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Recent Developments in Hardware-in-the-Loop Formation Navigation and Control

The Formation Flying Test-Bed (FFTB) at NASA Goddard Space Flight Center (GSFC) provides a hardware-in-the-loop test environment for formation navigation and control. The facility is evolving as a modular, hybrid, dynamic simulation facility for end-tc-end guidance, navigation, and control (GN&C) design and analysis of formation flying spacecraft. The core capabilities of the FFTB, as a platform for testing critical hardware and software algorithms in-the-loop, are reviewed with a focus on many recent improvements. Two significant upgrades to the FFTB are a message-oriented middleware (MOM) architecture, and a software crosslink for inter-spacecraft ranging. The MOM architecture provides a common messaging bus for software agents, easing integration, arid supporting the GSFC Mission Services Evolution Center (GMSEC) architecture via software bridge. Additionally, the FFTB s hardware capabilities are expanding. Recently, two Low-Power Transceivers (LPTs) with ranging capability have been introduced into the FFTB. The LPT crosslinks will be connected to a modified Crosslink Channel Simulator (CCS), which applies realistic space-environment effects to the Radio Frequency (RF) signals produced by the LPTs.

Mitchell, Jason W.↗

Evaluating the performance of portable air filter walls for the James Webb Space Telescope launch campaign

The James Webb Space Telescope (JWST) launched from the Centre Spatial Guyanais (CSG) in December 2021. JWST’s requirements permitted processing in International Organization for Standardization (ISO) Class 7 or better facilities, but CSG was only equipped with ISO Class 8 facilities. To temporarily upgrade the air cleanliness in the Payload Processing Facility, Fueling Hall, and Final Assembly Building Encapsulation Hall, NASA provided two portable High Efficiency Particulate Air (HEPA) and carbon filter walls that were used in each location. The walls were comprised of stacks of two modules high and arranged in push-push configurations as shown to be most effective via Computational Fluid Dynamics simulations of expected floor layouts in each facility. After delivery to NASA’s Goddard Space Flight Center in 2020, the walls underwent initial verification measurements inside a cleanroom and validation testing in an uncontrolled area to quantify their improvement of air cleanliness and particle and molecular fallout. Validation testing showed improvements of 83-99% for airborne particle counts, 79-91% for particle fallout, and 50-90% for molecular fallout. The particle improvements were applied to the contamination budget analysis that tracked current and predicted future cleanliness against End-of-Life requirements for JWST’s critical surfaces. At CSG, the walls successfully maintained an ISO Class 7 environment or better within their envelope in each location, despite their presence in ISO Class 8 facilities with dense integration operations.

HEPA, Contamination Control, Filtration↗

Evaluating the Performance of Portable Air Filter Walls for the James Webb Space Telescope Launch Campaign

The James Webb Space Telescope (JWST) launched from the Centre Spatial Guyanais (CSG) in December 2021. JWST’s requirements permitted processing in International Organization for Standardization (ISO) Class 7 or better facilities, but CSG was only equipped with ISO Class 8 facilities. To temporarily upgrade the air cleanliness in the Payload Processing Facility, Fueling Hall, and Final Assembly Building Encapsulation Hall, NASA provided two portable High Efficiency Particulate Air (HEPA) and carbon filter walls that were used in each location. The walls were comprised of stacks of two modules high and arranged in push-push configurations as shown to be most effective via Computational Fluid Dynamics simulations of expected floor layouts in each facility. After delivery to NASA’s Goddard Space Flight Center in 2020, the walls underwent initial verification measurements inside a cleanroom and validation testing in an uncontrolled area to quantify their improvement of air cleanliness and particle and molecular fallout. Validation testing showed improvements of 83-99% for airborne particle counts, 79-91% for particle fallout, and 50-90% for molecular fallout. The particle improvements were applied to the contamination budget analysis that tracked current and predicted future cleanliness against End-of-Life requirements for JWST’s critical surfaces. At CSG, the walls successfully maintained an ISO Class 7 environment or better within their envelope in each location, despite their presence in ISO Class 8 facilities with dense integration operations.

HEPA, Contamination Control, Filtration↗

1999 NSREC Short Course: Proton Effects and Test Issues for Satellite Designers: Displacement Effects

This portion of the Short Course is divided into two segments to separately address the two major proton-related effects confronting satellite designers: ionization effects and displacement damage effects. While both of these topics are deeply rooted in "traditional" descriptions of space radiation effects, there are several factors at play to cause renewed concern for satellite systems being designed today. For example, emphasis on Commercial Off-The-Shelf (COTS) technologies in both commercial and government systems increases both Total Ionizing Dose (TID) and Single Event Effect (SEE) concerns. Scaling trends exacerbate the problems, especially with regard to SEEs where protons can dominate soft error rates and even cause destructive failure. In addition, proton-induced displacement damage at fluences encountered in natural space environments can cause degradation in modern bipolar circuitry as well as in many emerging electronic and opto-electronic technologies.

