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NASA NTRS2001

NASA Tech Briefs, February 2001

The topics include: 1) Application Briefs; 2) National Design Engineering Show Preview; 3) Marketing Inventions to Increase Income; 4) A Personal-Computer-Based Physiological Training System; 5) Reconfigurable Arrays of Transistors for Evolvable Hardware; 6) Active Tactile Display Device for Reading by a Blind Person; 7) Program Automates Management of IBM VM Computer Systems; 8) System for Monitoring the Environment of a Spacecraft Launch; 9) Measurement of Stresses and Strains in Muscles and Tendons; 10) Optical Measurement of Temperatures in Muscles and Tendons; 11) Small Low-Temperature Thermometer With Nanokelvin Resolution; 12) Heterodyne Interferometer With Phase-Modulated Carrier; 13) Rechargeable Batteries Based on Intercalation in Graphite; 14) Signal Processor for Doppler Measurements in Icing Research; 15) Model Optimizes Drying of Wet Sheets; 16) High-Performance POSS-Modified Polymeric Composites; 17) Model Simulates Semi-Solid Material Processing; 18) Modular Cryogenic Insulation; 19) Passive Venting for Alleviating Helicopter Tail-Boom Loads; 20) Computer Program Predicts Rocket Noise; 21) Process for Polishing Bare Aluminum to High Optical Quality; 22) External Adhesive Pressure-Wall Patch; 23) Java Implementation of Information-Sharing Protocol; 24) Electronic Bulletin Board Publishes Schedules in Real Time; 25) Apparatus Would Extract Water From the Martian Atmosphere; 26) Review of Research on Supercritical vs Subcritical Fluids; 27) Hybrid Regenerative Water-Recycling System; 28) Study of Fusion-Driven Plasma Thruster With Magnetic Nozzle; 29) Liquid/Vapor-Hydrazine Thruster Would Produce Small Impulses; and 30) Thruster Based on Sublimation of Solid Hydrazine

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NASA NTRS2021

Marshall Space Flight Center Faculty Fellowship Program

The 2020 Marshall Aerospace Fellowship Program involved 11 faculty in the laboratories and departments at Marshall Space Flight Center and one faculty researcher working from Colorado. These faculty engineers and scientists worked with NASA collaborators on NASA projects, bringing new perspectives and solutions to bear. This Technical Memorandum is a compilation of nine research reports of the 2020 Marshall Aerospace Fellowship program, along with the Program Announcement (Appendix A) and the Program Description (Appendix B). The research affected the following five areas: (1) Materials (2) Spacecraft systems (3) Human-System Interactions (4) Vehicle systems (5) Space science Additive manufacturing was the single materials investigation during the summer of 2020. Spacecraft systems tasks dominated the fellows’ explorations: covering camera sensors for lunar surface mobility, a real-time system for navigation and mapping, flexible sensor modeling, and transmitter design for high data rate telemetry. One project concentrated on Human-System Interactions. Another fellow designed a model to predict heat leak into a cryogen tank, as in most vehicle systems. One of the scientists worked on a proposed space-based gravitational wave interferometer that will detect Galactic white dwarf binaries. Another space science fellow used a mature astrophysical code to synthesize galactic stellar populations. Our goal is to continue the Marshall Aerospace Program funded by Center project offices.

N. F. Six↗

NASA NTRS2014

An Experimental Study of Launch Vehicle Propellant Tank Fragmentation

In order to better understand launch vehicle abort environments, Bangham Engineering Inc. (BEi) built a test assembly that fails sample materials (steel and aluminum plates of various alloys and thicknesses) under quasi-realistic vehicle failure conditions. Samples are exposed to pressures similar to those expected in vehicle failure scenarios and filmed at high speed to increase understanding of complex fracture mechanics. After failure, the fragments of each test sample are collected, catalogued and reconstructed for further study. Post-test analysis shows that aluminum samples consistently produce fewer fragments than steel samples of similar thickness and at similar failure pressures. Video analysis shows that there are several failure 'patterns' that can be observed for all test samples based on configuration. Fragment velocities are also measured from high speed video data. Sample thickness and material are analyzed for trends in failure pressure. Testing is also done with cryogenic and noncryogenic liquid loading on the samples. It is determined that liquid loading and cryogenic temperatures can decrease material fragmentation for sub-flight thicknesses. A method is developed for capture and collection of fragments that is greater than 97 percent effective in recovering sample mass, addressing the generation of tiny fragments. Currently, samples tested do not match actual launch vehicle propellant tank material thicknesses because of size constraints on test assembly, but test findings are used to inform the design and build of another, larger test assembly with the purpose of testing actual vehicle flight materials that include structural components such as iso-grid and friction stir welds.

