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NASA NTRS2011

Qualifications of Bonding Process of Temperature Sensors to Deep-Space Missions

A process has been examined for bonding a platinum resistance thermometer (PRT) onto potential aerospace materials such as flat aluminum surfaces and a flexible copper tube to simulate coaxial cables for flight applications. Primarily, PRTs were inserted into a silver-plated copper braid to avoid stresses on the sensor while the sensor was attached with the braid to the base material for long-duration, deep-space missions. A1-1145/graphite composite (planar substrate) and copper tube have been used in this study to assess the reliability of PRT bonding materials. A flexible copper tube was chosen to simulate the coaxial cable to attach PRTs. The substrate materials were cleaned with acetone wipes to remove oils and contaminants. Later, the surface was also cleaned with ethyl alcohol and was air-dried. The materials were gently abraded and then were cleaned again the same way as previously mentioned. Initially, shielded (silver plated copper braid) PRT (type X) test articles were fabricated and cleaned. The base antenna material was pretreated and shielded, and CV-2566 NuSil silicone was used to attach the shielded PRT to the base material. The test articles were cured at room temperature and humidity for seven days. The resistance of the PRTs was continuously monitored during the thermal cycling, and the test articles were inspected prior to, at various intermediate steps during, and at the end of the thermal cycling as well. All of the PRTs survived three times the expected mission life for the JUNO project. No adhesion problems were observed in the PRT sensor area, or under the shielded PRT. Furthermore, the PRT resistance accurately tracked the thermal cycling of the chamber.

Ramesham, Rajeshuni↗

NASA NTRS1993

Axisymmetric micromechanics of elastic-perfectly plastic fibrous composites under uniaxial tension loading

The uniaxial response of a continuous fiber elastic-perfectly plastic composite is modeled herein as a two-element composite cylinder. An axisymmetric analytical micromechanics solution is obtained for the rate-independent elastic-plastic response of the two-element composite cylinder subjected to tensile loading in the fiber direction for the case wherein the core fiber is assumed to be a transversely isotropic elastic-plastic material obeying the Tsai-Hill yield criterion, with yielding simulating fiber failure. The matrix is assumed to be an isotropic elastic-plastic material obeying the Tresca yield criterion. It is found that there are three different circumstances that depend on the fiber and matrix properties: fiber yield, followed by matrix yielding; complete matrix yield, followed by fiber yielding; and partial matrix yield, followed by fiber yielding, followed by complete matrix yield. The order in which these phenomena occur is shown to have a pronounced effect on the predicted uniaxial effective composite response.

Lee, Jong-Won↗

NASA NTRS1998

Ground-Based Testing of Replacement Thermal Control Materials for the Hubble Space Telescope

The mechanical and optical properties of the metallized Teflon FEP thermal control materials on the Hubble Space Telescope (HST) have degraded over the nearly seven years the telescope has been in orbit. Given the damage to the outer layer of the multi-layer insulation (MLI) that was apparent during the second servicing mission (SM2), the decision was made to replace the outer layer during subsequent servicing missions. A Failure Review Board was established to investigate the damage to the MLI and identify a replacement material. The replacement material had to meet the stringent thermal requirements of the spacecraft and maintain mechanical integrity for at least ten years. Ten candidate materials were selected and exposed to ten-year HST-equivalent doses of simulated orbital environments. Samples of the candidates were exposed sequentially to low and high energy electrons and protons, atomic oxygen, x-ray radiation, ultraviolet radiation and thermal cycling. Following the exposures, the mechanical integrity and optical properties of the candidates were investigated using Optical Microscopy, Scanning Electron Microscopy (SEM), a Laboratory Portable Spectroreflectometer (LPSR) and a Lambda 9 Spectroreflectometer. Based on the results of these simulations and analyses, the Failure Review Board selected a replacement material and two alternates that showed the highest likelihood of providing the requisite thermal properties and surviving for ten years in orbit.

