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NASA NTRS2009

Effects of Hypervelocity Impacts on Silicone Elastomer Seals and Mating Aluminum Surfaces

While in space silicone based elastomer seals planned for use on NASA's Crew Exploration Vehicle (CEV) are exposed to threats from micrometeoroids and orbital debris (MMOD). An understanding of these threats is required to assess risks to the crew, the CEV orbiter, and missions. An Earth based campaign of hypervelocity impacts on small scale seal rings has been done to help estimate MMOD threats to the primary docking seal being developed for the Low Impact Docking System (LIDS). LIDS is being developed to enable the CEV to dock to the ISS (International Space Station) or to Altair (NASA's next lunar lander). The silicone seal on LIDS seals against aluminum alloy flanges on ISS or Altair. Since the integrity of a seal depends on both sealing surfaces, aluminum targets were also impacted. The variables considered in this study included projectile mass, density, speed, incidence angle, seal materials, and target surface treatments and coatings. Most of the impacts used a velocity near 8 km/s and spherical aluminum projectiles (density = 2.7 g/cubic centimeter), however, a few tests were done near 5.6 km/s. Tests were also performed using projectile densities of 7.7, 2.79, 2.5 or 1.14 g/cubic centimeter. Projectile incidence angles examined included 0 degrees, 45 degrees , and 60 degrees from normal to the plane of the target. Elastomer compounds impacted include Parker's S0383-70 and Esterline's ELA-SA-401 in the as received condition, or after an atomic oxygen treatment. Bare, anodized and nickel coated aluminum targets were tested simulating the candidate mating seal surface materials. After impact, seals and aluminum plates were leak tested: damaged seals were tested against an undamaged aluminum plate; and undamaged seals were placed at various locations over craters in aluminum plates. It has been shown that silicone elastomer seals can withstand an impressive level of damage before leaking beyond allowable limits. In general on the tests performed to date, the diameter of the crater in either the elastomer, or the aluminum, must be at least as big as 80% to 90% of width of the bulb of the seal before significant leakage occurs.

deGroh, Henry C., III↗
NASA NTRS2009

Projectile Density Effects on Shield Performance

In the past, the orbital debris environment was modeled as consisting entirely of aluminum particles. As a consequence, most of the impact test database on spacecraft micro-meteoroid and orbital debris (MMOD) shields, and the resulting ballistic limit equations used to predict shielding performance, has been based on using aluminum projectiles. Recently, data has been collected from returned spacecraft materials and other sources that indicate higher and lower density components of orbital debris also exist. New orbital debris environment models such as ORDEM2008 provide predictions of the fraction of orbital debris in various density bins (high = 7.9 g/cu cm, medium = 2.8 g/cu cm, and low = 0.9-1.1 g/cu cm). This paper describes impact tests to assess the effects of projectile density on the performance capabilities of typical MMOD shields. Updates to shield ballistic limit equations are provided based on results of tests and analysis.

Christiansen, Eric L.↗
NASA NTRS2009

Cratering Equations for Zinc Orthotitanate Coated Aluminum

The final STS-125 servicing mission (SM4) to the Hubble Space Telescope (HST) in May of 2009 saw the return of the 2nd Wide Field Planetary Camera (WFPC2) aboard the shuttle Discovery. This hardware had been in service on HST since it was installed during the SM1 mission in December of 1993 yielding one of the longest low Earth orbit exposure times (15.4 years) of any returned space hardware. The WFPC2 is equipped with a 0.8 x 2.2 m radiator for thermal control of the camera electronics (Figure 1). The space facing surface of the 4.1 mm thick aluminum radiator is coated with Z93 zinc orthotitanate thermal control paint with a nominal thickness of 0.1 0.2 mm. Post flight inspections of the radiator panel revealed hundreds of micrometeoroid/orbital debris (MMOD) impact craters ranging in size from less than 300 to nearly 1000 microns in diameter. The Z93 paint exhibited large spall areas around the larger impact sites (Figure 2) and the craters observed in the 6061-T651 aluminum had a different shape than those observed in uncoated aluminum. Typical hypervelocity impact craters in aluminum have raised lips around the impact site. The craters in the HST radiator panel had suppressed crater lips, and in some cases multiple craters were present instead of a single individual crater. Humes and Kinard observed similar behavior after the WFPC1 post flight inspection and assumed the Z93 coating was acting like a bumper in a Whipple shield. Similar paint behavior (spall) was also observed by Bland2 during post flight inspection of the International Space Station (ISS) S-Band Antenna Structural Assembly (SASA) in 2008. The SASA, with similar Z93 coated aluminum, was inspected after nearly 4 years of exposure on the ISS. The multi-crater phenomena could be a function of the density, composition, or impact obliquity angle of the impacting particle. For instance, a micrometeoroid particle consisting of loosely bound grains of material could be responsible for creating the multiple craters. Samples were obtained from the HST largest craters for examination by electron microscope equipped with x-ray spectrometers to determine impactor source (micrometeoroid or orbital debris). In an attempt to estimate the MMOD particle diameters that produced these craters, this paper will present equations for spall diameter, crater depth and crater diameter in Z93 coated aluminum. The equations will be based on hypervelocity impact tests of Z93 painted aluminum at the NASA White Sands Test Facility. Equations inputs for velocities beyond the testable regime are expected from hydrocode simulations of Z93 coated aluminum using CTH and ANSYS AUTODYN.