Richardson, Erin↗

NASA NTRS2011

Issues and Design Drivers for Deep Space Habitats

A cross-disciplinary team of scientists and engineers applied expertise gained in Lunar Lander development to the conceptual design of a long-duration, deep space habitat for Near Earth Asteroid (NEA) missions. The design reference mission involved two launches to assemble a 5-module vehicle for a 380-day round trip mission carrying 4 crew members. The conceptual design process yielded a number of interesting debates, some of which could be significant design drivers in a detailed Deep Space Habitat (DSH) design. These issues include: a) Launch loads: Potentially drives layout of equipment mounted to module floors or walls, and whether temporary internal structure is required to distribute launch loads to minimize shell mass; b) Unmanned loiter time: When added to an already lengthy mission, loiter time further drives risk and reliability, and poses issues for equipment shelf life such as material degradation or cryogenic fluids boil-off; c) Pointing and Visibility: A habitat embedded in a 5-module stack may drive Communications, Tracking, Guidance, and Navigation equipment out onto long booms to maintain line-of-sight visibility with targets. However, long booms will be more susceptible to disruption from exercise-induced vibration, potential damage during docking/undocking operations, and increased power distribution mass; d) Water: although it is assumed that a water processor will collect and recycle water, several interesting question were posed, such as: How much water to start with? Should potable water serve double-duty as radiation protection? And if so, should it be stowed in a single large tank, or smaller, portable containers? e) Design for repairability: one of the worst-case scenarios identified was a cabin depressurization that required suited repair from inside the module, potentially driving the need for long umbilical hoses or special equipment to allow smaller, mated modules to be used as safe havens for up to 180 days;

Anderson, Molly S.↗

NASA NTRS2021

CubeSat Active Thermal Control in Support of Advanced Payloads: The Active Thermal Architecture Project

The Active Thermal Architecture (ATA) is an advanced sub-1U Active Thermal Control technology (ATC) for high power payload support in 6U CubeSat form factors and above. The design utilizes a two-stage, single-phase mechanically pumped fluid loop coupled through a two-axis flexible rotary fluid hinge, to reject thermal power to a deployable tracking radiator. A COTS Ricor K508N cryocooler forms the second stage and provides cryogenic cooling to a custom Kevlar detector mount through a TMT pyrolytic graphene thermal strap. Passive vibration isolation and damping technologies prevent the transfer of jitter to the satellite systems. The ATA design utilizes state-of-the-art 3D fabrication techniques such as Ultrasonic Additive Manufacturing (UAM) to directly embed the working fluid channels into the HX, radiator, and CubeSat chassis allowing for the miniaturization and simplification of the ATA system into an integrated thermal control solution. This paper will focus on the design and ground-based characterization and qualification of the ATA system and provide performance metrics for its use as a thermal support subsystem for advanced infrared electro-optical CubeSat payloads. The ATA project is funded through a NASA Small Satellite Technology Program (SSTP) and is a partnership between the Center for Space Engineering at Utah State University and the Jet Propulsions Laboratory. The ATA active thermal control system has been raised to a TRL of 6 and hopes to provide payload support to advanced missions such as the SABER-Lite and JPL CIRAS projects.

