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Autonomous space processor for orbital debris advanced design project in support of solar system exploration

This paper is regarding a project in the Advanced Design Program at the University of Arizona. The project is named the Autonomous Space Processor for Orbital Debris (ASPOD) and is a NASA/Universities Space Research Association (USRA) sponsored design project. The development of ASPOD and the students' abilities in designing and building a prototype spacecraft are the ultimate goals of this project. This year's focus entailed the development of a secondary robotic arm and end-effector to work in tandem with an existent arm in the removal of orbital debris. The new arm features the introduction of composite materials and a linear drive system, thus producing a light-weight and more accurate prototype. The main characteristic of the end-effector design is that it incorporates all of the motors and gearing internally, thus not subjecting them to the harsh space environment. Furthermore, the arm and the end-effector are automated by a control system with positional feedback. This system is composed of magnetic and optical encoders connected to a 486 PC via two servo-motor controller cards. Programming a series of basic routines and sub-routines has allowed the ASPOD prototype to become more autonomous. The new system is expected to perform specified tasks with a positional accuracy of 0.5 cm.

Ramohalli, Kumar↗

A geopotential model from satellite tracking, altimeter, and surface gravity data: GEM-T3

An improved model of Earth's gravitational field, Goddard Earth Model T-3 (GEM-T3), has been developed from a combination of satellite tracking, satellite altimeter, and surface gravimetric data. GEM-T3 provides a significant improvement in the modeling of the gravity field at half wavelengths of 400 km and longer. This model, complete to degree and order 50, yields more accurate satellite orbits and an improved geoid representation than previous Goddard Earth Models. GEM-T3 uses altimeter data from GEOS 3 (1975-1976), Seasat (1978) and Geosat (1986-1987). Tracking information used in the solution includes more than 1300 arcs of data encompassing 31 different satellites. The recovery of the long-wavelength components of the solution relies mostly on highly precise satellite laser ranging (SLR) data, but also includes Tracking Network (TRANET) Doppler, optical, and satellite-to-satellite tracking acquired between the ATS 6 and GEOS 3 satellites. The main advances over GEM-T2 (beyond the inclusion of altimeter and surface gravity information which is essential for the resolution of the shorter wavelength geoid) are some improved tracking data analysis approaches and additional SLR data. Although the use of altimeter data has greatly enhanced the modeling of the ocean geoid between 65 deg N and 60 deg S latitudes in GEM-T3, the lack of accurate detailed surface gravimetry leaves poor geoid resolution over many continental regions of great tectonic interest (e.g., Himalayas, Andes). Estimates of polar motion, tracking station coordinates, and long-wavelength ocean tidal terms were also made (accounting for 6330 parameters). GEM-T3 has undergone error calibration using a technique based on subset solutions to produce reliable error estimates. The calibration is based on the condition that the expected mean square deviation of a subset gravity solution from the full set values is predicted by the solutions' error covariances. Data weights are iteratively adjusted until this condition for the error calibration is satisfied. In addition, gravity field tests were performed on strong satellite data sets withheld from the solution (thereby ensuring their independence). In these tests, the performance of the subset models on the withheld observations is compared to error projections based on their calibrated error covariances. These results demonstrate that orbit accuracy projections are reliable for new satellites which were not included in GEM-T3.

Lerch, F. J.↗

Department of Physics' Involvement of the Impact Testing Project of the High Speed Civil Transport Program (HSCT)

The project involved the impact testing of a kevlar-like woven polymer material, PBO. The purpose was to determine whether this material showed any promise as a lightweight replacement material for jet engine fan containment. The currently used metal fan containment designs carry a high drag penalty due to their weight. Projectiles were fired at samples of PBO by means of a 0.5 inch diameter Helium powered gun. The Initial plan was to encase the samples inside a purpose-built steel "hot box" for heating and ricochet containment. The research associate's responsibility was to develop the data acquisition programs and techniques necessary to determine accurately the impacting projectile's velocity. Beyond this, the Research Associate's duties include any physical computations, experimental design, and data analysis necessary.