Townsend, Jacqueline A.↗

NASA NTRS2023

Orbital Debris Shape Effect Investigations for Mitigating Risk

NASA’s Orbital Debris Program Office (ODPO) and Hypervelocity Impact Technology (HVIT) team have coordinated to better understand the risks to upper stages and spacecraft from non-spherical orbital debris. It is well understood that fragmentation (collision or explosion) events in orbit produce fragments of various materials, sizes, and shapes. To further characterize these parameters, the ODPO is developing the next-generation Orbital Debris Engineering Model (ORDEM) version 4.0 to include orbital debris shape distributions. Ground-based assets, such as radar and optical sensors, can provide size estimates and some insight into material based on radar return or optical filter photometry/spectroscopy, respectively. Characterizing an object’s shape requires more laboratory analyses to infer how shape affects these measurements. More importantly, in addition to size and material/density, the shape of fragments in orbit will alter the ballistic limit equations used in orbital debris risk assessments with NASA’s Bumper Code. The ODPO plans to release ORDEM 4.0 in the coming years. Performing ground-based laboratory impact tests on high-fidelity spacecraft mockups provides the means to directly measure size, mass, material/density, and shape of fragments, all key parameters needed to characterize real-world break up events. The DebriSat test, the results of which are provided, showcases the details of this type of experiment. The goal of this collaborative research between the ODPO and the HVIT team is to include a shape parameter in the environmental and breakup models used to assess risk for various space structures. This paper examines ground-based laboratory impact tests and the associated fragment shape categories. Provided these defined shapes, the approach is simplified by assuming a right circular cylinder (RCC) approximation with varying length-to-diameter ratios. Highlights of impact tests conducted by the HVIT team using non-spherical projectiles based on the RCC approximation are presented. Hydrocode simulations have also been performed to expand on the complexity of variations with non-spherical projectiles. Lastly, ray-tracing simulations of various RCCs of known material are provided to support the ongoing research on optical reflectance distributions with known shapes and to highlight how this may modify the current optical size estimation model. The status and plan forward are outlined for NASA's orbital debris shape effect investigation using a multidisciplinary approach by the ODPO and the HVIT team.

Heather Cowardin↗

NASA NTRS2023

Orbital Debris Shape Effect Investigations for Mitigating Risk

Heather Cowardin↗

NASA NTRS1974

Computer simulation of the NASA water vapor electrolysis reactor

The water vapor electrolysis (WVE) reactor is a spacecraft waste reclamation system for extended-mission manned spacecraft. The WVE reactor's raw material is water, its product oxygen. A computer simulation of the WVE operational processes provided the data required for an optimal design of the WVE unit. The simulation process was implemented with the aid of a FORTRAN IV routine.

Bloom, A. M.↗

NASA NTRS2003

Monte Carlo Methods in Materials Science Based on FLUKA and ROOT

A comprehensive understanding of mitigation measures for space radiation protection necessarily involves the relevant fields of nuclear physics and particle transport modeling. One method of modeling the interaction of radiation traversing matter is Monte Carlo analysis, a subject that has been evolving since the very advent of nuclear reactors and particle accelerators in experimental physics. Countermeasures for radiation protection from neutrons near nuclear reactors, for example, were an early application and Monte Carlo methods were quickly adapted to this general field of investigation. The project discussed here is concerned with taking the latest tools and technology in Monte Carlo analysis and adapting them to space applications such as radiation shielding design for spacecraft, as well as investigating how next-generation Monte Carlos can complement the existing analytical methods currently used by NASA. We have chosen to employ the Monte Carlo program known as FLUKA (A legacy acronym based on the German for FLUctuating KAscade) used to simulate all of the particle transport, and the CERN developed graphical-interface object-oriented analysis software called ROOT. One aspect of space radiation analysis for which the Monte Carlo s are particularly suited is the study of secondary radiation produced as albedoes in the vicinity of the structural geometry involved. This broad goal of simulating space radiation transport through the relevant materials employing the FLUKA code necessarily requires the addition of the capability to simulate all heavy-ion interactions from 10 MeV/A up to the highest conceivable energies. For all energies above 3 GeV/A the Dual Parton Model (DPM) is currently used, although the possible improvement of the DPMJET event generator for energies 3-30 GeV/A is being considered. One of the major tasks still facing us is the provision for heavy ion interactions below 3 GeV/A. The ROOT interface is being developed in conjunction with the CERN ALICE (A Large Ion Collisions Experiment) software team through an adaptation of their existing AliROOT (ALICE Using ROOT) architecture. In order to check our progress against actual data, we have chosen to simulate the ATIC14 (Advanced Thin Ionization Calorimeter) cosmic-ray astrophysics balloon payload as well as neutron fluences in the Mir spacecraft. This paper contains a summary of status of this project, and a roadmap to its successful completion.

