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Modular Low-Heater-Power Cathode/Electron Gun Assembly for Microwave and Millimeter Wave Traveling Wave Tubes

A low-cost, low-mass, electrically efficient, modular cathode/electron gun assembly has been developed by FDE Inc. of Beaverton, Oregon, under a Small Business Innovation Research (SBIR) contract with the NASA Glenn Research Center at Lewis Field. This new assembly offers significant improvements in the design and manufacture of microwave and millimeter wave traveling-wave tubes (TWT's) used for radar and communications. It incorporates a novel, low-heater-power, reduced size and mass, high-performance barium dispenser type thermionic cathode and provides for easy integration of the cathode into a large variety of conventional TWT circuits. Among the applications are TWT's for Earth-orbiting communication satellites and for deep space communications, where future missions will require smaller spacecraft, higher data transfer rates (higher frequencies and radiofrequency output power), and greater electrical efficiency. A particularly important TWT application is in the microwave power module (a hybrid microwave/millimeter wave amplifier consisting of a low-noise solid-state driver, a small TWT, and an electronic power conditioner integrated into a single compact package), where electrical efficiency and thermal loading are critical factors and lower cost is needed for successful commercialization. The design and fabrication are based on practices used in producing cathode ray tubes (CRT's), which is one of the most competitive and efficient manufacturing operations in the world today. The approach used in the design and manufacture of thermionic cathodes and electron guns for CRT's has been optimized for fully automated production, standardization of parts, and minimization of costs. It is applicable to the production of similar components for microwave tubes, with the additional benefits of low mass and significantly lower cathode heater power (less than half that of dispenser cathodes presently used in TWT s). Modular cathode/electron gun assembly. The modular cathode/electron gun assembly consists of four subassemblies the cathode, the focus electrode, the header (including the electrical feedthroughs), and the gun envelope (including the anode) a diagram of which is shown. The modular construction offers a number of significant advantages, including flexibility of design, interchangeability of parts, and a drop-in final assembly procedure for quick and accurate alignment. The gun can accommodate cathodes ranging in size from 0.050 to 0.250-in. in diameter and is applicable to TWT's over a broad range of sizes and operating parameters, requiring the substitution of only a few parts: that is, the cathode, focus electrode, and anode. The die-pressed cathode pellets can be made with either flat or concave (Pierce gun design) emitting surfaces. The gun can be either gridded (pulse operation) or ungridded (continuous operation). Important factors contributing to low cost are the greater use of CRT materials and parts, the standardization of processes (welding and mechanical capture), and tooling amenable to automated production. Examples are the use of simple shapes, drawn or stamped metal parts, and parts joined by welding or mechanical capture. Feasibility was successfully demonstrated in the retrofit and testing of a commercial Kaband (22-GHz) TWT. The modular cathode/electron gun assembly was computer modeled to replicate the performance of the original electron gun and fabricated largely from existing CRT parts. Significant test results included demonstration of low heater power (1.5-W, 1010 C brightness temperature for a 0.085-in.-diameter cathode), mechanical ruggedness (100g shock and vibration tests in accordance with military specifications (MIL specs)), and a very fast warmup. The results of these tests indicate that the low-cost CRT manufacturing approach can be used without sacrificing performance and reliability.

Wintucky, Edwin G.↗

Solid State Memory Study Final Report

Existing and future solid state nonvolatile memory technologies are described and evaluated in this report. Solid state memory technologies can offer size, speed, power, weight, and ruggedness advantages over conventional moving media storage technologoies such as disk or tape. This technology list is a broad sampling of past, present, emerging, and future solid state memory technologies.

Solid State Memory↗

Compact and Rugged Transceiver for Coherent Doppler Wind Lidar Applications in Space

High-accuracy, vertical profiles of the horizontal vector wind in earth s atmosphere, with the global coverage of an orbiting sensor, are a highly desired measurement of NASA, NOAA, and many other agencies and countries. It is the consensus of NASA and NOAA that the most cost effective, lowest risk measurement method with the earliest achievable mission date is the hybrid Doppler lidar method which utilizes both coherent- and direct-detection Doppler lidars to obtain the desired profiles. NASA Langley Research Center (LaRC) has advanced the 2-micron pulsed solid-state laser greatly over the past 15 years and has recently demonstrated 1.2 J of pulse energy whereas the requirement for a 400-km hybrid Doppler lidar mission is only 0.25 J. The IIP project reported here is an effort to increase the ruggedness and to compactly package the LaRC state-of-the-art laser technology.