VonMeerwall, Ernst D.↗

International Research Project on the Effects of Chemical Ageing of Polymers on Performance Properties: Chemical and Thermal Analysis

Work during the past six months has included significant research in several areas aimed at further clarification of the aging and chemical failure mechanism of thermoplastics (PVDF or Tefzel) pipes. Among the areas investigated were the crystallinity changes associated with both the Coflon and Tefzel after various simulated environmental exposures using X-ray diffraction analysis. We have found that significant changes in polymer crystallinity levels occur as a function of the exposures. These crystallinity changes may have important consequences on the fracture, fatigue, tensile, and chemical resistance of the materials. We have also noted small changes in the molecular weight distribution. Again these changes may result in variations in the mechanical and chemical properties in the material. We conducted numerous analytical studies with methods including X-ray Diffraction, Gel Permeation Chromatography, Fourier Transform Infrared Spectroscopy, Ultra- Violet Scanning Analysis, GC/Mass Spectrometry, Differential Scanning Calorimetry and Thermomechanical Analysis. In the ultra-violet analysis we noted the presence of an absorption band indicative of triene formation. We investigated a number of aged samples of both Tefzel and Coflon that were forwarded from MERL. We also cast films at SWT and subjected these films to a refluxing methanol 1% ethylene diamine solution. An updated literature search was conducted using Dialog and DROLLS to identify any new papers that may have been published in the open literature since the start of this project. The updated literature search and abstracts are contained in the Appendix section of this report.

Bulluck, J. W.↗

Excercise Within LBNP as an Artificial Gravity Countermeasure

Previous exercise in space has lacked sufficient loads to maintain preflight cardiovascular and musculoskeletal mass and function. Lower body negative pressure (LBNP) produces a static force equivalent to one Earth body weight by each 52 mm Hg of LBNP during supine posture. LBNP also provides transmural blood pressures simulating upright exercise. Thus, this artificial-gravity concept may help maintain cardiovascular and musculoskeletal systems of crewmembers during prolonged exposure to microgravity. Currently available, bungee cord assisted, treadmill exercise is limited by harness discomfort, lower than normal loads, abnormal post-flight gait, and the absence of gravitational blood pressures within the vascular system. PURPOSE: This project evaluates a method to create artificial gravity using supine LBNP treadmill exercise to prevent loss of physiologic function in microgravity simulated by 30 days of bed rest. Identical twins were used as volunteers so that statistical power could be maximized. This countermeasure is being transitioned to space flight. CURRENT STATUS OF RESEARCH Methods: Six sets of identical twins (6 females and 14 males, 21-36 years) remained in 6 head-down tilt (HDT) bed rest for 30 days to simulate prolonged microgravity. Six subjects were randomly selected to exercise supine in an LBNP chamber for 40 minutes six days per week (EX group), while their twin brothers served as non-exercise controls (CON). Pressure within the exercise LBNP chamber was adjusted to increase load, hence increasing exercise intensity. During supine treadmill exercise, LBNP (52-63 mmHg) was applied to produce foot ward forces equivalent to those for upright running on Earth at 1.0-1.2 times body weight (BW) and subjects performed an interval exercise protocol (40-80% peak exercise capacity [VO2pk]). Five minutes of resting LBNP immediately followed each exercise session. Results: Orthostatic tolerance time decreased significantly after 30 days bed rest in the CON group, but was relatively maintained in the EX group. VO2pk was maintained in EX males, but not in CON males. Isokinetic knee strength (extension, peak torque) decreased significantly in CON males, but was preserved in EX males. The EX group had significantly higher spine muscle strength after bed rest than the CON group. The cross-sectional area of spinal muscle at L4/5 level decreased significantly in the CON group but not in the EX group. Urinary n-telopeptide excretion, an index of bone resorption, was increased during bed rest in CON, but not in EX subjects. This suggests protection by LBNP exercise against the increase in bone resorption typically seen in simulated and actual microgravity. Significant changes in bone mineral density (BMD) in the spine and ribs were observed in CON subjects, but not in EX subjects. Conclusions: Our treadmill exercise protocol within LBNP plus a short period of post-exercise LBNP maintains orthostatic responses, upright exercise capacity and other important physiologic parameters during bed rest. These results document the efficacy of our apparatus and exercise protocol for maintaining physiologic structure and function during long-duration microgravity as simulated by 30 days of HDT bed rest. FUTURE PLANS: More sets of female identical twins are needed to reach significance. The LBNP exercise chamber will be redesigned for flight.