Hyde, James↗
NASA NTRS2009

Effects of Hypervelocity Impacts on Silicone Elastomer Seals and Mating Aluminum Surfaces

While in space silicone based elastomer seals planned for use on NASA's Crew Exploration Vehicle (CEV) are exposed to threats from micrometeoroids and orbital debris (MMOD). An understanding of these threats is required to assess risks to the crew, the CEV orbiter, and missions. An Earth based campaign of hypervelocity impacts on small scale seal rings has been done to help estimate MMOD threats to the primary docking seal being developed for the Low Impact Docking System (LIDS). LIDS is being developed to enable the CEV to dock to the ISS (International Space Station) or to Altair (NASA's next lunar lander). The silicone seal on LIDS seals against aluminum alloy flanges on ISS or Altair. Since the integrity of a seal depends on both sealing surfaces, aluminum targets were also impacted. The variables considered in this study included projectile mass, density, speed, incidence angle, seal materials, and target surface treatments and coatings. Most of the impacts used a velocity near 8 km/s and spherical aluminum projectiles (density = 2.7 g/cubic cm), however, a few tests were done near 5.6 km/s. Tests were also performed using projectile densities of 7.7, 2.79, 2.5 or 1.14 g/cubic cm. Projectile incidence angles examined included 0 deg, 45 deg, and 60 deg from normal to the plane of the target. Elastomer compounds impacted include Parker's S0383-70 and Esterline's ELA-SA-401 in the as received condition, or after an atomic oxygen treatment. Bare, anodized and nickel coated aluminum targets were tested simulating the candidate mating seal surface materials. After impact, seals and aluminum plates were leak tested: damaged seals were tested against an undamaged aluminum plate; and undamaged seals were placed at various locations over craters in aluminum plates. It has been shown that silicone elastomer seals can withstand an impressive level of damage before leaking beyond allowable limits. In general on the tests performed to date, the diameter of the crater in either the elastomer, or the aluminum, must be at least as big as 80% to 90% of width of the bulb of the seal before significant leakage occurs.

deGroh, Henry C., III↗
NASA NTRS2010

Data Collected During the Post-Flight Survey of Micrometeoroid and Orbital Debris Impact Features on the Hubble Wide Field Planetary Camera 2

Over a period of five weeks during the summer of 2009, personnel from the NASA's Orbital Debris Program Office and Meteoroid Environment Office performed a post-flight examination of the Hubble Space Telescope (HST) Wide Field Planetary Camera 2 (WFPC-2) radiator. The objective was to record details about all micrometeoroid and orbital debris (MMOD) impact features with diameters of 300 micron and larger. The WFPC-2 was located in a clean room at NASA's Goddard Space Flight Center. Using a digital microscope, the team examined and recorded position, diameter, and depth information for each of 685 craters. Taking advantage of the digital microscope's data storage and analysis features, the actual measurements were extracted later from the recorded images, in an office environment at the Johnson Space Center. Measurements of the crater include depth and diameter. The depth was measured from the undisturbed paint surface to the deepest point within the crater. Where features penetrate into the metal, both the depth in metal and the paint thickness were measured. In anticipation of hypervelocity tests and simulations, several diameter measurements were taken: the spall area, the area of any bare metal, the area of any discolored ("burned") metal, and the lips of the central crater. In the largest craters, the diameter of the crater at the surface of the metal was also measured. The location of each crater was recorded at the time of inspection. This paper presents the methods and results of the crater measurement effort, including the size and spatial distributions of the impact features. This effort will be followed by taking the same measurements from hypervelocity impact targets simulating the WFPC-2 radiator. Both data sets, combined with hydrocode simulation, will help validate or improve the MMOD environment in low Earth orbit.

