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NASA NTRS2003

Wafer-Level Membrane-Transfer Process for Fabricating MEMS

A process for transferring an entire wafer-level micromachined silicon structure for mating with and bonding to another such structure has been devised. This process is intended especially for use in wafer-level integration of microelectromechanical systems (MEMS) that have been fabricated on dissimilar substrates. Unlike in some older membrane-transfer processes, there is no use of wax or epoxy during transfer. In this process, the substrate of a wafer-level structure to be transferred serves as a carrier, and is etched away once the transfer has been completed. Another important feature of this process is that two electrodes constitutes an electrostatic actuator array. An SOI wafer and a silicon wafer (see Figure 1) are used as the carrier and electrode wafers, respectively. After oxidation, both wafers are patterned and etched to define a corrugation profile and electrode array, respectively. The polysilicon layer is deposited on the SOI wafer. The carrier wafer is bonded to the electrode wafer by using evaporated indium bumps. The piston pressure of 4 kPa is applied at 156 C in a vacuum chamber to provide hermetic sealing. The substrate of the SOI wafer is etched in a 25 weight percent TMAH bath at 80 C. The exposed buried oxide is then removed by using 49 percent HF droplets after an oxygen plasma ashing. The SOI top silicon layer is etched away by using an SF6 plasma to define the corrugation profile, followed by the HF droplet etching of the remaining oxide. The SF6 plasma with a shadow mask selectively etches the polysilicon membrane, if the transferred membrane structure needs to be patterned. Electrostatic actuators with various electrode gaps have been fabricated by this transfer technique. The gap between the transferred membrane and electrode substrate is very uniform ( 0.1 m across a wafer diameter of 100 mm, provided by optimizing the bonding control). Figure 2 depicts the finished product.

Yang, Eui-Hyeok↗

NASA NTRS2016

First-Principles Modeling Of Electromagnetic Scattering By Discrete and Discretely Heterogeneous Random Media

A discrete random medium is an object in the form of a finite volume of a vacuum or a homogeneous material medium filled with quasi-randomly and quasi-uniformly distributed discrete macroscopic impurities called small particles. Such objects are ubiquitous in natural and artificial environments. They are often characterized by analyzing theoretically the results of laboratory, in situ, or remote-sensing measurements of the scattering of light and other electromagnetic radiation. Electromagnetic scattering and absorption by particles can also affect the energy budget of a discrete random medium and hence various ambient physical and chemical processes. In either case electromagnetic scattering must be modeled in terms of appropriate optical observables, i.e., quadratic or bilinear forms in the field that quantify the reading of a relevant optical instrument or the electromagnetic energy budget. It is generally believed that time-harmonic Maxwell's equations can accurately describe elastic electromagnetic scattering by macroscopic particulate media that change in time much more slowly than the incident electromagnetic field. However, direct solutions of these equations for discrete random media had been impracticable until quite recently. This has led to a widespread use of various phenomenological approaches in situations when their very applicability can be questioned. Recently, however, a new branch of physical optics has emerged wherein electromagnetic scattering by discrete and discretely heterogeneous random media is modeled directly by using analytical or numerically exact computer solutions of the Maxwell equations. Therefore, the main objective of this Report is to formulate the general theoretical framework of electromagnetic scattering by discrete random media rooted in the Maxwell- Lorentz electromagnetics and discuss its immediate analytical and numerical consequences. Starting from the microscopic Maxwell-Lorentz equations, we trace the development of the first principles formalism enabling accurate calculations of monochromatic and quasi-monochromatic scattering by static and randomly varying multiparticle groups. We illustrate how this general framework can be coupled with state-of-the-art computer solvers of the Maxwell equations and applied to direct modeling of electromagnetic scattering by representative random multi-particle groups with arbitrary packing densities. This first-principles modeling yields general physical insights unavailable with phenomenological approaches. We discuss how the first-order-scattering approximation, the radiative transfer theory, and the theory of weak localization of electromagnetic waves can be derived as immediate corollaries of the Maxwell equations for very specific and well-defined kinds of particulate medium. These recent developments confirm the mesoscopic origin of the radiative transfer, weak localization, and effective-medium regimes and help evaluate the numerical accuracy of widely used approximate modeling methodologies.