Pinsky, Lawrence↗

NASA NTRS1987

Test program to evaluate ESD susceptibility of EVA suit material

This paper presents the details of a test program for the evaluation of the electrostatic discharge susceptibility of extravehicular activity equipment in polar orbits. In this program, laboratory simulation tests were performed to obtain the charging and ESD characteristics of the spacesuit material. The results from the simulation tests were used to generate the parameters for a system level ESD test for the existing EVA equipment. These test parameters were also used as a guide for the selection of the test apparatus.

Leung, Philip↗

NASA NTRS1996

Feasibility Study of Velocity and Temperature Measurements of an Arcjet Flow using Laser Resonance Doppler Velocimetric (LRDV) Technique

Thermal Protection System (TPS) materials are used in space vehicles to shield from high heating environment encountered during their atmospheric reentry. Arcjet wind tunnels are used to simulate the flowfield encountered by the spacecrafts, and are used for testing TPS materials. How well these tests simulate the actual heating environment encountered by space vehicles depends on the characteristics of the simulated flow. The flow characterization requires the determination of temperature, concentration, and velocity of the various atomic and molecular species present in the flow. However, determining these parameters requires a complex set of both analytical and experimental procedures. The ability to properly simulate the flight environment is directly related to the accuracy with which these techniques can be used to define the arcjet Laser Resonance Doppler Velocimetric (LRDV) technique can be used to accurately determine the velocity and temperature of a gaseous species. In this technique, the medium is probed with a laser beam that is in resonance with an absorbing transition of the species. The absorption lineshape is Doppler-shifted due to the flow velocity of the species, and the frequency shift is detected as the variation in intensity of the fluorescence emitted by the species. Thus a measurement of the Doppler shift and the width of a spectral line can give both the temperature and the velocity of the flowfield. This summer, our project was to make a feasibility study to set up an experimental arrangement for the laser resonance Doppler velocimetric technique using a ring dye laser. Experiments required troubleshooting, cleaning, testing, and alignment of two lasers and several diagnostics instruments. All instruments and lasers necessary for the project worked well, but the output power of the broadband fundamental dye laser was limited to about 20 mW. This was quite low as compared to that necessary to obtain second harmonic oscillation at 327.49 nm for the LRDV studies. Further optimization of the dye laser optical elements is necessary before it can be used for the experiment, which requires narrowband (about 20 Mhz) laser operation.

Rob, Mohammad A.↗

NASA NTRS1972

Contamination character of materials in space technology testing.

Determination of the nature and degree of contamination of mirrors in a vacuum environment in the presence of UV irradiation by outgases from some materials that are candidates for use inside spacecraft and simulated spacecraft environments. A vacuum apparatus was developed for testing contamination of mirrors. Offgases from heated test materials are deposited on a refrigerated mirror, half of which is UV irradiated. Reflectance is measured between 1100 and 25,000 A. Thermofit RNF-100, insulated wire TRT-24-19-V-93, and Eccofoam FS and FPH gave heavier deposits on the nonirradiated mirror. Moxness MS60 SO8, Scotch Tape Y-9050, RTV-577, RTV-41, Stycast 1090, and Epon 934 and 828 gave heavier deposits on the irradiated mirror. Raychem wire 44/0411, polyimide tape X1156, Insulgrease G-640, High Vacuum Silicone Grease, and RTV-602 gave only slight deposits on the irradiated and nonirradiated areas of the mirror.

Coulson, D. M.↗

NASA NTRS1987

New methods and materials for molding and casting ice formations

This study was designed to find improved materials and techniques for molding and casting natural or simulated ice shapes that could replace the wax and plaster method. By utilizing modern molding and casting materials and techniques, a new methodology was developed that provides excellent reproduction, low-temperature capability, and reasonable turnaround time. The resulting casts are accurate and tough.

Reehorst, Andrew L.↗

NASA NTRS1988

Microwave and millimeter-wave power generation in silicon carbide avalanche devices

Numerical simulations were performed to investigate the typical power-generating capabilities of SiC IMPATT diodes. Using available material parameters, SiC double-drift IMPATT diodes were simulated at 10, 35, 60, and 94 GHz, and the operating characteristics of these devices were compared to those of Si and GaAs devices. Compared to the Si and GaAs IMPATT performances in the pulsed mode, the SiC IMPATT performance was found to be far superior. The performance of SiC devices in the CW mode was also superior to that of GaAs devices, especially at lower frequencies. At a high frequency (94 GHz), the performance of the SiC device was found to be comparable to that of Si devices.