Hargens, A. R.↗

Designing Recyclable Biomass-Based Polyesters (Final Technical Report)

This project successfully demonstrated the production of sustainable polyesters from biomass-derived monomers, offering properties on par with or superior to fossil-based plastics such as LLDPE and PBAT. Using renewable chemical platforms like furfural and HMF, we synthesized over eight novel monomers and nearly 100 aliphatic-aromatic polyesters. Among these, PPeAT and PDDF emerged as highly promising candidates for flexible packaging applications, exhibiting excellent mechanical performance, tunable thermal properties, and enhanced barrier characteristics. Key advances included the development of ring-opening polymerization strategies using cyclic monomer intermediates to produce high molecular weight materials with excellent control. The resulting polymers achieved biobased content of at least 44 wt.%. We also implemented chemical recycling via catalytic methanolysis, recovering over 90% of monomers from PPeAT at semi-pilot scale. This supports a circular economy approach by enabling material reuse without performance loss. Techno-economic and life cycle assessments confirmed that these polyesters can reduce greenhouse gas emissions by up to 50% compared to petroleum-derived alternatives. Favorable mechanical properties may further reduce material demand, and cost competitiveness was demonstrated under specific market conditions. Feedstock cost and environmental footprint were identified as primary levers for future optimization. In summary, the project met or closely approached all technical targets, including biodegradability, strength, and processing compatibility. While minor issues such as color and melting point variation remain, the results strongly support continued development and scale-up of these sustainable materials.

09 BIOMASS FUELS↗

UAS Integration in the NAS Project: Overview of Flight Test Series 6

The National Aeronautics and Space Administration (NASA) Unmanned Aircraft Systems Integration in the National Airspace System (UAS-NAS) Project has conducted a series of flight test campaigns intended to support the reduction of barriers that prevent unmanned aircraft from flying without the required waivers from the Federal Aviation Administration (FAA). The 2019 Flight Test Series 6 (FT6) campaign furthered this path and supported three test configurations: 1) Radar Characterization, 2) Scripted Encounters and 3) Full Mission. Radar Characterization assessed the performance of Honeywell’s low size, weight, and power (low SWaP) radar system; Scripted Encounters investigated the timing of Detect and Avoid (DAA) alerting thresholds using a Department of Defense (DoD) Group 3 unmanned aircraft system (UAS) equipped with low SWaP sensors and three different live intruder aircraft flown at varying encounter geometries; and Full Mission validated human-in-the-loop simulations by collecting pilot performance data from a ground control station while controlling a live unmanned aircraft on a mission in both virtual and live air traffic controlled airspace. The subject pilot observed a research display that presented DAA advisories to maintain separation from live and virtual aircraft. The test was conducted over a twenty-week period within the R-2508 special use airspace located near Edwards Air Force Base (EAFB), CA. Over 240 encounters were flown during the test series and FT6 proved to be invaluable for the purposes of planning, managing, and executing this type of integrated flight test in both live and virtual environments. Data collected from FT6 was provided to the RTCA Special Committee 228 (SC-228) to help inform the Phase 2 Minimum Operational Performance Standards (MOPS). FT6 was the final test series for the UAS-NAS project that began in 2012. This paper provides an overview of FT6 and its success can be directly attributed to the diligent work of the men and women who supported this effort.

