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Hybrid Modeling Study on Grain Evolution in the Metal Welding Process and Its Potential Lunar Application

Metal is most commonly used structural material in a wide range of spacecraft, and welding is the principal method for joining metal components into functional systems. However, conducting welding experiments under extreme environments—such as microgravity or vacuum conditions in space—is prohibitively expensive and experimentally challenging. To overcome these limitations, multi-physics computational welding models provide a cost-effective and versatile alternative. In this work, the authors have developed a coupled thermal (fluid) microstructure simulation framework to model metal welding under varying gravity conditions. The framework integrates a mixed-mode heat transfer formulation (conduction, convection, and radiation) with molten pool fluid dynamics, enabling accurate prediction of temperature fields and weld-pool geometry. A grain growth model is further incorporated to capture the spatial and temporal evolution of microstructure, including grain size distribution and morphological transitions during solidification. This approach provides detailed insight into molten pool evolution and grain-level microstructure development throughout the welding process. By explicitly parameterizing environmental conditions, the model supports extrapolation to off-Earth manufacturing scenarios such as welding on the lunar surface. Tantalum—chosen in this study due to its high melting point, oxidation resistance, and mechanical stability at elevated temperatures—serves as the material system for model demonstration. Beyond Tantalum, the integrated multi-physics framework offers broad applicability for predictive welding simulations of various structural and refractory metals or alloys used in extreme terrestrial or extraterrestrial environments.

kinetic Monte Carlo (SPPARKS)↗

A new approach for performing contamination control bakeouts in JPL thermal vacuum test chambers

Contamination control requirements for the Wide Field/Planetary Camera II (WF/PC II) are necessarily stringent to protect against post-launch contamination of the sensitive optical surfaces, particularly the cold charge coupled device (CCD) imaging surfaces. Typically, thermal vacuum test chambers have employed a liquid nitrogen (LN2) cold trap to collect outgassed contaminants. This approach has the disadvantage of risking recontamination of the test article from shroud offgassing during post-test warmup of the chamber or from any shroud warming of even a few degrees during the bakeout process. By using an enclave, essentially a chamber within a chamber, configured concentrically and internally within an LN2 shroud, a method was developed, based on a design concept by Taylor, for preventing recontamination of test articles during bakeouts and subsequent post-test warmup of the vacuum chamber. Enclaves for testing WF/PC II components were designed and fabricated, then installed in three of JPL's Environmental Test Lab chambers. The design concepts, operating procedures, and test results of this development are discussed.

Johnson, Kenneth R.↗

Integrated lunar materials manufacturing process

A manufacturing plant and process for production of oxygen on the moon uses lunar minerals as feed and a minimum of earth-imported, process materials. Lunar feed stocks are hydrogen-reducible minerals, ilmenite and lunar agglutinates occurring in numerous, explored locations mixed with other minerals in the pulverized surface layer of lunar soil known as regolith. Ilmenite (FeTiO.sub.3) and agglutinates contain ferrous (Fe.sup.+2) iron reducible by hydrogen to yield H.sub.2 O and metallic Fe at about 700.degree.-1,200.degree. C. The H.sub.2 O is electrolyzed in gas phase to yield H.sub.2 for recycle and O.sub.2 for storage and use. Hydrogen losses to lunar vacuum are minimized, with no net hydrogen (or any other earth-derived reagent) consumption except for small leaks. Feed minerals are surface-mined by front shovels and transported in trucks to the processing area. The machines are manned or robotic. Ilmenite and agglutinates occur mixed with silicate minerals which are not hydrogen-reducible at 700.degree.-1,200.degree. C. and consequently are separated and concentrated before feeding to the oxygen generation process. Solids rejected from the separation step and reduced solids from the oxygen process are returned to the mine area. The plant is powered by nuclear or solar power generators. Vapor-phase water electrolysis, a staged, countercurrent, fluidized bed reduction reactor and a radio-frequency-driven ceramic gas heater are used to improve thermal efficiency.