Mehdi, I.↗

NASA NTRS2010

Corrosion-Resistant Container for Molten-Material Processing

In a carbothermal process, gaseous methane is passed over molten regolith, which is heated past its melting point to a temperature in excess of 1,625 C. At this temperature, materials in contact with the molten regolith (or regolith simulant) corrode and lose their structural properties. As a result, fabricating a crucible to hold the molten material and providing a method of contact heating have been problematic. Alternative containment approaches use a large crucible and limit the heat zone of the material being processed, which is inefficient because of volume and mass constraints. Alternative heating approaches use non-contact heating, such as by laser or concentrated solar energy, which can be inefficient in transferring heat and thus require higher power heat sources to accomplish processing. The innovation is a combination of materials, with a substrate material having high structural strength and stiffness and high-temperature capability, and a coating material with a high corrosion resistance and high-temperature capability. The material developed is a molybdenum substrate with an iridium coating. Creating the containment crucible or heater jacket using this material combination requires only that the molybdenum, which is easily processed by conventional methods such as milling, electric discharge machining, or forming and brazing, be fabricated into an appropriate shape, and that the iridium coating be applied to any surfaces that may come in contact with the corrosive molten material. In one engineering application, the molybdenum was fashioned into a container for a heat pipe. Since only the end of the heat pipe is used to heat the regolith, the container has a narrowing end with a nipple in which the heat pipe is snugly fit, and the external area of this nipple, which contacts the regolith to transfer heat into it, is coated with iridium. At the time of this reporting, no single material has been found that can perform the functions of this combination of materials, and other combinations of materials have not proven to be survivable to the corrosiveness of this environment. High-temperature processing of materials with similar constituencies as lunar regolith is fairly common. The carbo-thermal process is commonly used to make metallurgical-grade silicon for the semiconductor and solar-cell industries.

Stern, Theodore G.↗

NASA NTRS1993

JSC-1: A new lunar regolith simulant

Simulants of lunar rocks and soils with appropriate properties, although difficult to produce in some cases, will be essential to meeting the system requirements for lunar exploration. In order to address this need a new lunar regolith simulant, JSC-1, has been developed. JSC-1 is a glass-rich basaltic ash which approximates the bulk chemical composition and mineralogy of some lunar soils. It has been ground to produce a gain size distribution approximating that of lunar regolith samples. The simulant is available in large quantities (greater than 2000 lb; 907 kg). JSC-1 was produced specifically for large- and medium-scale engineering studies in support of future human activities on the Moon. Such studies include material handling, construction, excavation, and transportation. The simulant is also appropriate for research on dust control and spacesuit durability. JSC-1 can be used as a chemical or mineralogical analog to some lunar soils for resource studies such as oxygen or metal production, sintering, and radiation shielding.

Mckay, David S.↗

NASA NTRS1976

Ames T-3 fire test facility - Aircraft crash fire simulation

There is a need to characterize the thermal response of materials exposed to aircraft fuel fires. Large scale open fire tests are costly and pollute the local environment. This paper describes the construction and operation of a subscale fire test that simulates the heat flux levels and thermochemistry of typical open pool fires. It has been termed the Ames T-3 Test and has been used extensively by NASA since 1969 to observe the behavior of materials exposed to JP-4 fuel fires.

Fish, R. H.↗

NASA NTRS1985

Hydrodynamic models for novae with ejecta rich in oxygen, neon and magnesium

The characteristics of a new class of novae are identified and explained. This class consists of those objects that have been observed to eject material rich in oxygen, neon, magnesium, and aluminum at high velocities. We propose that for this class of novae the outburst is occurring not on a carbon-oxygen white dwarf but on an oxygen-neon-magnesium white dwarf which has evolved from a star which had a main sequence mass of approx. 8 solar masses to approx. 12 solar masses. An outburst was simulated by evolving 1.25 solar mass white dwarfs accreting hydrogen rich material at various rates. The effective enrichment of the envelope by ONeMg material from the core is simulated by enhancing oxygen in the accreted layers. The resulting evolutionary sequences can eject the entire accreted envelope plus core material at high velocities. They can also become super-Eddington at maximum bolometric luminosity. The expected frequency of such events (approx. 1/4) is in good agreement with the observed numbers of these novae.

