the parsing out of the multiple mechanisms contributing to any observed spaceflight-induced sensorimotor and cognitive behavioral changes.

De Dios, Y. E.↗

Development of the Two Phase Flow Separator Experiment for a Reduced Gravity Aircraft Flight

The recent hardware development and testing of a reduced gravity aircraft flight experiment has provided valuable insights for the future design of the Two Phase Flow Separator Experiment (TPFSE). The TPFSE is scheduled to fly within the Fluids Integration Rack (FIR) aboard the International Space Station (ISS) in 2020. The TPFSE studies the operational limits of gas and liquid separation of passive cyclonic separators. A passive cyclonic separator utilizes only the inertia of the incoming flow to accomplish the liquid-gas separation. Efficient phase separation is critical for environmental control and life support systems, such as recovery of clean water from bioreactors, for long duration human spaceflight missions. The final low gravity aircraft flight took place in December 2015 aboard NASA's C9 airplane.

fluid mechanics↗

US Navy Submarine Sea Trial of NASA developed Multi-Gas Monitor

During a successful 2 year technology demonstration of the tunable diode laser spectroscopy (TDLS) based Multi-Gas Monitor (MGM) on the International Space Station (ISS), we began discussing with the US Navy the possibility of conducting a sea trial of an MGM on a submarine. The sea trial would also include a gas chromatography/differential mobility spectrometer based Air Quality Monitor (AQM), which is used operationally on ISS for volatile organic compound analysis. AQM preparation and results will be the subject of a separate paper. The Navy's interest in testing NASA equipment in general relates to their ongoing search for better air monitoring technology. NASA's goal is studying submarines as closed environment analogs to spacecraft. MGM's core technology was developed by Vista Photonics Inc. using Small Business Innovation Research (SBIR) grants and expanded for various applications using NASA program funding. The MGM measures oxygen, carbon dioxide, ammonia and water vapor in ambient air, displays concentrations with temperature and pressure, and stores 30 second moving averages. The sea trial involves collocating the instrument with the Central Atmosphere Monitoring System (CAMS Mk II) of the submarine, connecting it to rack power prior to departure, and letting it run during the entire 90 day patrol. All data is stored within MGM, with no connection to the vessel data bus. Crew intervention is limited to checking MGM periodically to see that it is working and power cycling if necessary. After the trial is over, the unit with its data will be retrieved. Post sea trial calibration check and data analysis are planned and results will be compared with both CAMS Mk II data and results from MGM's ISS technology demonstration. Since the sea trial itself has been delayed, this paper describes the preparation of MGM for the sea trial and also provides a summary of the latest data from the ISS MGM technology demonstration.

Mudgett, Paul D.↗

Spectrometer for Sky-Scanning, Sun-Tracking Atmospheric Research (4STAR) Instrument Improvements

The Spectrometer for Sky-Scanning, Sun-Tracking Atmospheric Research (4STAR) combines airborne sun tracking and sky scanning with grating spectroscopy to improve knowledge of atmospheric constituents and their links to air-pollution and climate. Hyper-spectral measurements of direct-beam solar irradiance provide retrievals of gas constituents, aerosol optical depth, and aerosol and thin cloud optical properties. Sky radiance measurements in the principal and almucantar planes enhance retrievals of aerosol absorption, aerosol type, and size mode distribution. Zenith radiance measurements are used to retrieve cloud properties and phase, which in turn are used to quantify the radiative transfer below cloud layers. These airborne measurements tighten the closure between satellite and ground-based measurements. In contrast to the Ames Airborne Tracking Sunphotometer (AATS-14) predecessor instrument, new technologies for each subsystem have been incorporated into 4STAR. In particular, 4STAR utilizes a modular sun-trackingsky-scanning optical head with fiber optic signal transmission to rack mounted spectrometers, permitting miniaturization of the external optical head, and spectrometerdetector configurations that may be tailored for specific scientific objectives. This paper discusses technical challenges relating to compact optical collector design, radiometric dynamic range and stability, and broad spectral coverage at high resolution. Test results benchmarking the performance of the instrument against the AATS-14 standard and emerging science requirements are presented.