Mok, Mason↗

NASA NTRS2011

Liquid Oxygen/Liquid Methane Integrated Propulsion System Test Bed

In support of NASA?s Propulsion and Cryogenic Advanced Development (PCAD) project, a liquid oxygen (LO2)/liquid methane (LCH4) Integrated Propulsion System Test Bed (IPSTB) was designed and advanced to the Critical Design Review (CDR) stage at the Johnson Space Center. The IPSTB?s primary objectives are to study LO2/LCH4 propulsion system steady state and transient performance, operational characteristics and to validate fluid and thermal models of a LO2/LCH4 propulsion system for use in future flight design work. Two phase thermal and dynamic fluid flow models of the IPSTB were built to predict the system performance characteristics under a variety of operating modes and to aid in the overall system design work. While at ambient temperature and simulated altitude conditions at the White Sands Test Facility, the IPSTB and its approximately 600 channels of system instrumentation would be operated to perform a variety of integrated main engine and reaction control engine hot fire tests. The pressure, temperature, and flow rate data collected during this testing would then be used to validate the analytical models of the IPSTB?s thermal and dynamic fluid flow performance. An overview of the IPSTB design and analytical model development will be presented.

Flynn, Howard↗

NASA NTRS2015

Low-Cost, High-Performance Combustion Chamber

Ultramet designed and fabricated a lightweight, high-temperature combustion chamber for use with cryogenic LOX/CH4 propellants that can deliver a specific impulse of approx.355 seconds. This increase over the current 320-second baseline of nitrogen tetroxide/monomethylhydrazine (NTO/MMH) will result in a propellant mass decrease of 55 lb for a typical lunar mission. The material system was based on Ultramet's proven oxide-iridium/rhenium architecture, which has been hot-fire tested with stoichiometric oxygen/hydrogen for hours. Instead of rhenium, however, the structural material was a niobium or tantalum alloy that has excellent yield strength at both ambient and elevated temperatures. Phase I demonstrated alloys with yield strength-to-weight ratios more than three times that of rhenium, which will significantly reduce chamber weight. The starting materials were also two orders of magnitude less expensive than rhenium and were less expensive than the C103 niobium alloy commonly used in low-performance engines. Phase II focused on the design, fabrication, and hot-fire testing of a 12-lbf thrust class chamber with LOX/CH4, and a 100-lbf chamber for LOX/CH4. A 5-lbf chamber for NTO/MMH also was designed and fabricated.

Fortini, Arthur J.↗

NASA NTRS2004

Fiber-Optic Strain-Gage Tank Level Measurement System for Cryogenic Propellants

Measurement of tank level, particularly for cryogenic propellants, has proven to be a difficult problem. Current methods based on differential pressure, capacitance sensors, temperature sensors, etc.; do not provide sufficiently accurate or robust measurements, especially at run time. These methods are designed to measure tank-level, but when the fluids are in supercritical state, the liquid-gas interface disappears. Furthermore, there is a need for a non-intrusive measurement system; that is, the sensors should not require tank modifications and/or disturb the fluids. This paper describes a simple, but effective method to determine propellant mass by measuring very small deformations of the structure supporting the tank. Results of a laboratory study to validate the method, and experimental data from a deployed system are presented. A comparison with an existing differential pressure sensor shows that the strain gage system provides a much better quality signal across all regimes during an engine test. Experimental results also show that the use of fiber optic strain gages (FOSG) over classic foil strain gages extends the operation time (before the system becomes uncalibrated), and increases accuracy. Finally, a procedure is defined whereby measurements from the FOSG mounted on the tank supporting structure are compensated using measurements of a FOSG mounted on a reference plate and temperature measurements of the structure. Results describing the performance of a deployed system that measures tank level during propulsion tests are included.

Figueroa, Fernando↗

NASA NTRS1976

The development of large diameter, high pressure, cryogenic radial static seals

Two configurations of radial static seals are developed for high-pressure 773 kg per sq cm cryogenic applications: a U-shaped fluorocarbon seal and a delta-shaped PTFE seal. The U-seal is a common commercial design consisting of a spring-loaded cup-shaped jacket; the basic principle is that the soft plastic jacket provides the interface between the piston and the bore, the jacket being held in place by a metal spring. The delta seal is based on the principle that the soft plastic delta cross section furnishes the interface at the metal face and circumferential face of the gland and cylinder. Test results indicate that both the plastic U-seal and the delta seal designs are sufficiently flexible to accommodate assembly in bore or piston grooves. Of these two configurations, the delta seal is found to be superior as it meets all the design requirements for proof pressure testing the turbopump components of the main engine in the Space Shuttle.