Michael I Mishchenko↗

NASA NTRSDate not supplied

Carbon Tracers of Aqueous Processes: Isotopic Analysis of Cr Carbonate Grains With Implications for Bennu Samples

Carbonate grains in carbonaceous chondrites record aqueous alteration events on the asteroidal parent bodies, including evidence for episodic alteration, timing of alteration, and time and temperature evolution of volatiles. Spectral features in the 3.4 μm region at asteroid Bennu have been interpreted as coming from carbonate minerals. Coordinated analysis of carbonate grains will be a valuable tool for analysis of Bennu samples, and related analysis of analog materials provides important context for understanding aqueous alteration of carbonaceous asteroids more broadly. To that end, our team is analyzing carbonates in Bennu analog materials, using Raman spectroscopy to identify carbonates and assess the maturity of related organic materials, vacuum reflectance spectroscopy from the ultraviolet through thermal infrared range to constrain contributions from carbonates and organics, X-ray microtomography and electron probe microanalysis (EPMA) to assess the distribution of void space, transmission electron microscopy to characterize space weathering effects, and EPMA and secondary ion mass spectrometry (SIMS) to measure composition and isotopic ratios. Here, we describe in situ analysis of carbon and oxygen isotopes from carbonates in Grosvenor Mountains (GRO) 95577.

K E Miller↗

NASA NTRS1974

Weld-brazing of titanium

A joining process, designated weld-brazing, which combines resistance spotwelding and brazing has been developed at the NASA Langley Research Center. Resistance spot-welding is employed to position and align the parts and to establish a suitable faying surface gap for brazing; it contributes to the integrity of the joint. Brazing enhances the properties of the joint and reduces the stress concentrations normally associated with spotwelds. Ti-6Al-4V titanium alloy joints have been fabricated using 3003 aluminum braze both in a vacuum furnace and in a retort containing an inert gas environment.

Bales, T. T.↗

NASA NTRS1987

A theoretical evaluation of laser-sustained plasma thruster performance

An extensive numerical experiment has been conducted to evaluate rocket thruster performance using a laser-sustained hydrogen plasma as the propellant. The plasma was sustained using a 30 kW CO2 laser beam operated at 10.6 microns focused inside the thruster. The steady-state Navier-Stokes equations coupled with the laser power absorption process have been solved numerically. A pressure based Navier-Stokes solver using body-fitted coordinate was used to calculate the laser-supported rocket flow which included both recirculating and transonic flow regions. The local thermodynamic equilibrium (LTE) assumption was used for the plasma thermophysical and optical properties. Geometric ray tracing was adopted to describe the laser beam. Several different throat size thrusters operated at 150 and 300 kPa chamber stagnation pressure were studied. It was found that the thruster performance (vacuum specific impulse) was highly dependent on the operating conditions, and a properly designed laser supported thruster can attain a specific impulse around 1500 secs. The heat loading on the thruster wall was also estimated and was in the range of that for a conventional chemical rocket.

Jeng, San-Mou↗

NASA NTRS1991

Review and test of chilldown methods for space-based cryogenic tanks

The literature for tank chilldown methods applicable to cryogenic tankage in the zero gravity environment of earth orbit is reviewed. One method is selected for demonstration in a ground based test. The method selected for investigation was the charge-hold-vent method which uses repeated injection of liquid slugs, followed by a hold to allow complete vaporization of the liquid and a vent of the tank to space vacuum to cool tankage to the desired temperature. The test was conducted on a 175 cubic foot, 2219 aluminum walled tank weighing 329 pounds, which was previously outfitted with spray systems to test nonvented fill technologies. To minimize hardware changes, a simple control-by-pressure scheme was implemented to control injected liquid quantities. The tank cooled from 440 R sufficiently in six charge-hold-vent cycles to allow a complete nonvented fill of the test tank. Liquid hydrogen consumed in the process is estimated at 32 pounds.

Chato, David J.↗

NASA NTRS1991

Review and test of chilldown methods for space-based cryogenic tanks

Chato, David J.↗

NASA NTRS1991

Optical glow spectra arising from low-energy N2, N2(+) and electron bombardment of MgF2 surfaces

Photon emission spectra resulting from the impact of N2, N2(+), and electron beams on magnesium fluoride in an ultrahigh vacuum environment were measured and compared for beam energies in the range 200-2000 eV. Unexpectedly, only the ion- and electron-induced spectra exhibited broad fluorescence. The observed data suggest that the broad fluorescence arising from low-energy ion bombardment is due primarily to the transfer of electronic energy to the surface by resonance or Auger neutralization. Since molecular nitrogen is a major constituent of the atmosphere at orbital altitudes, these measurements bear directly on radiation-induced glow and erosion processes on surfaces of spacecraft in low-earth orbit.