UAS in the NAS↗

Designing Cellular Metal Structures for Thermal Insulation

This project focused on developing topology optimization software to design advanced metal thermal insulators. Initially, solid designs were created that matched the thermal performance of current baseline designs but were significantly heavier. To address this, cellular materials were incorporated, specifically the octet structure which is known for its high strength-to-weight ratio and thermal properties. By leveraging these cellular designs at various densities, superior thermal and mechanical performance was achieved without added weight. This novel approach enhances thermal management and structural integrity under extreme conditions, offering promising advancements for thermal protection systems.

36 MATERIALS SCIENCE↗

MLSPICE: Machine Learning based SPICE Modeling Platform for Power Magnetics

Electrical power converters are critical to a wide range of applications ranging from renewable integration to transportation electrification, and can be a key factor determining the size, weight, and efficiency of energy conversion systems. Magnetic components are typically the largest and least efficient components in power electronics. While there have been major strides in the modeling and analysis of power semiconductor devices and circuit simulations, the necessary advances in the design of power magnetics have lagged. In this project, we have transformed the modeling and design of power magnetics with machine learning enabled methods and catalyze simultaneous disruptive improvements for ML-based power electronics design tools. A fully automated open-source machine learning based magnetics modeling platform – the MagNet project - with innovations in full stack have been developed to greatly accelerate the design process and provide new insights to magnetic material and geometry design. The ARPA-E funded MagNet platform contains three major building blocks: 1) a ML-Integrated Data Acquisition System (MIDAS): a highly automated data acquisition testbed which is capable of measuring a large number of magnetic cores with a wide range of electrical circuit excitations; 2) a ML-integrated Core Loss Model (MICLM): a machine-learning trained modeling method for modeling the core loss and saturation effects of magnetic materials for arbitrary excitation waveforms; 3) ML-guided Magnetics SPICE Simulation Tool (PMSPICE): a fully integrated CAD tool which can simulate the magnetics in SPICE. It can help the designers to quickly model the linear and non-linear characteristics of magnetic components and evaluate their behavior in SPICE simulations. The developed MagNet system has fully demonstrated the proposed performance target and has been open sourced to the entire power electronics community to advance the modeling and design of power magnetics from many different angles.

36 MATERIALS SCIENCE↗

STS-93: Columbia / Chandra Mission Overview (from JSC)

A press briefing held on July 7, 1999 reviews the progress of the Chandra X ray Observatory project. The tape begins with an animated view of the launch of the Chandra X ray Observatory from the shuttle, as it was planned. Next is a press briefing. Bryan Austin, the Lead Flight Director, discusses the five day mission, and the reason for the shortened length, due to the added weight from the Chandra Observatory. He also reviews the other payloads, and activities that will take place during the mission. Kenneth Ledbetter, Science Director Mission Development, discusses the 4 great observatories and the role of each. They are the Hubble, which observed visible light; Compton Gamma Ray Observatory, the Chandra, and the Space Infrared Telescope Facility. A time line of the expected operational lifetime of each of the 4 great observatories is shown. Specific information about the Chandra Telescope is reviewed. The last press briefing presenter is Fred Wojtalik, who is the Chandra Program Manager. He reviews the Chandra's components, and acknowledges a few of the many companies that contributed to its building. He also reviews the orbital activation and checkout sequences. Question that follows, center around contingency plans if some part of the planned sequence is not successful. The costs are reviewed, and concerns about the Initial Upper Stage, the propulsion unit required to take the Chandra to its high orbit are addressed. The Chandra is planned to take an eliptical orbit, which is higher than the other space telescopes, thus far launched due to the requirement to avoid Earth generated X rays.