Marshall, Cheryl J.↗

Endurance cycling results in extreme environments

A new test bed for life testing flash memories in extreme environments is introducted. the test bed is based on a state-of-the-art development board. Since space applications often desire state-of-the-art devices, such a basis seems appropriate. Comparison of this tester to other such systems, including those with data presented here in the past is made. Limitations of different testers for varying applications are discussed. Recently developed data, using this test bed is also presented.

microelectronics↗

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↗

Containerless processing of undercooled melts

Containerless drop tube processing allows for significant levels of liquid undercooling through control of parameters such as sample size, surface coating and cooling rate. A laboratory scale (3 m) drop tube has been developed which allows the undercooling and solidification behavior of powder samples to be evaluated under low gravity free-fall conditions. The level of undercooling obtained in an InSb-Sb eutectic alloy has been evaluated by comparing the eutectic spacing in drop tube samples with a spacing/undercooling relationship established using thermal analysis techniques. Undercoolings of 0.17 and 0.23 T(e) were produced by processing under vacuum and He gas conditions respectively. Alternatively, the formation of an amorphous phase in a Ni-Nb eutectic alloy indicates that undercooling levels of approximately 500 C were obtained by drop tube processing. The influence of droplet size and gas environment on undercooling behavior in the Ni-Nb eutectic was evaluated through their effect on the amorphous/crystalline phase ratio. To supplement the structural analysis, heat flow modeling has been developed to describe the undercooling history during drop tube processing, and the model has been tested experimentally.

Shong, D. S.↗

Testing for Random Limit Load Versus Static Limit Load

This document is an effort to report the basic test findings in an ongoing quest for understanding how random load factors should be applied to structural components in order to verify the strength of space flight hardware. A Spacelab experiment known as the Atmospheric Emission Photometric Imager (AEPI) was subjected to both an expected flight random environment and the associated Miles' equation equivalent static load. During each of these tests, the fiberglass pedestal was instrumented with 16 triaxial strain gauges around its base. Component strains and invariant stresses were compared. As seen previously in other hardware tests, the stress distribution from the random environment was an order of magnitude below the comparable static stresses. With a proposed data acquisition system, a strain database will be developed that will quantify an empirical relationship between dynamic and static limit stresses. This event will allow a more accurate estimate of launch environment effects on new technology structural components.

Lee, H. M.↗

STOP Modeling for the JWST: Techniques, Results, and Sensitivities

The James Web Space Telescope (JWST) is a large, infrared-optimized, space telescope scheduled for launch to L2 in 2011. It must meet rigorous thermal stability requirements, almost all of which will be verified through analysis. Terrestrial testing will be performed but even that will require significant analytical interpretation of results. Preliminary analysis indicates that traditional second-order effects could cause the telescope to exceed established performance requirements. This leads to very large detailed models, primarily since composite tubes are being modeled using solid elements. To minimize differences between the current baseline and the model the project is using a number of rapid analysis cycles. The large size of the telescope models and the short cycle time creates a demanding multidisciplinary analysis environment.

John D. Johnston↗

Radiation Tests of Highly Scaled, High-Density, Commercial, Nonvolatile NAND Flash Memories - Update 2012

The space radiation environment poses a certain risk to all electronic components on Earth-orbiting and planetary mission spacecraft. In recent years, there has been increased interest in the use of high-density, commercial, nonvolatile flash memories in space because of ever-increasing data volumes and strict power requirements. They are used in a wide variety of spacecraft subsystems. At one end of the spectrum, flash memories are used to store small amounts of mission-critical data such as boot code or configuration files and, at the other end, they are used to construct multi-gigabyte data recorders that record mission science data. This report examines single-event effect (SEE) and total ionizing dose (TID) response in single-level cell (SLC) 32-Gb, multi-level cell (MLC) 64-Gb, and Triple-level (TLC) 64-Gb NAND flash memories manufactured by Micron Technology with feature size of 25 nm.