Atmopheric Research (4STAR)↗

Performance Evaluation of the International Space Station Flow Boiling and Condensation Experiment (FBCE) Test Facility

A ground-based experimental facility to perform flow boiling and condensation experiments is built in support of the development of the long duration Flow Boiling and Condensation Experiment (FBCE) destined for operation on board of the International Space Station (ISS) Fluid Integrated Rack (FIR). We performed tests with the condensation test module oriented horizontally and vertically. Using FC-72 as the test fluid and water as the cooling fluid, we evaluated the operational characteristics of the condensation module and generated ground based data encompassing the range of parameters of interest to the condensation experiment to be performed on the ISS. During this testing, we also evaluated the pressure drop profile across different components of the fluid subsystem, heater performance, on-orbit degassing subsystem, and the heat loss from different components. In this presentation, we discuss representative results of performance testing of the FBCE flow loop. These results will be used in the refinement of the flight system design and build-up of the FBCE which is scheduled for flight in 2019.

microgravity↗

Remote Advanced Payload Test Rig (RAPTR) Portable Payload Test System for the International Space Station (ISS)

The RAPTR was developed to test ISS payloads for NASA. RAPTR is a simulation of the Command and Data Handling (C&DH) interfaces of the ISS (MIL-STD 1553B, Ethernet and TAXI) and is designed to facilitate rapid testing and deployment of payload experiments to the ISS. The ISS Program's goal is to reduce the amount of time it takes a payload developer to build, test and fly a payload, including payload software. The RAPTR meets this need with its user oriented, visually rich interface. Additionally, the Analog and Discrete (A&D) signals of the following payload types may be tested with RAPTR: (1) EXPRESS Sub Rack Payloads; (2) ELC payloads; (3) External Columbus payloads; (4) External Japanese Experiment Module (JEM) payloads. The automated payload configuration setup and payload data inspection infrastructure is found nowhere else in ISS payload test systems. Testing can be done with minimal human intervention and setup, as the RAPTR automatically monitors parameters in the data headers that are sent to, and come from the experiment under test.

Calvert, John↗

Random Access Frame (RAF) System Neutral Buoyancy Evaluations

The Random Access Frame (RAF) concept is a system for organizing internal layouts of space habitats, vehicles, and outposts. The RAF system is designed as a more efficient improvement over the current International Standard Payload Rack (ISPR) used on the International Space Station (ISS), which was originally designed to allow for swapping and resupply by the Space Shuttle. The RAF system is intended to be applied in variable gravity or microgravity environments. This paper discusses evaluations and results of testing the RAF system in a neutral buoyancy facility simulating low levels of gravity that might be encountered in a deep space environment.

human spaceflight↗

Development of NASA's Sample Cartridge Assembly: Summary of GEDS Design, Development Testing, and Thermal Analyses

Outline: Background of ISS (International Space Station) Material Science Research Rack; NASA SCA (Sample Cartridge Assembly) Design; GEDS (Gravitational Effects in Distortion in Sintering) Experiment Ampoule Design; Development Testing Summary; Thermal Modeling and Analysis. Summary: GEDS design development challenging (GEDS Ampoule design developed through MUGS (Microgravity) testing; Short duration transient sample processing; Unable to measure sample temperatures); MUGS Development testing used to gather data (Actual LGF (Low Gradient Furnace)-like furnace response; Provided sample for sintering evaluation); Transient thermal model integral to successful GEDS experiment (Development testing provided furnace response; PI (Performance Indicator) evaluation of sintering anchored model evaluation of processing durations; Thermal transient model used to determine flight SCA sample processing profiles).

O'Connor, Brian↗

Development of NASA's Sample Cartridge Assembly: Summary of GEDS Design, Development Testing, and Thermal Analyses

NASA's Sample Cartridge Assembly (SCA) project is responsible for designing and validating a payload that contains materials research samples in a sealed environment. The SCA will be heated in the European Space Agency's (ESA) Low Gradient Furnace (LGF) that is housed inside the Material Science Research Rack (MSRR) located on the International Space Station (ISS). The first Principle Investigator (PI) to utilize the SCA will focus on Gravitational Effects on Distortion in Sintering (GEDS) research. This paper will give a summary of the design and development test effort for the GEDS SCA and will discuss the role of thermal analysis in developing test profiles to meet the science and engineering requirements. Lessons learned will be reviewed and salient design features that may differ for each PI will be discussed.