Burr, M. E.↗

NASA NTRS1992

CCD data acquisition systems at Lick and Keck Observatories

This paper will describe and compare two distinct but related CCD data acquisition systems (DAS) currently under development at Lick and Keck Observatories. Although these two systems have a number of major architectural differences, they share a considerable amount of common hardware and software. Both of these new systems build on a large body of proven software that is the foundation of the existing CCD DAS currently in use at Lick Observatory. Both will provide support for reading up to four on-chip amplifiers per CCD and/or reading out mosaics of CCD chips. In addition, they will provide the capability for interactive, real-time adjustment of CCD waveforms for engineering purposes. Each of these two systems is composed of three major subsystems: (1) an instrument computer and its software; (2) a data capture computer and its software; and (3) a CCD/dewar controller and its software. The instrument computer is a Unix workstation, and the functions it provides include user interfaces, the interactive real-time display of CCD images, and the recording of image and FITS header data to disk and/or tape. The data capture computer is responsible for the packaging and high-speed transfer of the CCD pixel data stream into a bulk RAM, and the subsequent transfer of this data to the instrument computer. The CCD/dewar controller generates the waveforms for clocking the CCD, digitizes the pixel data, and transmits it via high-speed link to the data capture computer. It is also responsible for monitoring and controlling the dewar temperature and cryogen levels. Given the number of different types of processors and high-speed data links employed in both systems, a major emphasis of this paper will be on the various forms of interprocessor communications utilized for data transfer and distributed process synchronization.

Kibrick, R. I.↗

NASA NTRS1998

Diode laser absorption sensors for gas-dynamic and combustion flows

Recent advances in room-temperature, near-IR and visible diode laser sources for tele-communication, high-speed computer networks, and optical data storage applications are enabling a new generation of gas-dynamic and combustion-flow sensors based on laser absorption spectroscopy. In addition to conventional species concentration and density measurements, spectroscopic techniques for temperature, velocity, pressure and mass flux have been demonstrated in laboratory, industrial and technical flows. Combined with fibreoptic distribution networks and ultrasensitive detection strategies, compact and portable sensors are now appearing for a variety of applications. In many cases, the superior spectroscopic quality of the new laser sources compared with earlier cryogenic, mid-IR devices is allowing increased sensitivity of trace species measurements, high-precision spectroscopy of major gas constituents, and stable, autonomous measurement systems. The purpose of this article is to review recent progress in this field and suggest likely directions for future research and development. The various laser-source technologies are briefly reviewed as they relate to sensor applications. Basic theory for laser absorption measurements of gas-dynamic properties is reviewed and special detection strategies for the weak near-IR and visible absorption spectra are described. Typical sensor configurations are described and compared for various application scenarios, ranging from laboratory research to automated field and airborne packages. Recent applications of gas-dynamic sensors for air flows and fluxes of trace atmospheric species are presented. Applications of gas-dynamic and combustion sensors to research and development of high-speed flows aeropropulsion engines, and combustion emissions monitoring are presented in detail, along with emerging flow control systems based on these new sensors. Finally, technology in nonlinear frequency conversion, UV laser materials, room-temperature mid-IR materials and broadly tunable multisection devices is reviewed to suggest new sensor possibilities.

Non-NASA Center↗

NASA NTRS2004

Development of a Lunar Consumables Storage and Distribution Depot

NASA is in the preliminary planning stages for a future lunar base as a response to President George W. Bush's recent announcement of a new sustained exploration program beyond low earth orbit. Kennedy Space Center engineers are supporting this program by utilizing experience in Spaceport system design and operations to help develop a Lunar Consumables Depot. This depot will store propellants, life support fluids, and other consumables either transported from Earth or manufactured from In Situ resources. The depot will distribute these consumables in an energy efficient manner to end users including spacecraft, habitation modules, and rovers. This paper addresses some of the changes to lunar base architecture design as a result of advances in knowledge of lunar resources over the past 35 years, as well as technology advances in the area of In Situ Resource Utilization and consumable storage and distribution. A general system level description of the depot will be presented, including overall design philosophy and high level requirements. Finally, specific subsystem technologies that have been or will be developed by KSC will be addressed. Examples of these technologies are automated umbilicals, cryogenic refrigerators, novel storage vessels, advanced heat switches and heat exchangers, and self healing gaskets and wires.