Gibson, Michael A.↗

The Roles of Beneficiation in Lunar Work

Natural feedstocks used for any process are intrinsically variable. They may also contain deleterious components or low concentrations of desired fractions. For these three reasons it is standard industrial practice to beneficiate feedstocks. This is true across all industries which trans-form raw materials into standardized units. On the Moon there are three natural resources: vacuum, radiation and regolith. To utilize in situ resources on the Moon it is reasonable to presume some beneficiation of the regolith (ground rock) resource will be desirable if not essential. As on Earth, this will require fundamental understanding of the physics and chemistry of the relevant processes, which are exceeding complex in detail. Further, simulants are essential test articles for evaluation of components and systems planned for lunar deployment. Simulants are of course made from geologic feedstocks. Therefore, there is variation, deleterious components and incorrect concentrations of desired fractions in the feedstocks used for simulants. Thus, simulant production can benefit from beneficiation of the input feedstocks. Beneficiation of geologic feedstocks is the subject of extractive metallurgy. Clearly, NASA has two discrete interests pertaining to the science and technology of extractive metallurgy.

Rickman, Doug L.↗

EVA Swab Kit: Tools and Techniques for Collecting Aseptic Samples from Crewed Space Missions

Introduction: When we send humans to search for life on other planets, we'll need to know what we brought with us versus what may already be there. To ensure our crewed spacecraft meet planetary protection requirements—and to protect our science from human contamination—we'll need to assess and verify whether micro-organisms may be leaking/venting from our spacesuits. This requires collecting samples under Extravehicular Activity (EVA) conditions. Detailed, systematic research on forward contamination from robotic spacecraft has been steadily progressing since the Viking missions, but systematic studies of contamination from space suits has not been conducted in many years. The modern EMU (Extravehicular Mobility Unit) suit used by NASA is designed to leak at rates as high as 100 cc/min. Before humans land on Mars there is a critical need to understand the types and quantities of microbes that could be introduced via space suits. The Human Forward Contamination Assessment team at NASA’s Johnson Space Center (JSC) has developed a prototype EVA swab tool [1,2,3,4] designed for use in space to sample cleaned and uncleaned space suits to determine the present day microbial load and eventually the rate of leakage. The ability to assess microbial leakage early in advanced space suit and life support system design cycles will help avoid costly hardware redesign later. Test Objectives: The primary objective of EMU testing was to characterize the type of micro-organisms typically found on or near selected suit pressure joints under suit differential pressure conditions. Most human-borne microbes can fit through a 0.5 to 1.0 µm gap. Knowing which joints are more likely to leak will inform hardware design decisions. Knowing which types of micro-organisms may leak from EVA suits provides a basis for subsequent studies to characterize the viability of those organisms under destination conditions, as well as how far they might spread through natural or human-influenced processes. That data, in turn, will inform exploration mission operations and hardware design. The secondary objective of testing was to evaluate the interface between a fully suited test subject and the EVA swab tool at vacuum. Bulky EVA suits can restrict movement and limit visibility through the helmet visor. Fully suited testing is important for identifying tool design issues prior to flight. At exploration destinations, such as Mars, suited crew may be required to periodically sample their suits as part of an environmental monitoring protocol. Suit Microbial Sampling Results: This report details results of microbial swabs collected from current flight suit configurations worn by crew members assigned to upcoming ISS expedition missions as well as swabs collected from prototype suits intended for use on the Orion spacecraft. These tests were intended to characterize the types of contaminants found on flight suits under current, typical handling conditions. No attempt was made to change suit handling procedures, provide additional sterilization, or to limit typical potential contaminant sources. Using culture based techniques, we cultivated 235 CFU (colony forming units) comprised of 26 bacterial species and one fungal species on the outside of the suits. The fungal species and 14 of the bacterial species were unique to the suit surfaces and were not detected in any of the background samples collected within the chambers. We sequenced 755,434 ribosomal fragments on all of the suit surfaces from swab samples. 