Opiela, J. N.↗
NASA NTRS2010

Orbital Debris: Quarterly News, Volume 14, Issue 2

This bulletin contains articles from the Orbital Debris Program office. This issue's articles are: "Orbital Debris Success Story --A Decade in the Making", "Old and New Satellite Breakups Identified," "Update on Three Major Debris Clouds," and "MMOD Inspection of the HST Bay 5 Multi-Layer Insulation Panel" about micrometeoroid and orbital debris (MMOD) inspection of the Hubble Space Telescope (HST) insulation panel. A project review is also included (i.e., "Small Debris Observations from the Iridium 33/Cosmos 2251 Collision.") There are also abstra cts of conference papers from the staff of the program office.

Liou, J. C.↗
NASA NTRS2010

Micrometeoroid and Orbital Debris Impact Inspection of the HST WFPC2 Radiator

Objectives: I.) Conduct micrometeoroid and orbital debris (MMOD) impact inspection of the Hubble Space Telescope (HST) Wide Field Planetary Camera 2 (WFPC2) radiator: a) Document the physical characteristics of large (> or equal to 300 microns) impact features. 1. Locations and distribution. 2. Crater shape, size, depth, volume b) Extract residues from craters for compositional analysis. c) Perform hypervelocity impact tests for data interpretation II. Use the data to validate or improve the near-Earth MMOD environment definition. a) Flux. b) Orbital debris versus meteoroids. c) Time history (limited).

Liou, J.-C.↗
NASA NTRS2011

Preliminary Assessment of Potential Habitat Composites' Durability when Exposed to a Long-Term Radiation Environment and Micrometeoroid Impacts

NASA's exploration goals include extending human presence beyond low earth orbit (LEO). As a result, habitation for crew is a critical requirement for meeting this goal. However, habitats are very large structures that contain a multitude of subsystems to sustain human life over long-durations in space, and one of the key challenges has been keeping weight to a minimum in order to reduce costs. Thus, light-weight and multifunctional structural materials are of great interest for habitation. NASA has started studying polymeric composite materials as potential lightweight and multifunctional structural materials for use in long-duration spaceflight. However, little is known about the survivability of these materials when exposed to the space environment outside of LEO for long durations. Thus, a study has been undertaken to investigate the durability of composite materials when exposed to long-duration radiation. Furthermore, as an addition to the primary study, a secondary preliminary investigation has been started on the micrometeoroid and orbital debris (MMOD) susceptibility of these materials after radiation exposure. The combined effects of radiation and MMOD impacts are the focus of this paper.

Rojdev, Kristina↗
NASA NTRS2012

HVI Ballistic Performance Characterization of Non-Parallel Walls

The Double-Wall, "Whipple" Shield [1] has been the subject of many hypervelocity impact studies and has proven to be an effective shield system for Micro-Meteoroid and Orbital Debris (MMOD) impacts for spacecraft. The US modules of the International Space Station (ISS), with their "bumper shields" offset from their pressure holding rear walls provide good examples of effective on-orbit use of the double wall shield. The concentric cylinder shield configuration with its large radius of curvature relative to separation distance is easily and effectively represented for testing and analysis as a system of two parallel plates. The parallel plate double wall configuration has been heavily tested and characterized for shield performance for normal and oblique impacts for the ISS and other programs. The double wall shield and principally similar Stuffed Whipple Shield are very common shield types for MMOD protection. However, in some locations with many spacecraft designs, the rear wall cannot be modeled as being parallel or concentric with the outer bumper wall. As represented in Figure 1, there is an included angle between the two walls. And, with a cylindrical outer wall, the effective included angle constantly changes. This complicates assessment of critical spacecraft components located within outer spacecraft walls when using software tools such as NASA's BumperII. In addition, the validity of the risk assessment comes into question when using the standard double wall shield equations, especially since verification testing of every set of double wall included angles is impossible.