Mueller, Robert P.↗

NASA NTRS2009

Providing Oxygen for the Crew of a Lunar Outpost

Oxygen (O2) is obviously essential for human space missions, but it is important to examine all the different ways it will be used and the potential sources that it may come from. This effort will lead to storage and delivery requirements and help to determine the optimum architecture from an overall systems engineering point of view. Accounting for all the oxygen in a Lunar Outpost mission includes meeting the metabolic needs of the crew while in the surface Habitat, leakage through the Habitat or Pressurized Rover walls, recharge of the space suit backpack and emergency situations. Current plans indicate that both primary and secondary O2 bottles for the space suit will be filled to a pressure of 20.7 MPa (3000 psia). Other uses of O2 require much lower pressure. Sources of O2 at a Lunar Outpost include compressed or liquefied O2 brought along specifically for life support, scavenged O2 from the Lander propulsion system, recovered O2 from waste water or exhaled carbon dioxide and O2 mined from the moon itself. Previously, eight technology options were investigated to provide the high pressure space suit O2. High pressure O2 storage was treated as the baseline technology and compared to the other seven. The other seven were cryogenic storage followed by high pressure vaporization, scavenging liquid oxygen (LOX) from Lander followed by vaporization, LOX delivery followed by sorption compression, low pressure water electrolysis followed by mechanical compression, high pressure water electrolysis, sharing a high pressure electrolyzer with a regenerative fuel cell power system, and making use of In- Situ Resource Utilization (ISRU). This system-level analysis was conducted by comparing equivalent system mass of the eight technologies in open and closed loop life support architectures. The most promising high pressure O2 generation technologies were recommended for development. Updates and an expansion of the earlier study have been made and the results are reported in this paper. Examples of recent analyses include feasibility of recovering space suit purge O2 in a Pressurized Rover and using sub-critical LOX for primary supply while using high-pressure gaseous O2 as the secondary supply for the space-suit. Preliminary analysis on scavenging LOX from the Lander and delivering it to the Habitat has also been incorporated into this integrated lunar fluids analysis

Ewert, Michael K.↗

NASA NTRS2010

Secondary Impacts on Structures on the Lunar Surface

The Altair Lunar Lander is being designed for the planned return to the Moon by 2020. Since it is hoped that lander components will be re-used by later missions, studies are underway to examine the exposure threat to the lander sitting on the Lunar surface for extended periods. These threats involve both direct strikes of meteoroids on the vehicle as well as strikes from Lunar regolith and rock thrown by nearby meteorite strikes. Currently, the lander design is comprised of up to 10 different types of pressure vessels. These vessels included the manned habitation module, fuel, cryogenic fuel and gas storage containers, and instrument bays. These pressure vessels have various wall designs, including various aluminum alloys, honeycomb, and carbon-fiber composite materials. For some of the vessels, shielding is being considered. This program involved the test and analysis of six pressure vessel designs, one of which included a Whipple bumper shield. In addition to the pressure vessel walls, all the pressure vessels are wrapped in multi-layer insulation (MLI). Two variants were tested without the MLI to better understand the role of the MLI in the impact performance. The tests of performed were to examine the secondary impacts on these structures as they rested on the Lunar surface. If a hypervelocity meteor were to strike the surface nearby, it would throw regolith and rock debris into the structure at a much lower velocity. Also, when the manned module departs for the return to Earth, its rocket engines throw up debris that can impact the remaining lander components and cause damage. Glass spheres were used as a stimulant for the regolith material. Impact tests were performed with a gas gun to find the V50 of various sized spheres striking the pressure vessels. The impacts were then modeled and a fast-running approximate model for the V50 data was developed. This model was for performing risk analysis to assist in the vessel design and in the identification of ideal long-term mission sites. This paper reviews the impact tests and analysis and modeling examining the impact threat to various components in the lander design.

