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NASA NTRS2018

Operational Testing of 4H-SiC JFET ICs for 60 Days Directly Exposed to Venus Surface Atmospheric Conditions

Prolonged Venus surface missions (lasting months instead of hours) have proven infeasible to date in the absence of a complete suite of electronics able to function for such durations without protection from the planet’s extreme conditions of ~460 °C, ~9.3 MPa (~ 92 Earth atmospheres) chemically reactive environment. Here we report testing data from a successful two-month (60-day) operational demonstration of two 175-transistor 4H-SiC junction field effect transistor (JFET) semiconductor integrated circuits (ICs) directly exposed (no cooling and no protective chip packaging) to a high-fidelity physical and chemical reproduction of Venus surface atmospheric conditions in a test chamber. These results extend the longest reported duration of electronics operation in Venus surface atmospheric conditions almost 3-fold and were accomplished using prototype SiC JFET chips of more than 7-fold increased complexity. The demonstrated advancement marks a significant step towards realization of electronics with sufficient complexity and durability for implementing robotic landers capable of returning months of scientific data from the surface of Venus.

Integrated Circuit↗

NASA NTRS2021

Europa Environmental Testing of Thermal Hardware for the Mapping Imaging Spectrometer for Europa (MISE) Instrument

The Europa Clipper spacecraft, scheduled for launch in June 2022, hosts a suite of instruments including the Mapping Imaging Spectrometer for Europa (MISE). MISE is a high-optical through-put pushbroom infrared imaging spectrometer that can collect measurements within Europa’s challenging radiation environment. It is externally mounted to the spacecraft and as a result is exposed to high radiation levels and cold temperatures. The instrument consists of a scan mirror assembly, an optical bench including a Dyson spectrometer and a telescope, and a structure that supports a cryocooler and a radiator. The cryocooler is used to actively cool the focal plane array and the spectrometer. The heat from the cryocooler is rejected through pyrolytic graphite sheet thermal straps to a honeycomb radiator. MISE will implement thermal hardware that will either not be used on other parts of the spacecraft or have a more extreme environment than the spacecraft. As a result, the MISE instrument performed numerous environmental tests on its thermal hardware. This paper discusses the results of the thermal cycling and radiation tests performed on the MISE thermal hardware including a Lockheed Martin Micro1-2 cryocooler, Pyrolytic graphite sheet thermal straps, Annealed pyrolytic graphite K-Core, Rosemount Platinum Resistance Thermometers, Tayco Kapton Thermofoil heaters, Dale Ohm resistors, and aluminum honeycomb and facesheets.

Strong, Patrick↗

NASA NTRS2020

Technologies for Future Venus Exploration

The purpose of this white paper is to provide an overview to the NRC Decadal Survey Inner Planets Sub-Panel on thermal protection system (TPS) technologies required for future Venus exploration missions. It considers the capability of heritage TPS technology used by the Pioneer Venus and Galileo probe missions and identifies new technologies that could enable greater science value and more ambitious missions in the future. A prime conclusion is that there are important advances regarding the availability of forebody TPS required for Venus entry probes. Specifically, the carbon phenolic flown on the Pioneer Venus probes has been deemphasized and a new 3D woven material system, Heatshield for Extreme Entry Environment Technology (HEEET) has replaced carbon phenolic. Along with the development of HEEET, there have been test facility upgrades and design tool improvements. These new material and test methods are enabling for Venus missions. However, without a mission scheduled in the near future, even these new developments are at risk of becoming unavailable. Therefore, we recommend that NASA invest in a cross-cutting technology program that focuses on sustainment of relevant TPS materials, entry systems, test facilities, design tools, and flight instrumentation.