Bohl, William↗
NASA NTRS2013

The Komplast Experiment: Space Environmental Effects after 12 Years in LEO (and Counting)

The Komplast materials experiment was designed by the Khrunichev State Research and Production Space Center, together with other Russian scientific institutes, and has been carried out by Mission Control Moscow since 18. Komplast panels fitted with material samples and sensors were located on the International Space Station (ISS) Functional Cargo Block (FGB) module exterior surface. Within the framework of this experiment, the purpose was to study the effect of the low earth orbit (LEO) environment on exposed samples of various materials. The panels were sent into orbit with the FGB when it launched on November 20, 1998. Panels #2 and #10 were retrieved during Russian extravehicular activity in February 2011 and sealed within cases to temporarily protect the samples from exposure to air until they could be studied on the ground. Panel #2 contained an experiment to detect micrometeoroid and orbital debris (MMOD) impacts, radiation and UV sensors, several pieces of electrical cable, and samples made from elastomeric and fluoroplastic materials. Panel #10 contained a temperature sensor, and both carbon composite and adhesive-bonded samples. A figure shows the location of panels #2 and #10 on the FGB module aft endcone. The panels were subsequently returned to Earth by Space Shuttle Discovery on the STS-133/ULF-5 mission after 12 years of LEO exposure and opened in an argon chamber at the Institute of Nuclear Physics at Moscow State University in July 2011. Based on the results of analyzing the readings from sensors located on Komplast panels and in studying material samples from the panels, the comprehensive effect of spaceflight factors on the FGB (at the locations of Panels #2 and #10) was evaluated. Total solar exposure was determined to be 960 +/- 200 kJ/square cm or 21,000 equivalent solar hours. Because of location of these two panels and the ISS flight attitude, atomic oxygen (AO) fluence was relatively low for such a long duration exposure, approximately 1.5x10 (exp 21) O atoms/sq. cm. Most of the AO fluence occurred during the early phase of ISS assembly. Temperatures ranged from a maximum of 107 C to a minimum of -80 C. The MMOD environment was determined, as is shown. Interestingly, the distribution of craters and low-velocity impact particles observed in the 5-50 micron size range was approx 2-3 orders of magnitude higher than that predicted by the ORDEM2000 model of natural and artificial origin microparticles in the ISS orbit. Contamination observations were also made, through the evaluation of optical properties on thermal control coatings and by the examination of visible deposits located near several samples on the panels, primarily from elastomeric samples. These elastomer samples were extensively investigated for their physical property changes and sealing capability. In addition, 16 samples of adhesive-bonded joints using three types of epoxy adhesive were evaluated studying fracture toughness, failure surface, and adhesive volume properties. Both rubber and adhesive-bonded specimens also underwent additional (post-flight) ground-based exposures to simulate a total 30 years in LEO prior to their evaluation. Overall, results indicate that space environmental effects will not adversely impact the service life of the FGB through 2028. Our investigation is complete and a summary of the results obtained from this uniquely long-duration exposure experiment will be presented.

Shaevich, S. K.↗
NASA NTRS2013

International Space Station (ISS) Soyuz Vehicle Descent Module Evaluation of Thermal Protection System (TPS) Penetration Characteristics

The descent module (DM) of the ISS Soyuz vehicle is covered by thermal protection system (TPS) materials that provide protection from heating conditions experienced during reentry. Damage and penetration of these materials by micrometeoroid and orbital debris (MMOD) impacts could result in loss of vehicle during return phases of the mission. The descent module heat shield has relatively thick TPS and is protected by the instrument-service module. The TPS materials on the conical sides of the descent module (referred to as backshell in this test plan) are exposed to more MMOD impacts and are relatively thin compared to the heat shield. This test program provides hypervelocity impact (HVI) data on materials similar in composition and density to the Soyuz TPS on the backshell of the vehicle. Data from this test program was used to update ballistic limit equations used in Soyuz TPS penetration risk assessments. The impact testing was coordinated by the NASA Johnson Space Center (JSC) Hypervelocity Impact Technology (HVIT) Group [1] in Houston, Texas. The HVI testing was conducted at the NASA-JSC White Sands Hypervelocity Impact Test Facility (WSTF) at Las Cruces, New Mexico. Figure