Kavaya, Michael J.↗

CompactPCI(Registered TradeMark) Connectors in Space Flight Applications

This report documents the current status of CompactPCI(Registered TradeMark) connectors in GSFC spaceflight applications. To the extent the information is known, this report summarizes to what component quality level each NASA contractor (referred to as OEM in this report) procured the parts, and what board level and system level testing was performed. The report also provides the current status of the reliability assessment for each GSFC project based on the results of testing and FMEA (Failure Mode Effects Analysis). This report addresses how the CompactPCI(Registered TradeMark) connectors came into existence, and how these became the connector style chosen by many designers of space flight hardware. It identifies the design philosophy and the lack of robustness which has led to several known failure modes. These failure modes include fretting of connector pins during vibration, shock and thermal cycling, exposure of underplating, and increased resistance, including brief excursions to very high resistance. Each of these are signs of aging, which becomes an increasing concern for long duration orbiting space flight applications. This report addresses the mitigation strategy to replace CompactPCI(Registered TradeMark) connectors with space qualified Hypertronics 2mm cPCI connectors. The Hypertronics 2mm cPCI connectors are pin-to-pin compatible with the CompactPCI(Registered TradeMark) connectors and meet all of the same technical requirements, except the ability to hot mate, and to mate directly with a CompactPCI of the opposite gender. A detailed comparison of the CompactPCI(Registered TradeMark) connector and the Hypertronics 2mm cPCI connector is provided to describe the ruggedness of Hypertronics connector for space flight applications. Finally, this report makes recommendations for flight hardware for the future missions where the hardware is yet to be built, as well as for the hardware which has already been built with CompactPCI(Registered TradeMark) connectors.

Williams, Richard↗

MISSE 6-Testing Materials in Space

The objective of the Materials International Space Station Experiment (MISSE) is to study the performance of novel materials when subjected to the synergistic effects of the harsh space environment by placing them in space environment for several months. In this paper, a few materials and components from NASA Langley Research Center (LaRC) that have been flown on MISSE 6 mission will be discussed. These include laser and optical elements for photonic devices. The pre-characterized MISSE 6 materials were packed inside a ruggedized Passive Experiment Container (PEC) that resembles a suitcase. The PEC was tested for survivability due to launch conditions. Subsequently, the MISSE 6 PEC was transported by the STS-123 mission to International Space Station (ISS) on March 11, 2008. The astronauts successfully attached the PEC to external handrails and opened the PEC for long term exposure to the space environment.

Prasad, Narasimha S↗

Solid State Light Evaluation in the U.S. Lab Mockup

This document constitutes the publication of work performed by the Space Human Factors Laboratory (mail code SF5 at the time) at the Johnson Space Center (JSC) in the months of June and July of 2000. At that time, the Space Human Factors Laboratory was part of the Space Human Factors Branch in the Flight Projects Division of the Space and Life Directorate. This report was originally to be a document for internal consumption only at JSC as it was seen to be only preliminary work for the further development of solid state illumination for general lighting on future space vehicles and the International Space Station (ISS). Due to funding constraints, immediate follow-on efforts were delayed and the need for publication of this document was overcome by other events. However, in recent years and with the development and deployment of a solid state light luminaire prototype on ISS, the time was overdue for publishing this information for general distribution and reference. Solid state lights (SSLs) are being developed to potentially replace the general luminaire assemblies (GLAs) currently in service in the International Space Station (ISS) and included in designs of modules for the ISS. The SSLs consist of arrays of light emitting diodes (LEDs), small solid state electronic devices that produce visible light in proportion to the electrical current flowing through them. Recent progressive advances in electrical power-to-light conversion efficiency in LED technology have allowed the consideration of LEDs as replacements for incandescent and fluorescent light sources in many circumstances, and their inherent advantages in ruggedness, reliability, and life expectancy make them attractive for applications in spacecraft. One potential area of application for the SSLs in the U.S. Laboratory Module of the ISS. This study addresses the suitability of the SSLs as replacements for the GLAs in this application.