Qi, J.↗

NASA NTRS2005

Vacuum Attachment for XRF Scanner

Vacuum apparatuses have been developed for increasing the range of elements that can be identified by use of x-ray fluorescent (XRF) scanners of the type mentioned in the two immediately preceding articles. As a consequence of the underlying physical principles, in the presence of air, such an XRF scanner is limited to analysis of chlorine and elements of greater atomic number. When the XRF scanner is operated in a vacuum, it extends the range of analysis to lower atomic numbers - even as far as aluminum and sodium. Hence, more elements will be available for use in XRF labeling of objects as discussed in the two preceding articles. The added benefits of the extended capabilities also have other uses for NASA. Detection of elements of low atomic number is of high interest to the aerospace community. High-strength aluminum alloys will be easily analyzed for composition. Silicon, a major contaminant in certain processes, will be detectable before the process is begun, possibly eliminating weld or adhesion problems. Exotic alloys will be evaluated for composition prior to being placed in service where lives depend on them. And in the less glamorous applications, such as bolts and fasteners, substandard products and counterfeit items will be evaluated at the receiving function and never allowed to enter the operation

Schramm, Harry F.↗

NASA NTRS2016

Engineering Polymer Blends for Impact Damage Mitigation

Structures containing polymers such as DuPont's Surlyn® 8940, demonstrate puncture healing when impacted by a 9 millimeter projectile traveling from speeds near 300 meters per second (1,100 feet per second) to hypervelocity impacts in the micrometeoroid velocity range of 5 kilometers per second (16,000 feet per second). Surlyn® 8940 puncture heals over a temperature range of minus 30 degrees Centigrade to plus 70 degrees Centigrade and shows potential for use in pressurized vessels subject to impact damage. However, such polymers are difficult to process and limited in applicability due to their low thermal stability, poor chemical resistance and overall poor mechanical properties. In this work, several puncture healing engineered melt formulations were developed. Moldings of melt blend formulations were impacted with a 5.56 millimeter projectile with a nominal velocity of 945 meters per second (3,100 feet per second) at about 25 degrees Centigrade, 50 degrees Centigrade and 100 degrees Centigrade, depending upon the specific blend being investigated. Self-healing tendencies were determined using surface vacuum pressure tests and tensile tests after penetration using tensile dog-bone specimens (ASTM D 638-10). For the characterization of tensile properties both pristine and impacted specimens were tested to obtain tensile modulus, yield stress and tensile strength, where possible. Experimental results demonstrate a range of new puncture healing blends which mitigate damage in the ballistic velocity regime.

Gordon, Keith L.↗

NASA NTRSDate not supplied

Designing the PLANET Chamber for Lunar Environment Ground Testing

The Planetary, Lunar, and Asteroid Natural Environments Testbed (PLANET) is a new 2m x 3m high-vacuum chamber facility currently being designed and built at NASA’s Marshall Space Flight Center. When completed, it will be one of the highest-fidelity space/surface environment simulation chambers in existence. Instrumented with equipment to produce charged particle radiation, full spectrum ultraviolet, low-density plasma, and thermal extremes, PLANET can be configured to recreate the most challenging space environments. Additionally, a large regolith bed and distribution system will expose hardware to lunar regolith simulants and dust. This paper will describe the process of designing and optimizing PLANET and discuss some common considerations for performing ground-based environmental testing for lunar exploration.

Erin G Hayward↗

NASA NTRS1990

Experiments for electromagnetic levitation in microgravity

Containerless processing is a promising research tool for investigating the properties of undercooled melts and their solidification. For conducting samples RF-electromagnetic levitation offers the possibility to obtain large undercoolings by avoiding heterogeneous nucleation at container walls. On earth, however, strong magnetic fields are needed to compensate the gravitational force which imposes a lower limit on the available temperatures and on the accessible undercooling range. Under microgravity conditions the magnetic positioning fields can be minimized and hence, undercooling becomes feasible under ultra-high vacuum conditions and lower temperatures become accessible. In contrast to other undercooling and solidification techniques, electromagnetic levitation allows for diagnostic measurements during the early steps of nucleation and phase selection. Experiments cover a wide field of research topics: nucleation, directional solidification at high velocities, generation of metastable phases, evolution of microstructures, properties of undercooled liquids. Examples from these classes including experiments selected for the IML-2 mission are discussed with emphasis on technical requirements. An overview is given on the German TEMPUS (electromagnetic levitation facility) program.