557,016 of these sequences represent DNA that survived at least 4 hours at vacuum. These sequences formed 2,464 OTU's (Operational Taxonomic Units, 97% similarity) showing low diversity in the samples. The most abundant sequences that survived vacuum belong to the genera Staphyloccocus, Ralstona, Bacillus and Rhodobacter all of which are common to the human microbiome. [5] See Danko et al., (2021) for more complete details of these first analyses. Further analysis of EVA suit materials with respect to the efficacy of various cleaning protocols and engineered containment solutions is planned to inform suit design for NASA’s Artemis Moon to Mars program crew testing. Swab Tool Function Results: The kit was demonstrated for fit and function in suited subject vacuum tests to determine how well the tool worked as an aseptic microbial sampling device as well as to identify any design elements that could be upgraded for EVA task specific improvement. It was found that sample acquisition efficacy could be enhanced by redesign of the sample canister to end-effector interface. Several modifications of the sample caddy assemblies to optimize EVA safety and functionality were also identified. Consequently, fabrication of the redesigned sample canister to end-effector assembly interfaces and and the sample caddy assemblies are required. Fabrication of sixteen flight sample canister assemblies (8 per each of two EVA Swab Kits) and two sample caddy assemblies are in process to be followed by hardware testing and certification to produce two flight-certified EVA Swab Kits for transport to ISS no earlier than summer of 2022. Sampling Strategy: The International Space Station is an ideal testbed for systematic studies of contamination from crewed vehicles since it has been continuously occupied for 20 years and exposed to non-terrestrial conditions. We will sample the exterior of the ISS during EVA using a purpose-built swab tool capable of maintaining sterility while undergoing temperature changes from -151 to +121°C under hard vacuum. Prior to each EVA, the project team will work with ISS mission managers to identify precise sampling locations, which will vary by EVA based on the translation paths and worksites scheduled for that particular EVA. Ideally, translation path handrails and areas near ECLSS (Environmental Control and Life Support System) external vent openings on a spacecraft would be assessed. There are currently more than a dozen ECLSS external vents on the ISS. Some are connected to systems that vent waste products, while others are intended to equalize cabin pressure. As EVA opportunity allows, microbial samples from any of these external vents would provide a valuable data point, though some will be more useful than others. Four criteria have been identified to help prioritize sampling sites near vents: • EVA Accessibility: To minimize cost, it is desired to piggy-back onto a planned EVA. Therefore, the sampling location must be readily accessible by an EVA crew • Type of Vented Products: Vent products that have been in direct contact with crew, such as cabin air, are more likely to contain microorganisms than vent products associated with isolated systems, such as experiment module combustion products. • Mass of Vented Products: Higher-flow vents are more likely to contain detectible levels of microbial contaminants than lower-flow vents. • Local Environment: Sample locations with relatively benign local conditions, such as warm surfaces shielded from direct ultraviolet (UV) radiation exposure, may be more likely to support microbial growth than locations with harsher local environmental conditions. Because EVA accessibility is the most important criteria, the proposal team worked with an astronaut and flight controllers using the Dynamic Onboard Ubiquitous Graphics (DOUG) tool. The DOUG virtual environment allows an operator to “fly” around the current ISS vehicle configuration to assess EVA translation paths, attach points, and keep-out zones. While analysis on station or rapid return to Earth would be preferable, samples collected from the exterior of the ISS have already been exposed to temperature variations between -157 and +121 °C as well as hard vacuum. Therefore, they should be fairly stable and robust. We hypothesize that samples collected from the ISS exterior could be stored for up to 6 months at -80°C without degradation. Sample canisters will be returned to Earth while frozen at -80°C for analysis, and sterilized canisters can be re-flown back to ISS to support additional sampling opportunities Relevance to NASA Exploration Objectives: These data will allow us to identify new or improved methods, technologies, and procedures for spacecraft sterilization and leakage mitigation to minimize the amount of contamination introduced to the environment by human explorers. This work is funded by NASA research grant: NNH18ZDA001N-PPR References: [1] Bell, M.S. et al. (2015) LPS XLVI, Abst. #1832 [2] Rucker et al. (2018) 42nd COSPAR (PPP.3) [3] Bell, M.S. et al. (2019) Mars Extant Life Conference, Abst. #5096.[4] Bell, M.S. et al., (2020) 43rd COSPAR (BO.2).[5] Danko D, et.al.,(2021)Front.Microbiol.12:608478.