Maida, James c.↗

Fiber Optic Cable Thermal Preparation to Ensure Stable Operation

Fiber optic cables are widely used in modern systems that must provide stable operation during exposure to changing environmental conditions. For example, a fiber optic cable on a satellite may have to reliably function over a temperature range of -50 C up to 125 C. While the system requirements for a particular application will dictate the exact method by which the fibers should be prepared, this work will examine multiple ruggedized fibers prepared in different fashions and subjected to thermal qualification testing. The data show that if properly conditioned the fiber cables can provide stable operation, but if done incorrectly, they will have large fluctuations in transmission.

Thoames Jr, William J.↗

Use of Photoelastic Modulators for High-accuracy Spectropolarimetric Imaging of Aerosols

Passive multiangular, multispectral, and polarimetric sensing approaches each have unique strengths for the measurement of tropospheric aerosol column abundances and microphysical properties. Current spaceborne multispectral and multiangular aerosols sensors operate at approximately 1 km resolution. Under NASA's Instrument Incubator Program, we are developing an electro-optic imaging approach that will enable adding high-accuracy polarimetry to such observations. To achieve a degree of linear polarization (DOLP) uncertainty of 0.5%, our approach temporally modulates the linear-polarization component of incoming light at a rapid rate, enabling each detector within a focal-plane array, combined with polarization analyzers, to measure the relative proportions of the linear Stokes components Q or U to the total intensity. Our system uses tandem photoelastic modulators (PEMs) within a high-reflectance, low diattenuation camera design. The two PEMs vibrate at slightly different resonant frequencies, leading to modulation of the polarized light at a heterodyne frequency of ~25 Hz. High-speed (1 kHz) readout of the detector arrays samples the output waveforms from which Q/I and U/I are derived. We report on experimental and theoretical analyses of PEM and optical system performance, along with plans for developing ruggedized PEMs capable of withstanding launch and on-orbit stresses.

photoelastics↗

Some Activities of MISSE 6 Mission

The objective of the Materials International Space Station Experiment (MISSE) is to study the performance of novel materials when subjected to the synergistic effects of the harsh space environment for several months. In this paper, a few laser and optical elements from NASA Langley Research Center (LaRC) that have been flown on MISSE 6 mission will be discussed. These items were characterized and packed inside a ruggedized Passive Experiment Container (PEC) that resembles a suitcase. The PEC was tested for survivability due to launch conditions. Subsequently, the MISSE 6 PEC was transported by the STS-123 mission to International Space Station (ISS) on March 11, 2008. The astronauts successfully attached the PEC to external handrails and opened the PEC for long term exposure to the space environment. The plan is to retrieve the MISSE 6 PEC by STS-128 mission in August 2009.

Prasad, Narasimha S.↗

Testing of NASA LaRC Materials under MISSE 6 and MISSE 7 Missions

The objective of the Materials International Space Station Experiment (MISSE) is to study the performance of novel materials when subjected to the synergistic effects of the harsh space environment for several months. MISSE missions provide an opportunity for developing space qualifiable materials. Two lasers and a few optical components from NASA Langley Research Center (LaRC) were included in the MISSE 6 mission for long term exposure. MISSE 6 items were characterized and packed inside a ruggedized Passive Experiment Container (PEC) that resembles a suitcase. The PEC was tested for survivability due to launch conditions. MISSE 6 was transported to the international Space Station (ISS) via STS 123 on March 11. 2008. The astronauts successfully attached the PEC to external handrails of the ISS and opened the PEC for long term exposure to the space environment. The current plan is to bring the MISSE 6 PEC back to the Earth via STS 128 mission scheduled for launch in August 2009. Currently, preparations for launching the MISSE 7 mission are progressing. Laser and lidar components assembled on a flight-worthy platform are included from NASA LaRC. MISSE 7 launch is scheduled to be launched on STS 129 mission. This paper will briefly review recent efforts on MISSE 6 and MISSE 7 missions at NASA Langley Research Center (LaRC).