O'Connor, Brian↗

Ultra-Stable Spectrometer for Sky-Scanning, Sun-Tracking Atmospheric Research (5STAR)

The Spectrometer for Sky-Scanning, Sun-Tracking Atmospheric Research (4STAR) combines airborne sun tracking and sky scanning with diffraction spectroscopy to improve knowledge of atmospheric constituents and their links to airpollution and climate. Direct beam hyperspectral measurement of optical depth improves retrievals of gas constituentsand determination of aerosol properties. Sky scanning enhances retrievals of aerosol type and size distribution.Hyperspectral cloud-transmitted radiance measurements enable the retrieval of cloud properties from below clouds.These measurements tighten the closure between satellite and ground-based measurements. 4STAR incorporates amodular sun-tracking sky-scanning optical head with optical fiber signal transmission to rack mounted spectrometers,permitting miniaturization of the external optical tracking head, and future detector evolution.4STAR has supported a broad range of flight experiments since it was first flown in 2010. This experience provides thebasis for a series of improvements directed toward reducing measurement uncertainty and calibration complexity, andexpanding future measurement capabilities, to be incorporated into a new 5STAR instrument. A 9-channel photodioderadiometer with AERONET-matched bandpass filters will be incorporated to improve calibration stability. A wide dynamic range tracking camera will provide a high precision solar position tracking signal as well as an image of sky conditions around the solar axis. An ultrasonic window cleaning system design will be tested. A UV spectrometer tailored for formaldehyde and SO2 gas retrievals will be added to the spectrometer enclosure. Finally, expansion capability for a 4 channel polarized radiometer to measure the Stokes polarization vector of sky light will be incorporated. This paper presents initial progress on this next-generation 5STAR instrument.

atmosphere↗

Challenges and Opportunities in Gen3 Embedded Cooling with High-Quality Microgap Flow

Gen3, Embedded Cooling, promises to revolutionize thermal management of advanced microelectronic systems by eliminating the sequential conductive and interfacial thermal resistances which dominate the present 'remote cooling' paradigm. Single-phase interchip microfluidic flow with high thermal conductivity chips and substrates has been used successfully to cool single transistors dissipating more than 40kW/sq cm, but efficient heat removal from transistor arrays, larger chips, and chip stacks operating at these prodigious heat fluxes would require the use of high vapor fraction (quality), two-phase cooling in intra- and inter-chip microgap channels. The motivation, as well as the challenges and opportunities associated with evaporative embedded cooling in realistic form factors, is the focus of this paper. The paper will begin with a brief review of the history of thermal packaging, reflecting the 70-year 'inward migration' of cooling technology from the computer-room, to the rack, and then to the single chip and multichip module with 'remote' or attached air- and liquid-cooled coldplates. Discussion of the limitations of this approach and recent results from single-phase embedded cooling will follow. This will set the stage for discussion of the development challenges associated with application of this Gen3 thermal management paradigm to commercial semiconductor hardware, including dealing with the effects of channel length, orientation, and manifold-driven centrifugal acceleration on the governing behavior.

microchannel↗

Expanding a Supercomputer Facility Using Modular Data Center Technology

With the expansion of high-end computing resources needed to support NASA's increasing demands for physics-based simulations, the facility housing Pleiades-the agency's largest supercomputer-recently reached its power and cooling capacity. In response, the NASA Advanced Supercomputing Division at Ames Research Center undertook a prototype project that resulted in a new facility based on modular data center technology. The facility, a ~1000 square-foot module on a concrete pad with room for 16-18 compute racks, was completed in fall 2016 and an SGI computer system, named Electra, was deployed there in early 2017. Cooling is performed via an evaporative system built into the module, and preliminary experience shows a Power Usage Effectiveness (PUE) of ~1.03. Electra achieved over a petaflop on the LINPACK benchmark, sufficient to rank number 96 on the November 2016 TOP500 list. The system consists of 1,152 InfiniBand-connected Intel Xeon Broadwell-based nodes. Its users access their files on a facility wide file system shared by all compute assets via Mellanox MetroX InfiniBand extenders, which connect the Electra fabric to Lustre routers InfiniBand fabric over fiber-optic links about 300 meters long. The prototype has exceeded expectations and is serving as a blueprint for future expansions.*†

Facility↗

Two-Phase Flow System Design Status of the Flow Boiling and Condensation Experiment