Starrfield, S.↗

NASA NTRSDate not supplied

Large Vehicle Lunar Landing Surface Interaction and In-Situ Resource Based Risk Mitigation: Landing & Launch Pads

A key capability required for the exploration of planetary bodies is the ability to land on the surface. Previous work performed by NASA and other institutions has primarily focused on landing small spacecraft on planetary surfaces and the associated small-to-medium thrusters required for the soft landing. In the case of human exploration—particularly the establishment of long duration exploration and habitation outposts—the ability to land large landers, such as the SpaceX Starship, is necessary. These larger landing systems require the use of more powerful engines, with higher engine exhaust temperatures and higher landing loads. Understanding the excavation of material by the engines, as well as the potential for the landing legs to sink into the subsurface, is key in ensuring reliable and safe landings. A further improvement in landing reliability can be achieved by constructing landing / launch pads, especially with in-situ resources. Some material excavation by the plume is inevitable, leaving at least a portion of the surface scoured and uneven under the lander and ejecting regolith particles and rocks at very high velocities. One possible solution would be to robotically build landing / launch pads (ideally autonomously) at the destination using in-situ materials. In this case, the first one or few landers will need to land on unimproved surfaces at higher risk; however, they would bring the required equipment to build the landing pads with mostly local resources, thus increasing the reliability of safe landing for subsequent larger landers. A number of methods to build in-situ landing and launch pads have already been developed. These methods include no or some addition of required binder additives to the local regolith material, different processing approaches and result in varying landing pad strengths. A sub-scale rocket engine plume, was used to simulate some of the conditions of a landing on the Moon to assess the effectiveness of various materials for an in-situ built landing pad, The GO2/GCH4 rocket engine fired on 1m2 area coupons of representative pad materials. The results will allow continued development towards materials that satisfy the landing pad properties required for the effective risk reduction and increased reliability for landing people and equipment on the lunar surface. This work contained two parts: (1) computer modeling of a large rocket engine plume interacting with regolith on the Moon, using the Granular Gas Flow Solver (GGFS) provided by CFD Research Corporation as well as other computational fluid dynamics codes (CFD) such as Loci/CHEM. (2) Developing landing/launch pad materials that could be used for in-situ construction on the lunar surface in the future, to mitigate the calculated effects of a large vehicle rocket engine landing and launching on the Moon. The resulting computed values of plume impingement surface temperature, stagnation pressure, gas velocity, shear stress and heat flux were then matched as closely as possible in the Earth’s atmosphere in a sub-scale rocket engine GO2/CH4 test which was provided by Masten Space Systems in Mojave, California. The rocket engine was mounted on a test stand with vertical translation capabilities so that the landing operations of a lander could be simulated (Figure 1).The pad materials test coupons were placed at the surface of a large bin containing simulated lunar basalt regolith and subjected to a test firing as shown in Figure 2. The results of this testing will be presented with related findings, analysis and discussion.

Plume Surface Interaction↗

NASA NTRS2011

Design and Test of Advanced Thermal Simulators for an Alkali Metal-Cooled Reactor Simulator

The Early Flight Fission Test Facility (EFF-TF) at NASA Marshall Space Flight Center (MSFC) has as one of its primary missions the development and testing of fission reactor simulators for space applications. A key component in these simulated reactors is the thermal simulator, designed to closely mimic the form and function of a nuclear fuel pin using electric heating. Continuing effort has been made to design simple, robust, inexpensive thermal simulators that closely match the steady-state and transient performance of a nuclear fuel pin. A series of these simulators have been designed, developed, fabricated and tested individually and in a number of simulated reactor systems at the EFF-TF. The purpose of the thermal simulators developed under the Fission Surface Power (FSP) task is to ensure that non-nuclear testing can be performed at sufficiently high fidelity to allow a cost-effective qualification and acceptance strategy to be used. Prototype thermal simulator design is founded on the baseline Fission Surface Power reactor design. Recent efforts have been focused on the design, fabrication and test of a prototype thermal simulator appropriate for use in the Technology Demonstration Unit (TDU). While designing the thermal simulators described in this paper, effort were made to improve the axial power profile matching of the thermal simulators. Simultaneously, a search was conducted for graphite materials with higher resistivities than had been employed in the past. The combination of these two efforts resulted in the creation of thermal simulators with power capacities of 2300-3300 W per unit. Six of these elements were installed in a simulated core and tested in the alkali metal-cooled Fission Surface Power Primary Test Circuit (FSP-PTC) at a variety of liquid metal flow rates and temperatures. This paper documents the design of the thermal simulators, test program, and test results.

Garber, Anne E.↗