Mary Suzanne Bell↗

Plastic deformation and wear process at a surface during unlubricated sliding

The plastic deformation and wear of a 304 stainless steel surface sliding against an aluminum oxide rider with a spherical surface (the radius of curvature: 1.3 cm) were observed by using scanning electron and optical microscopes. Experiments were conducted in a vacuum of one million Pa and in an environment of fifty thousandth Pa of chlorine gas at 25 C. The load was 500 grams and the sliding velocity was 0.5 centimeter per second. The deformed surface layer which accumulates and develops successively is left behind the rider, and step shaped proturbances are developed even after single pass sliding under both environmental conditions. A fully developed surface layer is gradually torn off leaving a characteristic pattern. The mechanism for tearing away of the surface layer from the contact area and sliding track contour is explained assuming the simplified process of material removal based on the adhesion theory for the wear of materials.

Yamamoto, T.↗

Plastic deformation and wear process at a surface during unlubricated sliding

The plastic deformation and wear of a 304 stainless steel surface sliding against an aluminum oxide rider with a spherical surface (the radius of curvature: 1.3 cm) were observed by using scanning electron and optical microscopes. Experiments were conducted in a vacuum of one million Pa and in an environment of fifty thousandth Pa of chlorine gas at 25 C. The load was 500 grams and the sliding velocity was 0.5 centimeter per second. The deformed surface layer which accumulates and develops successively is left behind the rider, and step shaped proturbances are developed even after single pass sliding under both environmental conditions. A fully developed surface layer is gradually torn off leaving a characteristic pattern. The mechanism for tearing away of the surface layer from the contact area and sliding track contour is explained assuming the simplified process of material removal based on the adhesion theory for the wear of materials. Previously announced in STAR as N82-32735

Yamamoto, T.↗

Manufacturing in space.

Space, in contrast to earth, offers total gravity control and unequaled vacuum, temperature, pressure, and radiation characteristics. In zero-g molecular forces such as cohesion and adhesion become controlling factors even in the largest bulk processes. The absence of relative mass accelerations eliminates the need for support of solid matter. Stability in liquid-solid, liquid-liquid, or liquid-gas mixtures, and the absence of thermal convection is obtained because there is no relative motion in fluids due to differences in density. Applications of these characteristics include liquid-matrix preparation of composites, fine-grain castings, supersaturated alloys, combinations which exhibit liquid-phase immiscibility, the containerless free suspension of materials, surface-tension casting, surface-tension drawing, adhesion casting, and controlled density casting.

Wuenscher, H. F.↗

Time-dependent polar distribution of outgassing from a spacecraft

A technique has been developed to obtain a characterization of the self-generated environment of a spacecraft and its variation with time, angular position, and distance. The density, pressure, outgassing flux, total weight loss, and other important parameters were obtained from data provided by two mass measuring crystal microbalances, mounted back to back, at distance of 1 m from the spacecraft equivalent surface. A major outgassing source existed at an angular position of 300 deg to 340 deg, near the rocket motor, while the weakest source was at the antennas. The strongest source appeared to be caused by a material diffusion process which produced a directional density at 1 m distance of about 1.6 x 10 to the 11th power molecules/cu cm after 1 hr in vacuum and decayed to 1.6 x 10 to the 9th power molecules/cu cm after 200 hr. The total average outgassing flux at the same distance and during the same time span changed from 1.2 x 10 to the minus 7th power to 1.4 x to the minus 10th power g/sq cm/s. These values are three times as large at the spacecraft surface. Total weight loss was 537 g after 10 hr and about 833 g after 200 hr. Self-contamination of the spacecraft was equivalent to that in orbit at about 300-km altitude.

Scialdone, J. J.↗

Production

The manufacturing tasks and life support systems that would pertain to a space habitat located at the Lagrange equilibrium point L5 are examined. Aluminum and titanium could be obtained from the moon minerals anorthosite and ilmenite, respectively. Although hydrogen required for purifying the metals would probably have to be imported from earth, the L5 project should have abundant energy for the processing. Methods of utilizing various glasses and ceramics common in the moon are being investigated. Manufacturing processes, such as capillary brazing, ceramic melting, laser welding, and other techniques, are considered with respect to their suitability at zero gravity and in a vacuum. With regard to life support, high-intensity agriculture is discussed, with attention to the use of a mirror system to provide continuous illumination.

