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At least 865 records · Page 48

High-power RF switch

Switch designed for vacuum environments can handle 5 kilowatts of microwave power. Arcing between conductors is prevented by filling gaps with Teflon rather than with inert gas as in conventional switches. Thus, switch is not susceptible to gas leakage, problem faced by conventional switches in high-vacuum applications. Compact three-port switch, developed for microwave radar transmitters aboard spacecraft, is operated by depressing spring-mounted insulating pins that can be remotely actuated by relay. When pin is depressed, it routes microwave signals to selected output port.

Caro, E. R.↗

Application of powder metallurgy technique to produce improved bearing elements for cryogenic aerospace engine turbopumps

Traditionally, vacuum melted 440C stainless steel is used for high performance bearings for aerospace cryogenic systems where corrosion due to condensation is a major concern. For the Space Shuttle Main Engine (SSME), however, 440C performance in the high-pressure turbopumps has been marginal. A basic assumption of this study was that powder metallurgy, rather than cast/wrought, processing would provide the finest, most homogeneous bearing alloy structure. Preliminary testing of P/M alloys (hardness, corrosion resistance, wear resistance, fatigue resistance, and fracture toughness) was used to 'de-select' alloys which did perform as well as baseline 440C. Five out of eleven candidate materials (14-4/6V, X-405, MRC-2001, T-440V, and D-5) based on preliminary screening were selected for the actual rolling-sliding five-ball testing. The results of this test were compared with high-performance vacuum-melted M50 bearing steel. The results of the testing indicated outstanding performance of two P/M alloys, X-405 and MRC-2001, which eventually will be further evaluated by full-scale bearing testing.

Moxson, V. S.↗

Mitigating the Effects of Au-Al Intermetallic Compounds Due to High-Temperature Processing of Surface-Electrode Ion Traps

Stringent physical requirements need to be met for the high-performing surface-electrode ion traps used in quantum computing and timekeeping. In particular, these traps must survive a high-temperature environment for vacuum chamber preparation and support high RF voltage on closely spaced electrodes. Due to the use of gold wire bonds on aluminum pads, intermetallic growth can lead to wire bond failure via breakage or high resistance, limiting the lifetime of a trap assembly to a single multiday bake at 200 ° C. Using traditional thick metal stacks to prevent intermetallic growth, however, can result in trap failure due to RF breakdown events. Through high-temperature experiments, we conclude that an ideal metal stack for ion traps is Ti/Pt/Au (20/100/250 nm), which allows for a cumulative bakeable time of roughly 86 days without compromising the trap voltage performance. This increase in the bakeable lifetime of ion traps will remove the need to discard otherwise functional ion traps when vacuum hardware is upgraded, which will greatly benefit ion trap experiments.

Haltli, Raymond A.↗

High-temperature electric stator

Thermal vacuum tests are conducted on high-temperature stator without a rotor. Electrical characteristics remained satisfactory during tests, insulation improved slightly, and conductor resistance remained constant. The assembly included a bore seal for hermetically sealing the stator from the rotor cavity.

Kueser, P.↗

Brushless dc motor has high efficiency, long life

Brushless dc motor operates as a commutator in a vacuum environment with high efficiency and long life. Because of its excellent response time, it can be used in the servomechanism field.

Studer, P. A.↗

High-temperature metal purification using a compact, portable rf heating and levitation system on the wake shield

The potential use of a compact, battery-operated rf levitator and heating system to purify high-temperature melting materials in space is described. The wake shield now being fabricated for the Space Vacuum Epitaxy Center will provide an Ultra-high vacuum (10(exp -14) Torr hydrogen, 10(exp -14) Torr helium, 10(exp -30) Torr oxygen). The use of the wake shield to purify Nb, Ti, W, Ir, and other metals to a purity level not achievable on earth is described.