Irom, Farokh↗

Natural Frequency Testing and Model Correlation of Rocket Engine Structures in Liquid Hydrogen - Phase I, Cantilever Beam

Many structures in the launch vehicle industry operate in liquid hydrogen (LH2), from the hydrogen fuel tanks through the ducts and valves and into the pump sides of the turbopumps. Calculating the structural dynamic response of these structures is critical for successful qualification of this hardware, but accurate knowledge of the natural frequencies is based entirely on numerical or analytical predictions of frequency reduction due to the added-fluid-mass effect because testing in LH2 has always been considered too difficult and dangerous. This fluid effect is predicted to be approximately 4-5% using analytical formulations for simple cantilever beams. As part of a comprehensive test/analysis program to more accurately assess pump inducers operating in LH2, a series of frequency tests in LH2 were performed at NASA/Marshall Space Flight Center's unique cryogenic test facility. These frequency tests are coupled with modal tests in air and water to provide critical information not only on the mass effect of LH2, but also the cryogenic temperature effect on Young's Modulus for which the data is not extensive. The authors are unaware of any other reported natural frequency testing in this media. In addition to the inducer, a simple cantilever beam was also tested in the tank to provide a more easily modeled geometry as well as one that has an analytical solution for the mass effect. This data will prove critical for accurate structural dynamic analysis of these structures, which operate in a highly-dynamic environment.

Brown, Andrew M.↗

Continued Development of a Highly Reflective Solar Coating for Cryogenic Liquid Storage in Space

State-of-the-art solar reflectors absorb 6-8 % of the sun's irradiant power, which is adequate for spacecraft thermal control; but not for storage of cryogens in tanks exposed to the Sun. A solar reflector must absorb less than 0.4% of the Sun's power, while radiating effectively in the far IR, to allow LOX storage. Hibbard realized this in 1960's, at about the same time that nearly perfect optical reflectors were developed based on particle scattering. In 2015, under funding from the NASA Innovative Advanced Concepts Program (NIAC), these breakthroughs were rediscovered. Theoretical analysis showed that a tank coated with a thick (1 cm) layer of 150 nm particles, composed of a broadband material, could allow the tank to chill to cryogenic temperatures, even in the presence of 1 AU solar irradiance. Subsequent work lead to the demonstration and testing of BaF2 based rigid coupons. Placing one of these in a cryocooler-based simulated deep space environment and irradiating with simulated sunlight has shown about 1% absorption. This is better than the state-of-the-art but not yet sufficient for LOX storage.This paper will review the background material presented above but will concentrate on work performed over the last year, including the design and build-up of the testing apparatus. Since our last publication, we have changed materials from BaF2 to Y2O3. Y2O3 has slightly higher solar absorptance, but is hydrophobic and higher index.

Swanger, Adam↗

Radiation tests of highly scaled, high-density, commercial, nonvolatile NAND flash memories— update 2012

The space radiation environment poses a certain risk to all electronic components on Earth-orbiting and planetary mission spacecraft. In recent years, there has been increased interest in the use of high-density, commercial, nonvolatile flash memories in space because of ever-increasing data volumes and strict power requirements. They are used in a wide variety of spacecraft subsystems. At one end of the spectrum, flash memories are used to store small amounts of mission-critical data such as boot code or configuration files and, at the other end, they are used to construct multi-gigabyte data recorders that record mission science data. This report examines single-event effect (SEE) and total ionizing dose (TID) response in single-level cell (SLC) 32-Gb, multi-level cell (MLC) 64-Gb, and Triple-level (TLC) 64-Gb NAND flash memories manufactured by Micron Technology with feature size of 25 nm.

Allen, Gregory R.↗

Proton Effects and Test Issues for Satellite Designers: Ionization Effects - Section 4

This portion of the Short Course is divided into two segments to separately address the two major proton-related effects confronting satellite designers: ionization effects and displacement damage effects. While both of these topics are deeply rooted in "traditional" descriptions of space radiation effects, there are several factors at play to cause renewed concern for satellite systems being designed today. For example, emphasis on Commercial Off-The-Shelf (COTS) technologies in both commercial and government systems increases both Total Ionizing Dose (TID) and Single Event Effect (SEE) concerns. Scaling trends exacerbate the problems, especially with regard to SEEs where protons can dominate soft error rates and even cause destructive failure. In addition, proton-induced displacement damage at fluences encountered in natural space environments can cause degradation in modern bipolar circuitry as well as in many emerging electronic and opto-electronic technologies. A crude, but nevertheless telling, indication of the level of concern for proton effects follows from surveying the themes treated in papers presented at this conference. The table lists themes found in the IEEE Transaction on Nuclear Science (TNS) December issue from the past year and compares them with the December issue's content a decade earlier. Ten years ago there were nine papers, or about 10% of the total, dealing with the four indicated topics. At that time, single event effects from protons were the primary concern, and these were thought to be possible only when a nuclear reaction initiated energetic recoil atoms. This is shown in the table as the 'traditional" SEE subject. A decade later, submissions addressing this topic had doubled, while papers devoted to displacement damage studies had increased from one to nine! More importantly, displacement damage effects in the natural space environments have become a concern for degradation in modern devices (other than solar cells), and this was not so ten years earlier.