Davis, Bruce A.↗
NASA NTRS2013

Determine ISS Soyuz Orbital Module Ballistic Limits for Steel Projectiles Hypervelocity Impact Testing

A new orbital debris environment model (ORDEM 3.0) defines the density distribution of the debris environment in terms of the fraction of debris that are low-density (plastic), medium-density (aluminum) or high-density (steel) particles. This hypervelocity impact (HVI) program focused on assessing ballistic limits (BLs) for steel projectiles impacting the enhanced Soyuz Orbital Module (OM) micrometeoroid and orbital debris (MMOD) shield configuration. The ballistic limit was defined as the projectile size on the threshold of failure of the OM pressure shell as a function of impact speeds and angle. The enhanced OM shield configuration was first introduced with Soyuz 30S (launched in May 2012) to improve the MMOD protection of Soyuz vehicles docked to the International Space Station (ISS). This test program provides HVI data on U.S. materials similar in composition and density to the Russian materials for the enhanced Soyuz OM shield configuration of the vehicle. Data from this test program was used to update ballistic limit equations used in Soyuz OM penetration risk assessments. The objective of this hypervelocity impact test program was to determine the ballistic limit particle size for 440C stainless steel spherical projectiles on the Soyuz OM shielding at several impact conditions (velocity and angle combinations). This test report was prepared by NASA-JSC/ HVIT, upon completion of tests.

Lyons, Frankel↗
NASA NTRS2015

HVI Ballistic Limit Charaterization of Fused Silica Thermal Pane

The Orion spacecraft's windows are exposed to the micrometeroid and orbital debris (MMOD) space environments while in space as well as the Earth entry environment at the mission's conclusion. The need for a low-mass spacecraft window design drives the need to reduce conservatism when assessing the design for loss of crew due to MMOD impact and subsequent Earth entry. Therefore, work is underway at NASA and Lockheed Martin to improve characterization of the complete penetration ballistic limit of an outer fused silica thermal pane. Hypervelocity impact tests of the window configuration at up to 10 km/s and hydrocode modeling have been performed with a variety of projectile materials to enable refinement of the fused silica ballistic limit equation.

Bohl, William E.↗
NASA NTRS2015

DRAGONS-A Micrometeoroid and Orbital Debris Impact Sensor on the ISS

The Debris Resistive/Acoustic Grid Orbital Navy-NASA Sensor (DRAGONS) is intended to be a large area impact sensor for in situ measurements of micrometeoroids and orbital debris (MMOD) in the sub-millimeter to millimeter size regime in the near Earth space environment. These MMOD particles are too small to be detected by ground-based radars and optical telescopes, but still large enough to be a serious threat to human space activities and robotic missions in the low Earth orbit (LEO) region. The nominal detection area of DRAGONS is 1 sq m, consisting of four 0.5 m × 0.5 m independent panels, but the dimensions of the panels can easily be modified to accommodate different payload constraints. The approach of the DRAGONS design is to combine three particle impact detection concepts to maximize information that can be extracted from each detected impact. The first is a resistive grid consisting of 75-micrometer-wide resistive lines, coated in parallel and separated by 75 micrometer gaps on a 25-micrometer thin film. When a particle a few hundred micrometers or larger strikes the grid, it would penetrate the film and sever some resistive lines. The size of the damage area can be estimated from the increased resistance. The second concept is based on polyvinylidene fluoride (PVDF) acoustic impact sensors. Multiple PVDF sensors are attached to the thin film to provide the impact timing information. From the different signal arrival times at different acoustic sensors, the impact location can be calculated via triangulation algorithms. The third concept employs a dual-layer film system where a second 25-micrometer film is placed 15 cm behind the resistive-grid film. Multiple PVDF acoustic sensors are also attached to the second film. The combination of impact timing and location information from the two films allows for direct measurements of the impact direction and speed. The DRAGONS technology development has been funded by several NASA organizations since 2002, first by the NASA Science Mission Directorate and the NASA Exploration Systems Mission Directorate, then by the NASA JSC Innovative Research and Development Program and the NASA Orbital Debris Program Office. The NASA Orbital Debris Program Office leads the effort with collaboration from the U.S. Naval Academy, Naval Research Laboratory, University of Kent at Canterbury in Great Britain, and Virginia Tech. The project recently reached a major milestone when DRAGONS was approved for a technology demonstration mission by the International Space Station (ISS) Program in October 2014. The plan is to deploy a 1 sq m DRAGONS on the ISS with the detection surface facing the ram-direction for 2 to 3 years. The tentative launch schedule is in early 2017. This mission will collect data on orbital debris in the sub-millimeter size regime to better define the small orbital debris environment at the ISS altitude. The mission will also advance the DRAGONS Technology Readiness Level to 9 and greatly enhance the opportunities to deploy DRAGONS on other spacecraft to high LEO orbits in the future.