Hibbs, A. R.↗

The SCEPTRE facility: Improved simulation of the space environment through the application of advanced technology

SCEPTRE (Space Combined Effects Primary Test Research Equipment) is the Air Force Materials Laboratory's primary device for performance testing of spacecraft thermal control materials. It has been undergoing a major upgrade in the last two years aimed at making it capable of simulating the synergistic effects of vacuum, ultraviolet radiation, and electron radiation. In the course of this work, a number of advances have been made in the areas of computer data processing, solar simulation, and the analysis of test results.

Ruley, J. D.↗

Advances in sputtered and ion plated solid film lubrication

The glow discharge or ion assisted vacuum deposition techniques, primarily sputtering and ion plating, have rapidly emerged and offer great potential to deposit solid lubricants. The increased energizing of these deposition processes lead to improved adherence and coherence, favorable morphological growth, higher density, and reduced residual stresses in the film. These techniques are of invaluable importance where high precision machines tribo-components require very thin, uniform lubricating films (0.2 m), which do not interface with component tolerances. The performance of sputtered MoS2 films and ion plated Au and Pb films are described in terms of film thickness, coefficient of friction, and wear lives.

Spalvins, T.↗

Undercooling of bulk high temperature metals in the 100 meter drop tube

The 100-meter drop tube at NASA Marshall Space Flight Center provides an excellent opportunity to study the effects of containerless, microgravity processing in metals and alloys. In a series of experiments high melting temperature pure metals were melted in an electron beam furnace and dropped in vacuum. Sample sizes ranged from 0.175 to 1.2 grams. Large undercoolings on the order of 18 percent of the melting temperature were observed in Ti, Zr, Nb, Mo, Rh, Ta, and Pt. Undercoolings of 5 to 18 percent T(m) were observed in Ru and Ir. These undercooling results are consistent, repeatable, and occur in a high percentage of experiments. The experimental technique will be presented as well as the resultant microstructures of undercooled drops. The data will be discussed with respect to nucleation theory.

Hofmeister, William↗

Characterization of welded HP 9-4-30 steel for the advanced solid rocket motor

Solid rocket motor case materials must be high-strength, high-toughness, weldable alloys. The Advanced Solid Rocket Motor (ASRM) cases currently being developed will be made from a 9Ni-4Co quench and temper steel called HP 9-4-30. These ultra high-strength steels must be carefully processed to give a very clean material and a fine grained microstructure, which insures excellent ductility and toughness. The HP 9-4-30 steels are vacuum arc remelted and carbon deoxidized to give the cleanliness required. The ASRM case material will be formed into rings and then welded together to form the case segments. Welding is the desired joining technique because it results in a lower weight than other joining techniques. The mechanical and corrosion properties of the weld region material were fully studied.

Watt, George William↗

Lunar site characterization and mining

Lunar mining requirements do not appear to be excessively demanding in terms of volume of material processed. It seems clear, however, that the labor-intensive practices that characterize terrestrial mining will not suffice at the low-gravity, hard-vacuum, and inaccessible sites on the Moon. New research efforts are needed in three important areas: (1) to develop high-speed, high-resolution through-rock vision systems that will permit more detailed and efficient mine site investigation and characterization; (2) to investigate the impact of lunar conditions on our ability to convert conventional mining and exploration equipment to lunar prototypes; and (3) to develop telerobotic or fully robotic mining systems for operations on the Moon and other bodies in the inner solar system. Other aspects of lunar site characterization and mining are discussed.

Glass, Charles E.↗

Luminescence from VUV Irradiated Cosmic Ice Analogs and Organic Residues

The optical luminescent properties for a variety of vacuum-ultraviolet (VUV) irradiated cosmic ice analogs and the complex organic residues produced from irradiation might be applicable to Solar System and interstellar observations and processes for various astronomical objects with an ice heritage. Some examples include grain temperature determination and vaporization rates, nebula radiation balance, albedo values, color analysis, and biomarker identification. Detailed results are presented for the mixed molecular ice: H2O:CH3OH:NH3:CO (100:50:1:1), a realistic representation for an interstellar/precometary ice. The irradiated ices and the room-temperature residues resulting from this energetic processing have remarkable photoluminescent properties in the visible (520-570 nm). The luminescence dependence on temperature, thermal cycling, and VUV exposure of the residue is described.