Christiansen, Eric↗

NASA NTRS2011

NASA Tech Briefs, March 2011

Topics covered include: Optimal Tuner Selection for Kalman-Filter-Based Aircraft Engine Performance Estimation; Airborne Radar Interferometric Repeat-Pass Processing; Plug-and-Play Environmental Monitoring Spacecraft Subsystem; Power-Combined GaN Amplifier with 2.28-W Output Power at 87 GHz; Wallops Ship Surveillance System; Source Lines Counter (SLiC) Version 4.0; Guidance, Navigation, and Control Program; Single-Frame Terrain Mapping Software for Robotic Vehicles; Auto Draw from Excel Input Files; Observation Scheduling System; CFDP for Interplanetary Overlay Network; X-Windows Widget for Image Display; Binary-Signal Recovery; Volumetric 3D Display System with Static Screen; MMIC Replacement for Gunn Diode Oscillators; Feature Acquisition with Imbalanced Training Data; Mount Protects Thin-Walled Glass or Ceramic Tubes from Large Thermal and Vibration Loads; Carbon Nanotube-Based Structural Health Monitoring Sensors; Wireless Inductive Power Device Suppresses Blade Vibrations; Safe, Advanced, Adaptable Isolation System Eliminates the Need for Critical Lifts; Anti-Rotation Device Releasable by Insertion of a Tool; A Magnetically Coupled Cryogenic Pump; Single Piezo-Actuator Rotary-Hammering Drill; Fire-Retardant Polymeric Additives; Catalytic Generation of Lift Gases for Balloons; Ionic Liquids to Replace Hydrazine; Variable Emittance Electrochromics Using Ionic Electrolytes and Low Solar Absorptance Coatings; Spacecraft Radiator Freeze Protection Using a Regenerative Heat Exchanger; Multi-Mission Power Analysis Tool; Correction for Self-Heating When Using Thermometers as Heaters in Precision Control Applications; Gravitational Wave Detection with Single-Laser Atom Interferometers; Titanium Alloy Strong Back for IXO Mirror Segments; Improved Ambient Pressure Pyroelectric Ion Source; Multi-Modal Image Registration and Matching for Localization of a Balloon on Titan; Entanglement in Quantum-Classical Hybrid; Algorithm for Autonomous Landing; Quantum-Classical Hybrid for Information Processing; Small-Scale Dissipation in Binary-Species Transitional Mixing Layers; Superpixel-Augmented Endmember Detection for Hyperspectral Images; Coding for Parallel Links to Maximize the Expected Value of Decodable Messages; and Microwave Tissue Soldering for Immediate Wound Closure.

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NASA NTRS2014

Tri-Gas Pressurization System Testing and Modeling for Cryogenic Applications

The use of Tri‐gas in rocket propulsion systems is somewhat of a new technology. This paper defines Tri‐gas as a mixture of gases composed largely of helium with a small percentage of a stoichiometric mixture of hydrogen and oxygen. When exposed to a catalyst the hydrogen and oxygen in the mixture combusts, significantly raising the temperature of the mixture. The increase in enthalpy resulting from the combustion process significantly decreases the required quantity of gas needed to pressurize the ullage of the vehicle propellant tanks. The objective of this effort was to better understand the operating characteristics of Tri‐gas in a pressurization system with low temperature applications. In conjunction with ongoing programs at NASA Marshall Space Flight Center, an effort has been undertaken to evaluate the operating characteristics of Tri‐gas through modeling and bench testing. Through improved understanding of the operating characteristics, the risk of using this new technology in a launch vehicle propulsion system was reduced. Bench testing of Tri‐gas was a multistep process that targeted gas characteristics and performance aspects that pose a risk to application in a pressurization system. Pressurization systems are vital to propulsion system performance. Keeping a target ullage pressure in propulsions tanks is necessary to supply propellant at the conditions and flow rates required to maintain desired engine functionality. The first component of testing consisted of sampling Tri‐gas sources that had been stagnant for various lengths of time in order to determine the rate at which stratification takes place. Second, a bench test was set up in which Tri‐gas was sent through a catalyst bed. This test was designed to evaluate the performance characteristics of Tri‐gas, under low temperature inlet temperatures, in a flight‐like catalyst bed reactor. The third, most complex, test examined the performance characteristics of Tri‐gas at low temperature temperatures in a test configuration built to more closely resemble a vehicle pressurization system. The results of these bench tests address various risks that all relate to underperformance of Tri‐gas pressurization systems.