Source record↗

Data Mining Activity for Bone Discipline: Calculating a Factor of Risk for Hip Fracture in Long-Duration Astronauts

The factor-of-risk (Phi), defined as the ratio of applied load to bone strength, is a biomechanical approach to hip fracture risk assessment that may be used to identify subjects who are at increased risk for fracture. The purpose of this project was to calculate the factor of risk in long duration astronauts after return from a mission on the International Space Station (ISS), which is typically 6 months in duration. The load applied to the hip was calculated for a sideways fall from standing height based on the individual height and weight of the astronauts. The soft tissue thickness overlying the greater trochanter was measured from the DXA whole body scans and used to estimate attenuation of the impact force provided by soft tissues overlying the hip. Femoral strength was estimated from femoral areal bone mineral density (aBMD) measurements by dual-energy x-ray absorptiometry (DXA), which were performed between 5-32 days of landing. All long-duration NASA astronauts from Expedition 1 to 18 were included in this study, where repeat flyers were treated as separate subjects. Male astronauts (n=20) had a significantly higher factor of risk for hip fracture Phi than females (n=5), with preflight values of 0.83+/-0.11 and 0.36+/-0.07, respectively, but there was no significant difference between preflight and postflight Phi (Figure 1). Femoral aBMD measurements were not found to be significantly different between men and women. Three men and no women exceeded the theoretical fracture threshold of Phi=1 immediately postflight, indicating that they would likely suffer a hip fracture if they were to experience a sideways fall with impact to the greater trochanter. These data suggest that male astronauts may be at greater risk for hip fracture than women following spaceflight, primarily due to relatively less soft tissue thickness and subsequently greater impact force.

Ellman, R.↗

The Digital Astronaut Project Computational Bone Remodeling Model (Beta Version) Bone Summit Summary Report

Under the conditions of microgravity, astronauts lose bone mass at a rate of 1% to 2% a month, particularly in the lower extremities such as the proximal femur [1-3]. The most commonly used countermeasure against bone loss in microgravity has been prescribed exercise [4]. However, data has shown that existing exercise countermeasures are not as effective as desired for preventing bone loss in long duration, 4 to 6 months, spaceflight [1,3,5,6]. This spaceflight related bone loss may cause early onset of osteoporosis to place the astronauts at greater risk of fracture later in their lives. Consequently, NASA seeks to have improved understanding of the mechanisms of bone demineralization in microgravity in order to appropriately quantify this risk, and to establish appropriate countermeasures [7]. In this light, NASA's Digital Astronaut Project (DAP) is working with the NASA Bone Discipline Lead to implement well-validated computational models to help predict and assess bone loss during spaceflight, and enhance exercise countermeasure development. More specifically, computational modeling is proposed as a way to augment bone research and exercise countermeasure development to target weight-bearing skeletal sites that are most susceptible to bone loss in microgravity, and thus at higher risk for fracture. Given that hip fractures can be debilitating, the initial model development focused on the femoral neck. Future efforts will focus on including other key load bearing bone sites such as the greater trochanter, lower lumbar, proximal femur and calcaneus. The DAP has currently established an initial model (Beta Version) of bone loss due to skeletal unloading in femoral neck region. The model calculates changes in mineralized volume fraction of bone in this segment and relates it to changes in bone mineral density (vBMD) measured by Quantitative Computed Tomography (QCT). The model is governed by equations describing changes in bone volume fraction (BVF), and rates of changes in bone cell populations that remove and replace bone in packets within the bone region. The DAP bone model is unique in several respects. In particular in takes former models of volume fraction changes one step higher in fidelity and separates BVF into separate equations for mineralized and osteoid volume fractions governed by a mineralization rate. This more closely follows the physiology of the remodeling unit cycles where bone is first resorbed and then followed by the action of osteoblasts to lay down collagen matrix which eventually becomes mineralized. In another respect, the modules allow the functional description of the time rate of change of other parameters and variables in the model during a computational simulation. More detailed description of the model, preliminary validation results, current limitation and caveats, and planned advancements are provided in sections 2 through 5. The DAP bone model is being developed primarily as a research tool, and not as a clinical tool like QCT. Even if it transitions to a clinical tool, it is not intended to replace QCT or any other clinical tool. Moreover, the DAP bone model does not predict bone fracture. Its purpose is to provide valuable additional data via "forward prediction" simulations for during and after spaceflight missions to gain insight on, (1) mechanisms of bone demineralization in microgravity, and (2) the volumetric changes at the various bone sites in response to in-flight and post-flight exercise countermeasures. This data can then be used as input to the Keyak [8] (or equivalent) FE analysis method to gain insight on how bone strength may change during and after flight. This information can also be useful to help optimize exercise countermeasure protocols to minimize changes in bone strength during flight, and improve regain of bone strength post-flight. To achieve this goal, the bone model will be integrated with DAP's exercise countermeasure models to simulate the effect of exercise prescriptions on preserving bone. More specifically, the model will accept loading history due to muscle and joint force on bone and produce quantified remodeling within the bone region under influence of the applied stress. Furthermore, because they tend to respond differently, the bone remodeling model includes both trabecular bone and cortical bone.