Prasad, Narasimha S.↗

Model-Driven Development of Reliable Avionics Architectures for Lunar Surface Systems

This paper discusses a method used for the systematic improvement of NASA s Lunar Surface Systems avionics architectures in the area of reliability and fault-tolerance. This approach utilizes an integrated system model to determine the effects of component failure on the system s ability to provide critical functions. A Markov model of the potential degraded system modes is created to characterize the probability of these degraded modes, and the system model is run for each Markov state to determine its status (operational or system loss). The probabilistic results from the Markov model are first produced from state transition rates based on NASA data for heritage failure rate data of similar components. An additional set of probabilistic results are created from a representative set of failure rates developed for this study, for a variety of component quality grades (space-rated, mil-spec, ruggedized, and commercial). The results show that careful application of redundancy and selected component improvement should result in Lunar Surface Systems architectures that exhibit an appropriate degree of fault-tolerance, reliability, performance, and affordability.

Borer, Nicholas↗

Spontaneous-Desorption Ionizer for a TOF-MS

A time-of-flight mass spectrometer (TOF-MS) like the one mentioned in the immediately preceding article has been retrofitted with an ionizer based on a surface spontaneous-desorption process. This ionizer includes an electron multiplier in the form of a microchannel plate (MCP). Relative to an ionizer based on a hot-filament electron source, this ionizer offers advantages of less power consumption and greater mechanical ruggedness. The current density and stability characteristics of the electron emission of this ionizer are similar to those of a filament-based ionizer. In tests of various versions of this ionizer in the TOF-MS, electron currents up to 100 nA were registered. Currents of microamperes or more - great enough to satisfy requirements in most TOFMS applications - could be obtained by use of MCPs different from those used in the tests, albeit at the cost of greater bulk. One drawback of this ionizer is that the gain of the MCP decreases as a function of the charge extracted thus far; the total charge that can be extracted over the operational lifetime is about 1 coulomb. An MCP in the ion-detector portion of the TOF-MS is subject to the same limitation.

Schultz, J. Albert↗

Very High-Speed Digital Video Capability for In-Flight Use

digital video camera system has been qualified for use in flight on the NASA supersonic F-15B Research Testbed aircraft. This system is capable of very-high-speed color digital imaging at flight speeds up to Mach 2. The components of this system have been ruggedized and shock-mounted in the aircraft to survive the severe pressure, temperature, and vibration of the flight environment. The system includes two synchronized camera subsystems installed in fuselage-mounted camera pods (see Figure 1). Each camera subsystem comprises a camera controller/recorder unit and a camera head. The two camera subsystems are synchronized by use of an MHub(TradeMark) synchronization unit. Each camera subsystem is capable of recording at a rate up to 10,000 pictures per second (pps). A state-of-the-art complementary metal oxide/semiconductor (CMOS) sensor in the camera head has a maximum resolution of 1,280 1,024 pixels at 1,000 pps. Exposure times of the electronic shutter of the camera range from 1/200,000 of a second to full open. The recorded images are captured in a dynamic random-access memory (DRAM) and can be downloaded directly to a personal computer or saved on a compact flash memory card. In addition to the high-rate recording of images, the system can display images in real time at 30 pps. Inter Range Instrumentation Group (IRIG) time code can be inserted into the individual camera controllers or into the M-Hub unit. The video data could also be used to obtain quantitative, three-dimensional trajectory information. The first use of this system was in support of the Space Shuttle Return to Flight effort. Data were needed to help in understanding how thermally insulating foam is shed from a space shuttle external fuel tank during launch. The cameras captured images of simulated external tank debris ejected from a fixture mounted under the centerline of the F-15B aircraft. Digital video was obtained at subsonic and supersonic flight conditions, including speeds up to Mach 2 and altitudes up to 50,000 ft (15.24 km). The digital video was used to determine the structural survivability of the debris in a real flight environment and quantify the aerodynamic trajectories of the debris.