Willnecker, R.↗

NASA NTRS2001

Production of Bulk and Fiber Glass in Space

The production of bulk glass and fiber glass in space and on the moon and Mars should lead to superior products. Specifically glass plates for windows and optical elements could be produced with theoretical strengths by production in vacuum. Water vapor is known to decrease glass strength by up to two orders of magnitude from theoretical. A low gravity glass plate apparatus prototype has been designed and built which uses centrifugal force to shape the glass and solar energy to melt the glass. Glass fiber could be produced on the moon or Mars from in-situ materials using standard technologies. This material could then be used as reinforcement in composite materials in construction of bases. Also, it has been shown that processing in reduced gravity suppresses crystallization in certain heavy metal fluoride glasses. It is proposed to reprocess optical fiber preforms on the space station and then pull these into optical fiber. It is estimated that the attenuation coefficient should be reduced by two orders of magnitude.

Tucker, Dennis S.↗

NASA NTRS2013

Investigation of VEGGIE Root Mat

VEGGIE is a plant growth facility that utilizes the phenomenon of capillary action as its primary watering system. A cloth made of Meta Aramid fiber, known as Nomex is used to wick water up from a reservoir to the bottom of the plants roots. This root mat system is intended to be low maintenance with no moving parts and requires minimal crew interface time. Unfortunately, the water wicking rates are inconsistent throughout the plant life cycle, thus causing plants to die. Over-wicking of water occurs toward the beginning of the cycle, while under-wicking occurs toward the middle. This inconsistency of wicking has become a major issue, drastically inhibiting plant growth. The primary objective is to determine the root cause of the inconsistent wicking through experimental testing. Suspect causes for the capillary water column to break include: a vacuum effect due to a negative pressure gradient in the water reservoir, contamination of material due to minerals in water and back wash from plant fertilizer, induced air bubbles while using syringe refill method, and material limitations of Nomex's ability to absorb and retain water. Experimental testing will be conducted to systematically determine the cause of under and over-wicking. Pressure gages will be used to determine pressure drop during the course of the plant life cycle and during the water refill process. A debubbler device will be connected to a root mat in order to equalize pressure inside the reservoir. Moisture and evaporation tests will simultaneously be implemented to observe moisture content and wicking rates over the course of a plant cycle. Water retention tests will be performed using strips of Nomex to determine materials wicking rates, porosity, and absorptivity. Through these experimental tests, we will have a better understanding of material properties of Nomex, as well as determine the root cause of water column breakage. With consistent test results, a forward plan can be achieved to resolve the issue and give valuable insight for the next generation of VEGGIE.

Subbiah, Arun M.↗

NASA NTRS1998

Contactless Growth of ZnSe Single Crystals by Physical Vapor Transport

ZnSe crystals were grown by self-seeded physical vapor transport (PVT) technique in the horizontal configuration. The source materials were heat treated by H2 reduction to remove the oxide followed by baking under dynamic vacuum to adjust the source composition toward that of congruent sublimation. Contactless growth of ZnSe single crystals have been performed consistently using three different source materials. The crystals grew away from the wall during the later stage of the growth with large (110) facets tend to align parallel to the gravity direction. The Scanning Electron Micrography (SEM) micrographs and the Atomic Force Microscope (AFM) images showed that large (110) terraces and steps dominate the as-grown facets. The measured residual gas pressures in the processed ampoules agree well among various source materials and the major components were CO and H2. No preferred growth direction was found. The one-dimensional diffusion model on the mass flux of a multi-species PVT system was employed to analyze the conditions for contactless growth. The calculated thermal profile for supersaturation is very close to the thermal profile measured inside the empty furnace bore in the region of contactless growth. The effects of convective flows in the vapor phase inside the ampoule on the growth processes are discussed.