Pennline, James↗

Ultrasonic Characterization of Aerospace Composites

Composite materials have seen an increased use in aerospace in recent years and it is expected that this trend will continue due to the benefits of reduced weight, increased strength, and other factors. Ongoing work at NASA involves the investigation of the large-scale use of composites for spacecraft structures (SLS components, Orion Composite Crew Module, etc). NASA is also involved in work to enable the use of composites in advanced aircraft structures through the Advanced Composites Project (ACP). In both areas (space and aeronautics) there is a need for new nondestructive evaluation and materials characterization techniques that are appropriate for characterizing composite materials. This paper will present an overview of NASA's needs for characterizing aerospace composites, including a description of planned and ongoing work under ACP for the detection of composite defects such as fiber waviness, reduced bond strength, delamination damage, and microcracking. The research approaches include investigation of angle array, guided wave, and phase sensitive ultrasonic methods. The use of ultrasonic simulation tools for optimizing and developing methods will also be discussed.

Leckey, Cara↗

Commercial Application of In-Space Assembly

In-Space assembly (ISA) expands the opportunities for cost effective emplacement of systems in space. Currently, spacecraft are launched into space and deploy into their operational configuration through a carefully choreographed sequence of operations. The deployment operation dictates the arrangement of the primary systems on the spacecraft, limiting the ability to take full advantage of launch vehicles volume and mass capability. ISA enables vastly different spacecraft architectures and emplacement scenarios to be achieved, including optimal launch configurations ranging from single launch and assembly to on-orbit aggregation of multiple launches at different orbital locations and times. The spacecraft can be visited at different orbital locations and times to effect expansion and maintenance of an operational capability. To date, the primary application of ISA has been in large programs funded by government organizations, such as the International Space Station. Recently, Space Systems Loral (SSL) led a study funded by the Defense Advanced Research Projects Agency (DARPA), called Dragonfly, to investigate the commercial applicability and economic advantages of ISA. In the study, it was shown that ISA enables SSL to double the capability of a commercial satellite system by taking advantage of alternate packaging approaches for the reflectors. The study included an ultra-light-weight robotic system, derived from Mars manipulator designs, to complete assembly of portions of the antenna system using a tool derived from DARPA orbital express and National Aeronautics and Space Administration (NASA) automated structural assembly experience. The mechanical connector that enables robotic ISA takes advantage of decades of development by NASA from the 1970's to 1980's during the Space Station Freedom program, the precursor to the ISS. The mechanical connector was originally designed for rapid astronaut assembly while also providing a high quality structural connection with linear load deflection response. The paper will discuss the business case for ISA, the general approach taken to exploit on-orbit assembly in the GEO communication satellite market, and the concept of operations associated with the ISA approach, thus laying the foundation for ISA to become an accepted operational approach for commercial in-space operations.