Marshall, Paul W.↗

Annual Conference on Nuclear and Space Radiation Effects, 18th, University of Washington, Seattle, WA, July 21-24, 1981, Proceedings

Single event upset phenomena are discussed, taking into account cosmic ray induced errors in IIL microprocessors and logic devices, single event upsets in NMOS microprocessors, a prediction model for bipolar RAMs in a high energy ion/proton environment, the search for neutron-induced hard errors in VLSI structures, soft errors due to protons in the radiation belt, and the use of an ion microbeam to study single event upsets in microcircuits. Basic mechanisms in materials and devices are examined, giving attention to gamma induced noise in CCD's, the annealing of MOS capacitors, an analysis of photobleaching techniques for the radiation hardening of fiber optic data links, a hardened field insulator, the simulation of radiation damage in solids, and the manufacturing of radiation resistant optical fibers. Energy deposition and dosimetry is considered along with SGEMP/IEMP, radiation effects in devices, space radiation effects and spacecraft charging, EMP/SREMP, and aspects of fabrication, testing, and hardness assurance.

Tasca, D. M.↗

Containment of a silicone fluid free surface in reduced gravity using barrier coatings

In support of the Surface Tension Driven Convection Experiment planned for flight aboard the Space Shuttle, tests were conducted under reduced gravity in the 2.2-sec Drop Tower and the 5.0-sec Zero-G facility at the NASA Lewis Research Center. The dynamics of controlling the test fluid, a 10-cSt viscosity silicone fluid in a low gravity environment were investigated using different container designs and barrier coatings. Three container edge designs were tested without a barrier coating; a square edge, a sharp edge with a 45-deg slope, and a sawtooth edge. All three edge designs were successful in containing the fluid below the edge. G-jitter experiments were made in scaled down containers subjected to horizontal accelerations. The data showed that a barrier coating is effective in containing silicone fluid under g-levels up to 10 sup -1 sub g sub 0. In addition, a second barrier coating was found which has similar anti-wetting characteristics and is also more durable.

Pline, Alexander D.↗

An Earth-Based Equivalent Low Stretch Apparatus to Assess Material Flammability for Microgravity & Extraterrestrial Fire-Safety Applications

One of the performance goals for NASA's enterprise of Human Exploration and Development of Space (HEDS) is to develop methods, data bases, and validating tests for material flammability characterization, hazard reduction, and fire detection/suppression strategies for spacecraft and extraterrestrial habitats. This work addresses these needs by applying the fundamental knowledge gained from low stretch experiments to the development of a normal gravity low stretch material flammability test method. The concept of the apparatus being developed uses the low stretch geometry to simulate the conditions of the extraterrestrial environment through proper scaling of the sample dimensions to reduce the buoyant stretch in normal gravity. The apparatus uses controlled forced-air flow to augment the low stretch to levels which simulate Lunar or Martian gravity levels. In addition, the effect of imposed radiant heat flux on material flammability can be studied with the cone heater. After breadboard testing, the apparatus will be integrated into NASA's White Sands Test Facility's Atmosphere-Controlled Cone Calorimeter for evaluation as a new materials screening test method.

Olson, S. L.↗

Experimental Methods in Reduced-gravity Soldering Research

The National Center for Microgravity Research, NASA Glenn Research Center, and NASA Johnson Space Center are conducting an experimental program to explore the influence of reduced gravity environments on the soldering process. An improved understanding of the effects of the acceleration environment is important to application of soldering during current and future human space missions. Solder joint characteristics that are being considered include solder fillet geometry, porosity, and microstructural features. Both through-hole and surface mounted devices are being investigated. This paper focuses on the experimental methodology employed in this project and the results of macroscopic sample examination. The specific soldering process, sample configurations, materials, and equipment were selected to be consistent with those currently on-orbit. Other apparatus was incorporated to meet requirements imposed by operation onboard NASA's KC-135 research aircraft and instrumentation was provided to monitor both the atmospheric and acceleration environments. The contingent of test operators was selected to include both highly skilled technicians and less skilled individuals to provide a population cross-section that would be representative of the skill mix that might be encountered in space mission crews.

Pettegrew, Richard D.↗