Corda, Stephen↗

Silicon Photo-Multiplier Readouts for Scintillators in High-Energy Astronomy

New scintillator materials have recently been shown to hold great potential for low-cost, reliable gamma-ray detectors in high-energy astronomy. New devices for the detection of scintillation light promise to make scintillator-based instruments even more attractive by reducing mass and power requirements,in particular, silicon photo-multipliers (SiPMs) are starting to become commercially available that offer gains and quantum efficiencies similar to those of photo-multiplier tubes (PMTs), but with greatly reduced mass, high ruggedness, low voltage requirements, and no sensitivity to magnetic fields. We have conducted laboratory tests of a sample of commercially available SiPMs coupled to LaBr3;Ce, a scintillator of relevance to to future high-energy astrophysics missions. We present results for gamma-ray spectroscopy. compare the SiPM performance to that of a PMT, and discuss the extent to which SiPMs offer significant advantages for scintillator-based space missions.

Bloser, Peter F.↗

Optical Structural Health Monitoring Device

This non-destructive, optical fatigue detection and monitoring system relies on a small and unobtrusive light-scattering sensor that is installed on a component at the beginning of its life in order to periodically scan the component in situ. The method involves using a laser beam to scan the surface of the monitored component. The device scans a laser spot over a metal surface to which it is attached. As the laser beam scans the surface, disruptions in the surface cause increases in scattered light intensity. As the disruptions in the surface grow, they will cause the light to scatter more. Over time, the scattering intensities over the scanned line can be compared to detect changes in the metal surface to find cracks, crack precursors, or corrosion. This periodic monitoring of the surface can be used to indicate the degree of fatigue damage on a component and allow one to predict the remaining life and/or incipient mechanical failure of the monitored component. This wireless, compact device can operate for long periods under its own battery power and could one day use harvested power. The prototype device uses the popular open-source TinyOS operating system on an off-the-shelf Mica2 sensor mote, which allows wireless command and control through dynamically reconfigurable multi-node sensor networks. The small size and long life of this device could make it possible for the nodes to be installed and left in place over the course of years, and with wireless communication, data can be extracted from the nodes by operators without physical access to the devices. While a prototype has been demonstrated at the time of this reporting, further work is required in the system s development to take this technology into the field, especially to improve its power management and ruggedness. It should be possible to reduce the size and sensitivity as well. Establishment of better prognostic methods based on these data is also needed. The increase of surface roughness with fatigue is closely connected to the microstructure of the metal, and ongoing research is seeking to connect this observed evidence of the fatigue state with microstructural theories of fatigue evolution to allow more accurate prognosis of remaining component life. Plans are also being discussed for flight testing, perhaps on NASA s SOFIA platform.

Buckner, Benjamin D.↗

Adapting PC104Plus for Space

This article addresses the issues associated with adapting the commercial PC104Plus standard and its associated architecture to the requirements of space applications. In general, space applications exhibit extreme constraints on power, weight, and volume. EMI and EMC are also issues of significant concern. Additionally, space applications have to survive high radiation environment. Finally, NASA is always concerned about achieving cost effective solutions that are compatible with safety and launch constraints. Weight and volume constraints are directly related to high launch cost. Power on the other hand is not only related to the high launch costs, but are related to the problem of dissipating the resulting heat once in space. The article addresses why PC104Plus is an appropriate solution for the weight and volume issues. The article also addresses what NASA did electrically to reduce power consumption and mechanically dissipate the associated heat in a microgravity and vacuum environment, and how these solutions allow NASA to integrate various sizes of ruggedized custom PC104 boards with COTS, PC104 complaint boards for space applications. In addition to the mechanical changes to deal with thermal dissipation NASA also made changes to minimize EMI. Finally, radiation issues are addressed as well as the architectural and testing solutions and the implications for use of COTS PC104Plus boards.