Hahs, C. A.↗

Long-term survival of bacterial spores in space

On board of the NASA Long Duration Exposure Facility (LDEF), spores of Bacillus subtilis in monolayers (10(exp 6)/sample) or multilayers (10(exp 8)/sample) were exposed to the space environment for nearly six years and their survival was analyzed after retrieval. The response to space parameters, such as vacuum (10(exp -6) Pa), solar electromagnetic radiation up to the highly energetic vacuum-ultraviolet range 10(exp 9) J/sq m) and/or cosmic radiation (4.8 Gy), was studied and compared to the results of a simultaneously running ground control experiment. If shielded against solar ultraviolet (UV)-radiation, up to 80% of spores in multilayers survive in space. Solar UV-radiation, being the most deleterious parameter of space, reduces survival by 4 orders of magnitude or more. However, up to 10(exp 4) viable spores were still recovered, even in completely unprotected samples. Substances, such as glucose or buffer salts serve as chemical protectants. With this 6 year study in space, experimental data are provided to the discussion on the likelihood of 'Panspermia'.

Horneck, G.↗

Effects of Ambient High Temperature Exposure on Alumina-Titania High Emittance Surfaces for Solar Dynamic Systems

Solar dynamic (SD) space power systems require durable, high emittance surfaces on a number of critical components, such as heat receiver interior surfaces and parasitic load radiator (PLR) elements. To enhance surface characteristics, an alumina-titania coating has been applied to 500 heat receiver thermal energy containment canisters and the PLR of NASA Lewis Research Center's (LeRC) 2 kW SD ground test demonstrator (GTD). The alumina-titania coating was chosen because it had been found to maintain its high emittance under vacuum (less than or equal to 10(exp -6) torr) at high temperatures (1457 F (827 C)) for an extended period (approximately 2,700 hours). However, preflight verification of SD systems components, such as the PLR require operation at ambient pressure and high temperatures. Therefore, the purpose of this research was to evaluate the durability of the alumina-titania coating at high temperature in air. Fifteen of sixteen alumina-titania coated Incoloy samples were exposed to high temperatures (600 F (316 C) to l500 F (816 C)) for various durations (2 to 32 hours). Samples, were characterized prior to and after heat treatment for reflectance, solar absorptance, room temperature emittance and emittance at 1,200 F (649 C). Samples were also examined to detect physical defects and to determine surface chemistry using optical microscopy, scanning electron microscopy operated with an energy dispersive spectroscopy (EDS) system, and x ray photoelectron spectroscopy (XPS). Visual examination of the heat-treated samples showed a whitening of samples exposed to temperatures of 1,000 F (538 C) and above. Correspondingly, the optical properties of these samples had degraded. A sample exposed to 1,500 F (816 C) for 24 hours had whitened and the thermal emittance at 1,200 F (649 C) had decreased from the non-heat treated value of 0.94 to 0.62. The coating on this sample had become embrittled with spalling off the substrate noticeable at several locations. Based on this research it is recommended that preflight testing of SD components with alumina-titania coatings be restricted to temperatures no greater than 600 F (316 C) in air to avoid optical degradation. Moreover, components with the alumina-titania coating are likely to experience optical property degradation with direct atomic oxygen exposure in space.

deGroh, Kim K.↗

Space ultra-vacuum facility and method of operation

A wake shield space processing facility (10) for maintaining ultra-high levels of vacuum is described. The wake shield (12) is a truncated hemispherical section having a convex side (14) and a concave side (24). Material samples (68) to be processed are located on the convex side of the shield, which faces in the wake direction in operation in orbit. Necessary processing fixtures (20) and (22) are also located on the convex side. Support equipment including power supplies (40, 42), CMG package (46) and electronic control package (44) are located on the convex side (24) of the shield facing the ram direction. Prior to operation in orbit the wake shield is oriented in reverse with the convex side facing the ram direction to provide cleaning by exposure to ambient atomic oxygen. The shield is then baked-out by being pointed directed at the sun to obtain heating for a suitable period.