Taylor, B.↗

NASA NTRS2008

Engineering Design Unit Primary Mirror Segment

The James Webb Space Telescope Primary Mirror Engineering Design Unit (EDU) recently demonstrated the final manufacturing process at L-3-SSG/Tinsley in Richmond, California. Shown in the picture below, the EDU is a prototype 1.4 meter diameter Beryllium mirror that is identical to the 18 flight mirror segments and is used to check out all mirror manufacturing processes prior to the actual flight mirror processing. This recent result gives confidence that all manufacturing processes are in place to figure the 18 flight mirrors. Lessons learned from the EDU have been applied to the flight mirrors improving the performance and processing time and all 18 flight mirrors are well along in their processing at L3-SSG/Tinsley. As a result of completing the final manufacturing demonstration, the EDU mirror was sent to Ball Aerospace in Boulder, Colorado where it is now undergoing integration with the hexapod mount assembly and optical testing checkout. After integration to mount assemblies, flight mirrors will be sent for cryogenic (50 degrees Kelvin) optical testing where the cryogenic distortions will be measured. After cryogenic testing, mirrors will eventually be returned to Tinsley for final cryogenic polishing. During final cryogenic polishing, the inverse of the measured cryogenic distortions will be polished into the mirror to assure the mirror works at it's cryogenic operating temperature. Once cryogenic polishing is completed to final specifications, the mirror will be coated and sent for final cryogenic testing.

Alongi, Chris↗

NASA NTRS2009

Oxygen Compatibility of Brass-Filled PTFE Compared to Commonly Used Fluorinated Polymers for Oxygen Systems

Safe and reliable seal materials for high-pressure oxygen systems sometimes appear to be extinct species when sought out by oxygen systems designers. Materials that seal well are easy to find, but these materials are typically incompatible with oxygen, especially in cryogenic liquid form. This incompatibility can result in seals that leak, or much worse, seals that easily ignite and burn during use. Materials that are compatible with oxygen are easy to find, such as the long list of compatible metals, but these metallic materials are limiting as seal materials. A material that seals well and is oxygen compatible has been the big game in the designer's safari. Scientists at the Materials Combustion Research Facility (MCRF), part of NASA/Marshall Space Flight Center (MSFC), are constantly searching for better materials and processes to improve the safety of oxygen systems. One focus of this effort is improving the characteristics of polymers used in the presence of an oxygen enriched environment. Very few systems can be built which contain no polymeric materials; therefore, materials which have good impact resistance, low heat of combustion, high auto-ignition temperature and that maintain good mechanical properties are essential. The scientists and engineers at the Materials Combustion Research Facility, in cooperation with seal suppliers, are currently testing a new formulation of polytetrafluoroethylene (PTFE) with Brass filler. This Brass-filled PTFE is showing great promise as a seal and seat material for high pressure oxygen systems. Early research has demonstrated very encouraging results, which could rank this material as one of the best fluorinated polymers ever tested. This paper will compare the data obtained for Brass-filled PTFE with other fluorinated polymers, such as TFE-Teflon (PTFE) , Kel-F 81, Viton A, Viton A-500, Fluorel , and Algoflon . A similar metal filled fluorinated polymer, Salox-M , was tested in comparison to Brass-filled PTFE to demonstrate the importance of the metal chosen and relative percentage of filler. General conclusions on the oxygen compatibility of this formulation are drawn, with an emphasis on comparing and contrasting the materials performance to the performance of the current state-of-the-art oxygen compatible polymers.

Herald, Stephen D.↗