Abbott, Larry↗

Achievable Performance and Effective Interrogator Design for SAW RFID Sensor Tags

For many NASA missions, remote sensing is a critical application that supports activities such as environmental monitoring, planetary science, structural shape and health monitoring, non-destructive evaluation, etc. The utility of the remote sensing devices themselves is greatly increased if they are passive V that is, they do not require any on-board power supply such as batteries V and if they can be identified uniquely during the sensor interrogation process. Additional passive sensor characteristics that enable greater utilization in space applications are small size and weight, long read ranges with low interrogator power, ruggedness, and operability in extreme environments (vacuum, extreme high/low temperature, high radiation, etc.) In this paper, we consider one very promising passive sensor technology, called surface acoustic wave (SAW) radio-frequency identification (RFID), that satisfies all of these criteria. In general, RFID is a method of identifying items using radio waves to interrogate tags encoded with a unique identifier that are affixed to the items of interest. In the case of passive tags, only the interrogator, which transmits power to the tags in the form of radio-frequency electromagnetic radiation, requires access to a power supply. Passive RFID technologies are used today in many applications, including asset tracking and management, security and access control, and remote sensing. To date, most of the development and application in RFID technology has focused on either asset/inventory tracking and control or security and access control because these are the largest commercial application areas. Recently however, there has been growing interest in using passive RFID technology for remote sensing applications, and SAW devices are at the forefront of RFID sensing technology development. Although SAW RFID tags have great potential for use in numerous space-based remote sensing applications, the limited collision resolution capability of current generation tags limits the performance in a cluttered sensing environment. That is, as more SAW-based sensors are added to the environment, numerous tag responses are superimposed at the receiver and decoding all or even a subset of the telemetry becomes increasingly difficult. Background clutter generated by reflectors other than the sensors themselves is also a problem, as is multipath interference and signal distortion, but the limiting factor in many remote sensing applications can be expected to be tag mutual interference. This problem may be greatly mitigated by proper design of the SAW tag waveform, but that remains an open research problem, and in the meantime, several other related questions remain to be answered including: (1) What are the fundamental relationships between tag parameters such as bit-rate, time-bandwidth-product, SNR, and achievable collision resolution? (2) What are the differences in optimal or near-optimal interrogator designs between noise-limited environments and interference-limited environments? (3) What are the performance characteristics of different interrogator designs in term of parameters such as transmitter power level, range, and number of interfering tags? In this paper, we will present the results of a research effort aimed at providing at least partial answers to all of these questions.

Barton Richard J.↗

Robust IR Remote Sensing Technique of the Total Column of Trace Gases Including Carbon Dioxide and Methane

Progress on the development of a differential radiometer based upon the Fabry-Perot interferometer (FPI) for methane (CH4) and carbon dioxide (C02) detection in the atmosphere is presented. Methane measurements are becoming increasingly important as a component of NASA's programs to understand the global carbon cycle and quantifY the threat of global warming. Methane is the third most important greenhouse gas in the Earth's radiation budget (after water vapor and carbon dioxide) and the second most important anthropogenic contributor to global warming. The importance of global warming and air quality to society caused the National Research Council to recommend that NASA develop the following missions [1]: ASCENDS (Active Sensing of C02 Emissions over Nights, Days, and Seasons), GEOCAPE (Geostationary Coastal and Air Pollution Events), and GACM (Global Atmosphere Composition Mission). Though methane measurements are not specifically called out in these missions, ongoing environmental changes have raised the importance of understanding the methane budget. In the decadal survey is stated that "to close the carbon budget, we would also address methane, but the required technology is not obvious at this time. If appropriate and cost-effective methane technology becomes available, we strongly recommend adding a methane capability". In its 2007 report the International Panel on Climate Change identified methane as a key uncertainty in our understanding saying that the causes of recent changes in the growth rate of atmospheric CH4 are not well understood. What we do know is that methane arises from a number of natural sources including wet lands and the oceans plus man made sources from agriculture, as well as coal and petroleum production and distribution. It has recently been pointed out that large amount of methane are frozen in the permafrost of Canada and Siberia. There is a fear that melting of this permafrost driven by global warming may release large amounts of methane very suddenly further exacerbating climate change [2]. Last year our group began a joint effort with Johns Hopkins Applied Physics Laboratory to investigate the possibility of developing a small unmanned aerial vehicle (UAV) equipped to measure greenhouse gases-particularly methane. Although we are targeting our system for smaller UAV's the instrument will be directly applicable to missions involving larger NASA UAV's such as Global Hawk or even on missions utilizing manned aircraft. Because of its small size, inherent ruggedness and simplicity some version of our proposed instrument may find a role as a satellite instrument for NASA or NOAA.

Georgieva, E. M.↗