Naumann, Robert J.↗

A Combined Computational, Experimental, and Technology Development Approach to In-Space Laser Manufacturing Maturation at NASA Marshall Space Flight Center

In-space manufacturing (ISM) is emerging as a field vital to continued access and capabilities in the space environment. NASA Marshall Space Flight Center (MSFC) is advancing the frontier of in-space laser manufacturing (ISLM) techniques through work initially focused on maturing laser beam welding (LBW) and laser forming (LF) for use in space. Such techniques proffer the ability to assemble and join structures in space from sheet metal or other stock – extant satellites, in situ resource utilization of Lunar regolith, etc. – by forming to desired shapes and then joining via in-space welding (ISW). ISLM processes are useful for assembly, joining, modification, and repair of structures in free space and on the Lunar surface such as large observatories, antennas, trusses, blast/thermal/radiation shields, pressure vessels, and more. However, these techniques are not yet qualified & certified (Q&C) for regular application in space. It would be prohibitively expensive, laborious, and time-consuming to perform Q&C via traditional experimental approaches as data collection & experimentation in space is resource-intensive. As such, benchmark experiments and focused, properly instrumented technology demonstration efforts in space can collect sufficient data that – when combined with verified computational models in an integrated computational materials engineering (ICME) approach – can validate ICME tools capable of translating more readily obtained ground data to in-space, in situ, computationally informed Q&C of ISLM techniques. Several ISLM projects at MSFC are obtaining the data required to validate ICME tools through both ground and flight experiments. A parabolic flight experiment of LBW under vacuum is manifested for August 2024, including both microgravity and Lunar gravity profiles. This collaboration with the Ohio State University is investigating common aerospace alloys such as 316L stainless steel, 2219 aluminum alloy, and Ti64 titanium alloy. In situ data collection includes videography, thermography, and reference thermocouples to build a thermal model of the welds. This will elucidate the relevant physics when combined with post-flight microstructural examination and mechanical testing. MSFC is also progressing towards a suborbital flight experiment of LBW under vacuum, which could provide reams of data on ISW during sustained, high-quality reduced gravity. The effect of combined thermal (cryogenic and high-temperature) and vacuum exposure on both LBW (NASA-funded) and LF (DARPA-funded) is being investigated through ground experiments. In addition to the copious data collected during these ground experiments, ruggedization of LBW hardware will also be pursued. The datasets from these experiments will be used to validate computational models which will inform future ISLM efforts in an ICME framework. A variety of techniques across lengths scales, from CALPHAD-driven thermodynamics & kinetics to phase field modeling of solidification to kinetic Monte Carlo simulations of grain evolution at the mesoscale, will be employed to accelerate the infusion and eventual Q&C of LBW and LF for use in space. The development of data-driven surrogate models to bridge ground to flight experiments and thereby reduce the need for resource-intensive experiments in space will also be investigated. These ICME techniques, surrogate models, and datasets from ground testing can also be employed to advance manufacturing in terrestrial environments.

in-space welding↗

Surface Texturing Investigated for a High Solar Absorptance Low Infrared Emittance Solar Collector

The objective of this work was to design, build, and vacuum test a high solar absorptance, low infrared emittance solar collector for heat engine and thermal switching applications. Mini-satellites proposed by the Applied Physics Laboratory for operation in environments that are subject to radiation threat may utilize a heat engine for power and a thermal bus for thermal control. To achieve this goal, a surface having high solar absorptance and low infrared emittance is needed. At the NASA Glenn Research Center, one concept being pursued to achieve this goal is texturing high thermal conductivity graphite epoxy composites using a directed atomic oxygen beam and then coating the textured surface with a reflective metallic coating. Coupons were successfully textured, coated, and evaluated. A variety of texturing conditions were explored, and textures were documented by scanning electron microscopy. Copper, gold, silver, iridium, and aluminum coatings were applied, and the highest solar absorptance to infrared emittance ratio was found to be 1.3. A full-sized solar collector was manufactured with this ratio, and the amount of heat collected was observed using an Inconel calorimeter installed in a bench-top vacuum chamber equipped with a solar simulator. Results to date indicate good heat flow through the system, with 9 W of heat flow measured by the calorimeter.

Jaworske, Donald A.↗