Gudipati, Murthy S.↗

The Manufacturing Process for the NASA Composite Crew Module Demonstration Structure

This paper will describe the approaches and methods selected in fabrication of a carbon composite demonstration structure for the Composite Crew Module (CCM) Program. The program is managed by the NASA Safety and Engineering Center with participants from ten NASA Centers and AFRL. Multiple aerospace contractors are participating in the design development, tooling and fabrication effort as well. The goal of the program is to develop an agency wide design team for composite habitable spacecraft. The specific goals for this development project are: a).To gain hands on experience in design, building and testing a composite crew module. b) To validate key assumptions by resolving composite spacecraft design details through fabrication and testing of hardware. This abstract is based on Preliminary Design data..The final design will continue to evolve through the fall of 2007 with fabrication mostly completed by conference date. From a structures perspective, the.CCM can be viewed as a pressure module with variable pressure time histories and a series of both impact and quasi-static, high intensity point, line, and area distributed loads. The portion of the overall space vehicle being designed and. fabricated by the CCM team is just the pressure module and primary loading points. The heaviest point loads are applied and distributed to the pressure module at.an aluminum Service Module/Alternate Launch Abort System (SM/ALAS) fittings and at Main and Drogue Chute fittings. Significant line loads with metal to metal impact is applied at.the Lids ring. These major external point and line loads as well as pressure impact loads (blast and water landing) are applied to the lobed floor though the reentry shield and crushable materials. The pressure module is divided into upper and lower. shells that mate together with a bonded belly band splice joint to create the completed structural assembly. The benefits of a split CCM far outweigh the risks of a joint. These benefits include lower tooling cost and less manufacturing risk. Assembly of the top and bottom halves of the pressure shell will allow access to the interior of the shell throughout remaining fabrication sequence and can also potentially permit extensive installation of equipment and .crew facilities prior to final assembly of the two shell halves. A Pi pre-form is a woven carbon composite material which is provided in pre-impregnated form and frozen for long term storage. The cross-section shape allows the top of the pi to be bonded to a flat or curved surface with a second flat plate composite section bonded between two upstanding legs of the Pi. One of the regions relying on the merits of the Pi pre-form is the backbone. All connections among plates of the backbone structure, including the upper flanges, and to the lobe base of the pressure shell are currently joined by Pi pre-forms. The intersection of backbone composite plates is formed by application of two Pi pre-forms, top flanges and lobed surfaces are bonded with one Pi pre-form. The process of applying the pre-impregnated pi-preform will be demonstrated to include important steps like surface preparation, forming, application of pressure dams, vacuum bagging for consolidation, and curing techniques. Chopped carbon fiber tooling was selected over other traditional metallic and carbon fiber tooling. The requirement of schedule and cost economy for a moderate reuse cure tool warranted composite tooling options. Composite tooling schedule duration of 18 weeks compared favorably against other metallic tooling including invar tooling. Composite tooling also shows significant cost savings over low CTE metallic options. The composite tooling options were divided into two groups and the final decision was based on the cost, schedule, tolerance, temperature, and reuse requirements.

Pelham, Larry↗

Extraction of Thermal Performance Values from Samples in the Lunar Dust Adhesion Bell Jar

A simulation chamber has been developed to test the performance of thermal control surfaces under dusty lunar conditions. The lunar dust adhesion bell jar (LDAB) is a diffusion pumped vacuum chamber (10-8 Torr) built to test material samples less than about 7 cm in diameter. The LDAB has the following lunar dust stimulant processing capabilities: heating and cooling while stirring in order to degas and remove absorbed water; RF air-plasma for activating the dust and for organic contaminant removal; RF H/He-plasma to simulate solar wind; dust sieving system for controlling particle sizes; and a controlled means of introducing the activated dust to the samples under study. The LDAB is also fitted with an in situ Xe arc lamp solar simulator, and a cold box that can reach 30 K. Samples of thermal control surfaces (2.5 cm diameter) are introduced into the chamber for calorimetric evaluation using thermocouple instrumentation. The object of this paper is to present a thermal model of the samples under test conditions, and to outline the procedure to extract the absorptance, emittance, and thermal efficiency from the pristine and sub-monolayer dust covered samples

Gaier, James R.↗