Lymer, John↗

Fiber-Optic Strain-Based Deflection and Twist Sensing for a High-Aspect-Ratio Swept Wing

Designs of aircraft structures have been moving toward leaner, lightweight designs for increased fuel efficiency. The Passive Aeroelastic Tailored (PAT) wing developed under the NASA Advanced Air Transport Technology (AATT) project is an example of a swept-wing design with high aspect ratio that incorporates lightweight highly-flexible tailored composite construction. The passive aeroelastic tailored structural design has explored the design space to enable aeroelastically tailored wing structures to increase aspect ratios (from 9 to 14) and ultimately reduce weight by 20 percent to 25 percent without impacting aeroelastic performance. To further study the aeroelastic performance of such a wing, the NASA Armstrong Flight Research Center (AFRC) (Edwards, California) has developed efficient real-time structural algorithms that are used in conjunction with a fiber-optic measurement system for lightweight vehicle applications. The AFRC Fiber Optic Sensing System (FOSS) provides up to 8,000 distributed surface strain measurements at one-half-inch increments and can be used to estimate a variety of structural parameters such as shape and load. This report discusses the implementation of strain-based displacement and twist-sensing techniques applied to the PAT wing test article tested at the NASA AFRC Flight Loads Laboratory. Empirical FOSS strain data are collected under varying loading conditions. Strain data are processed with the displacement and twist-sensing algorithms and independently verified by comparison to conventional ground-based instrumentation.

Pena, Francisco↗

Highly Integrated WBG Power Module for Next Generation Plug-In Vehicles

Current inverter technologies used in electric vehicles (EVs) are bulky, heavy, and expensive. The performance of the inverter is also limited by the traditional Si-based semiconductor and packaging technology. These constraints are responsible for extra weight and volume in the vehicle that reduces the driving range along with usable space within the vehicle. Moreover, operating temperature restrictions, and boundaries on the inverter location within the vehicle drastically reduces the inverter performance. Thus an improved inverter design is required for next generation electric vehicles. The objective of this project was to research, develop and demonstrate a highly integrated WBG power module targeting the next generation of plugin hybrid electric vehicles (PHEVs). This power module needed to be functionally and mechanically optimized for General Motors (GM) traction inverter architecture. General Motors was the prime contractor, led the project, and oversaw the design, build, and test of the integrated power module. Virginia Polytechnic Institute and State University (VT) performed modeling and simulation tasks as well as power module design support. Monolith Semiconductor, Inc provided SiC dies and consulted on devices for the inverter. Oak Ridge National Laboratory (ORNL) performed power module technology evaluations, design evaluations of interconnect options, and performed material analysis and cross-sectioning of die activities.

33 ADVANCED PROPULSION SYSTEMS↗

Ultrasonic seam welding on thin silicon solar cells

The ultrathin silicon solar cell has progressed to where it is a serious candidate for future light weight or radiation tolerant spacecraft. The ultrasonic method of producing welds was found to be satisfactory. These ultrathin cells could be handled without breakage in a semiautomated welding machine. This is a prototype of a machine capable of production rates sufficiently large to support spacecraft array assembly needs. For comparative purposes, this project also welded a variety of cells with thicknesses up to 0.23 mm as well as the 0.07 mm ultrathin cells. There was no electrical degradation in any cells. The mechanical pull strength of welds on the thick cells was excellent when using a large welding force. The mechanical strength of welds on thin cells was less since only a small welding force could be used without cracking these cells. Even so, the strength of welds on thin cells appears adequate for array application. The ability of such welds to survive multiyear, near Earth orbit thermal cycles needs to be demonstrated.

Stofel, E. J.↗

Microencapsulated Phase-Change Materials For Storage Of Heat

Report describes research on engineering issues related to storage and transport of heat in slurries containing phase-change materials in microscopic capsules. Specific goal of project to develop lightweight, compact, heat-management systems used safely in inhabited areas of spacecraft. Further development of obvious potential of technology expected to lead to commercialization and use in aircraft, electronic equipment, machinery, industrial processes, and other sytems in which requirements for management of heat compete with severe restrictions on weight or volume.

Colvin, David P.↗