Liou, J.-C.↗
NASA NTRS2014

Shell-NASA Vibration-Based Damage Characterization

This article describes collaborative research between Shell International Exploration and Production (IE&P) scientists and ISAG personnel to investigate the feasibility of ultrasonic-based characterization of spacecraft tile damage for in-space inspection applications. The approach was proposed by Shell personnel in a Shell-NASA "speed-matching" session in early 2011 after ISAG personnel described challenges inherent in the inspection of MMOD damage deep within spacecraft thermal protection system (TPS) tiles. The approach leveraged Shell's relevant sensor and analytical expertise. The research addressed the difficulties associated with producing 3D models of MMOD damage cavities under the surface of a TPS tile, given that simple image-based sensing is constrained by line of sight through entry holes that have diameters considerably smaller than the underlying damage cavities. Damage cavity characterization is needed as part of a vehicle inspection and risk reduction capability for long-duration, human-flown space missions. It was hoped that cavity characterization could be accomplished through the use of ultrasonic techniques that allow for signal penetration through solid material.

Rollins, John M.↗
NASA NTRS2016

The Orion Exploration Flight Test Post Flight Solid Particle Flight Environment Inspection and Analysis

Orbital debris in the millimeter size range can pose a hazard to current and planned spacecraft due to the high relative impact speeds in Earth orbit. Fortunately, orbital debris has a relatively short life at lower altitudes due to atmospheric effects; however, at higher altitudes orbital debris can survive much longer and has resulted in a band of high flux around 700 to 1,500 km above the surface of the Earth. While large orbital debris objects are tracked via ground based observation, little information can be gathered about small particles except by returned surfaces, which until the Orion Exploration Flight Test number one (EFT-1), has only been possible for lower altitudes (400 to 500 km). The EFT-1 crew module backshell, which used a porous, ceramic tile system with surface coatings, has been inspected post-flight for potential micrometeoroid and orbital debris (MMOD) damage. This paper describes the pre- and post-flight activities of inspection, identification and analysis of six candidate MMOD impact craters from the EFT-1 mission.

Miller, Joshua E.↗
NASA NTRS2017

Failure Mechanisms of Ni-H2 and Li-Ion Batteries Under Hypervelocity Impacts

Lithium-Ion (Li-Ion) batteries have yielded significant performance advantages for many industries, including the aerospace industry, and have been selected to replace nickel hydrogen (Ni-H2) batteries for the International Space Station (ISS) program to meet the energy storage demands. As the ISS uses its vast solar arrays to generate its power, the solar ar-rays meet their sunlit power demands and supply excess power to battery packs for power de-livery on the sun obscured phase of the approximate 90 minute low Earth orbit. These large battery packs are located on the exterior of the ISS, and as such, the battery packs are ex-posed to external environment threats like naturally occurring meteoroids and artificial orbital debris (MMOD). While the risks from these solid particle environments has been known and addressed to an acceptable risk of failure through shield design, it is not possible to completely eliminate the risk of loss of these assets on orbit due to MMOD, and as such, failure consequences to the ISS have been considered.

Miller, J. E.↗
NASA NTRS2017

Solar Array Mast Imagery Discussion for ISIW

SAW Mast inspection background: In 2012, NASA's Flight Safety Office requested the Micro Meteoroid and Orbital Debris (MMOD) office determine the probability of damage to the Solar Array Wing (SAW) mast based on the exposure over the life time of the ISS program. As part of the risk mitigation of the potential MMOD strikes. ISS Program office along with the Image Science and Analysis Group (ISAG) began developing methods for imaging the structural components of the Mast.

Kilgo, Gary↗