The Flow Boiling and Condensation Experiment (FBCE) is a flight experiment that is designed to operate in the Fluids Integrated Rack (FIR) on the International Space Station (ISS). The goal of the FBCE is to obtain heat transfer data, as well as general flow data, for two-phase flow systems in microgravity. This will help in the design of thermal management systems that are able to utilize latent heat transfer more efficiently.

deFiebre, Jesse↗

Electra: A Modular-Based Expansion of NASA's Supercomputing Capability

NASA has increasingly relied on high-performance computing (HPC) re- sources for computational modeling, simulation, and data analysis to meet the science and engineering goals of its missions in space exploration, aeronautics, and Earth and space science. The NASA Advanced Supercomputing (NAS) Division at Ames Research Center in Silicon Valley, Calif., hosts NASA’s premier supercomputing resources, integral to achieving and enhancing the success of the agency’s missions. NAS provides a balanced environment, funded under the High-End Computing Capability (HECC) project, comprised of world-class supercomputers, including its flagship distributed-memory cluster, Pleiades; high-speed networking; and massive data storage facilities, along with multi-disciplinary support teams for user support, code porting and optimization, and large-scale data analysis and scientific visualization. However, as scientists have increased the fidelity of their simulations and engineers are conducting larger parameter-space studies, the requirements for supercomputing resources have been growing by leaps and bounds. With the facility housing the HECC systems reaching its power and cooling capacity, NAS undertook a prototype project to investigate an alternative approach for housing supercomputers. Modular supercomputing, or container-based computing, is an innovative concept for expanding NASA’s HPC capabilities. With modular supercomputing, additional containers—similar to portable storage pods—can be connected together as needed to accommodate the agency’s ever-increasing demand for computing resources. In addition, taking advantage of the local weather permits the use of cooling technologies that would additionally save energy and reduce annual water usage. The first stage of NASA’s Modular Supercomputing Facility (MSF) prototype, which resulted in a 1,000 square-foot module on a concrete pad with room for 16 compute racks, was completed in Fall 2016 and an SGI (now HPE) computer system, named Electra, was deployed there in early 2017. Cooling is performed via an evaporative system built into the module, and preliminary experience shows a Power Usage Effectiveness (PUE) measurement of 1.03. Electra achieved over a petaflop on the LINPACK benchmark, sufficient to rank number 96 on the November 2016 TOP500 list [14]. The system consists of 1,152 InfiniBand-connected Intel Xeon Broadwell-based nodes. Its users access their files on a facility-wide file system shared by all HECC compute assets via Mellanox MetroX InfiniBand extenders, which connect the Electra fabric to Lustre routers in the primary facility over fiber-optic links about 900 feet long. The MSF prototype has exceeded expectations and is serving as a blueprint for future expansions. In the remainder of this chapter, we detail how modular data center technology can be used to expand an existing compute resource. We begin by describing NASA’s requirements for supercomputing and how resources were provided prior to the integration of the Electra module-based system.

Biswas, Rupak↗

Assembly and Integrated Systems Testing for the Flow Boiling and Condensation Experiment (FBCE)

The Flow Boiling and Condensation Experiment (FBCE) is a flight experiment that is designed to operate in the Fluids Integrated Rack (FIR) on the International Space Station (ISS). The objective of the FBCE is to develop an integrated two-phase flow experiment that will serve as a primary platform for obtaining flow boiling and condensation heat transfer data in microgravity. This data will enable the design and analysis of two-phase thermal management systems for future NASA missions that require increased efficiency beyond the current single-phase systems. The FBCE consists of seven modules, each of which must link together mechanically, electrically, and fluidically upon final integration. Five of the modules provide the fluidic and electronic components required to bring the test fluid to the inlet conditions required by the test module, where the primary science is conducted. These inlet conditions encompass fluid quality ranging from a superheated vapor to a subcooled liquid at a variety of flow rates and pressures. The FBCE is currently manufacturing two test modules, each of which has its own separate test campaign with the five support modules. Each of the modules presents a unique challenge in its assembly and checkout, particularly related to ensuring the final hardware configuration can meet the fluid and thermal requirements levied upon them. Following assembly, a series of flight verification tests will be performed, including thermal testing, EMI testing, and final integration in a FIR Ground Integration Unit. This presentation discusses the status of the FBCE as it continues through final verification testing, including current test results and lessons learned throughout the assembly and integration phase of the project. In addition, future options for additional flight test sections will be explored that will benefit the broader NASA thermal and fluids community.

deFiebre, Jesse↗