Su, Ching-Hua↗

NASA NTRS2008

Contamination Sources Effects Analysis (CSEA) - A Tool to Balance Cost/Schedule While Managing Facility Availability

A CSEA is similar to a Failure Modes Effects Analysis (FMEA). A CSEA tracks risk, deterrence, and occurrence of sources of contamination and their mitigation plans. Documentation is provided spanning mechanical and electrical assembly, precision cleaning, thermal vacuum bake-out, and thermal vacuum testing. These facilities all may play a role in contamination budgeting and reduction ultimately affecting test and flight. With a CSEA, visibility can be given to availability of these facilities, test sequencing and trade-offs. A cross-functional team including specialty engineering, contamination control, electrostatic dissipation, manufacturing, testing, and material engineering participate in an exercise that identifies contaminants and minimizes the complexity of scheduling these facilities considering their volatile schedules. Care can be taken in an efficient manner to insure correct cleaning processes are employed. The result is reduction in cycle time ("schedule hits"), reduced cost due to rework, reduced risk and improved communication and quality while achieving adherence to the Contamination Control Plan.

Wilcox, Margaret↗

NASA NTRS2011

Spray-On Foam Insulations for Launch Vehicle Cryogenic Tanks

Spray-on foam insulation (SOFI) has been developed for use on the cryogenic tanks of space launch vehicles beginning in the 1960s with the Apollo program. The use of SOFI was further developed for the Space Shuttle program. The External Tank (ET) of the Space Shuttle, consisting of a forward liquid oxygen tank in line with an aft liquid hydrogen tank, requires thermal insulation over its outer surface to prevent ice formation and avoid in-flight damage to the ceramic tile thermal protection system on the adjacent Orbiter. The insulation also provides system control and stability with throughout the lengthy process of cooldown, loading, and replenishing the tank. There are two main types of SOFI used on the ET: acreage (with the rind) and closeout (machined surface). The thermal performance of the seemingly simple SOFI system is a complex of many variables starting with the large temperature difference of from 200 to 260 K through the typical 25-mm thickness. Environmental factors include air temperature and humidity, wind speed, solar exposure, and aging or weathering history. Additional factors include manufacturing details, launch processing operations, and number of cryogenic thermal cycles. The study of the cryogenic thermal performance of SOFI under large temperature differentials is the subject of this article. The amount of moisture taken into the foam during the cold soak phase, termed Cryogenic Moisture Uptake, must also be considered. The heat leakage rates through these foams were measured under representative conditions using laboratory standard liquid nitrogen boiloff apparatus. Test articles included baseline, aged, and weathered specimens. Testing was performed over the entire pressure range from high vacuum to ambient pressure. Values for apparent thermal conductivity and heat flux were calculated and compared with prior data. As the prior data of record was obtained for small temperature differentials on non-weathered foams, analysis of the different methods is provided. Recent advancements and applications of SOFI systems on future launch vehicles and spacecraft are also addressed.

Fesmire, J. E.↗

NASA NTRS2013

Polymer-Reinforced, Non-Brittle, Lightweight Cryogenic Insulation

The primary application for cryogenic insulating foams will be fuel tank applications for fueling systems. It is crucial for this insulation to be incorporated into systems that survive vacuum and terrestrial environments. It is hypothesized that by forming an open-cell silica-reinforced polymer structure, the foam structures will exhibit the necessary strength to maintain shape. This will, in turn, maintain the insulating capabilities of the foam insulation. Besides mechanical stability in the form of crush resistance, it is important for these insulating materials to exhibit water penetration resistance. Hydrocarbon-terminated foam surfaces were implemented to impart hydrophobic functionality that apparently limits moisture penetration through the foam. During the freezing process, water accumulates on the surfaces of the foams. However, when hydrocarbon-terminated surfaces are present, water apparently beads and forms crystals, leading to less apparent accumulation. The object of this work is to develop inexpensive structural cryogenic insulation foam that has increased impact resistance for launch and ground-based cryogenic systems. Two parallel approaches will be pursued: a silica-polymer co-foaming technique and a post foam coating technique. Insulation characteristics, flexibility, and water uptake can be fine-tuned through the manipulation of the polyurethane foam scaffold. Silicate coatings for polyurethane foams and aerogel-impregnated polyurethane foams have been developed and tested. A highly porous aerogel-like material may be fabricated using a co-foam and coated foam techniques, and can insulate at liquid temperatures using the composite foam

Hess, David M.↗