Thermal Protection Systems↗

DOE OSTI2024

Submerged Fatigue Testing of Marine Energy Advanced Materials: Preprint

Marine energy structures are typically made of advanced composite materials and are subjected to extreme ocean environments in service. In extreme ocean environments, seawater currents and waves load structures repeatedly, which cause two environmental conditions: water intrusion and mechanical fatigue. In prior research, the two environmental conditions were applied sequentially, where composite specimens were aged and then mechanically tested. To understand the combined effects of dynamic loading and water intrusion on composite materials, the present study involves the static and fatigue four-point bend testing of composite coupons in a water tank. The water tank was designed and built to fit either a 100 kN or a 250 kN load frame. Flexural strength value, cycles to failure, and failure mode results from submerged fatigue testing will be used to inform marine energy structure designs. The coupon-scale test method will be used to scale up to and inform methods for subsequent subcomponent testing and standards development. The benefits of designing marine energy structures to informed standards are decreased lifetime costs and increased reliability and energy production, ultimately leading to a sustainable and low-carbon energy system.

composite materials↗

NASA NTRS2013

Development and Execution of Autonomous Procedures Onboard the International Space Station to Support the Next Phase of Human Space Exploration

Now that major assembly of the International Space Station (ISS) is complete, NASA's focus has turned to using this high fidelity in-space research testbed to not only advance fundamental science research, but also demonstrate and mature technologies and develop operational concepts that will enable future human exploration missions beyond low Earth orbit. The ISS as a Testbed for Analog Research (ISTAR) project was established to reduce risks for manned missions to exploration destinations by utilizing ISS as a high fidelity micro-g laboratory to demonstrate technologies, operations concepts, and techniques associated with crew autonomous operations. One of these focus areas is the development and execution of ISS Testbed for Analog Research (ISTAR) autonomous flight crew procedures intended to increase crew autonomy that will be required for long duration human exploration missions. Due to increasing communications delays and reduced logistics resupply, autonomous procedures are expected to help reduce crew reliance on the ground flight control team, increase crew performance, and enable the crew to become more subject-matter experts on both the exploration space vehicle systems and the scientific investigation operations that will be conducted on a long duration human space exploration mission. These tests make use of previous or ongoing projects tested in ground analogs such as Research and Technology Studies (RATS) and NASA Extreme Environment Mission Operations (NEEMO). Since the latter half of 2012, selected non-critical ISS systems crew procedures have been used to develop techniques for building ISTAR autonomous procedures, and ISS flight crews have successfully executed them without flight controller involvement. Although the main focus has been preparing for exploration, the ISS has been a beneficiary of this synergistic effort and is considering modifying additional standard ISS procedures that may increase crew efficiency, reduce operational costs, and raise the amount of crew time available for scientific research. The next phase of autonomous procedure development is expected to include payload science and human research investigations. Additionally, ISS International Partners have expressed interest in participating in this effort. The recently approved one-year crew expedition starting in 2015, consisting of one Russian and one U.S. Operating Segment (USOS) crewmember, will be used not only for long duration human research investigations but also for the testing of exploration operations concepts, including crew autonomy.

beyond low earth orbit (BLEO)↗

DOE OSTI2020

Decoding Early Candidacy of High Entropy Alloys for Nuclear Application using the Advanced Test Reactor through Predictive Methods and Combinatorial Testing

High Entropy Alloys (HEAs) are identified candidates for nuclear applications owing to their superb mechanical and thermal properties. In line with evaluating their candidacy, a challenge remains in their validity as structural replacements for extreme environments. Each compositional graded specimen consists up to four different compositions spanning the fueled zone for non-prototypical neutron irradiation testing in the Advanced Test Reactor (ATR) at Idaho National Laboratory (INL). We have fabricated a set of four compositionally graded specimens using spark plasma sintering that include at least five of the following elements: Cr, C, Al, Zr, Mo, Nb, Ta, V, Ti, W, and Fe. In time for this meeting the role of temperature expected to play a role in-pile cladding chemical interactions (FCCI), mechanical interactions (FCMI), irradiation damage, creep, and resistance will be reported. The irradiated portion has a scheduled irradiation date in April 2020 and with post irradiation examination (PIE) to follow.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

NASA NTRS1970

Low-temperature radiation-resistant material for ball-bearing retainers

Radiation resistant material, made of polyimide polymers and S-glass cloth, is used in ball bearing retainers for extreme environments. Material displays satisfactory wear resistance, lubricity, and stability. Results of comparative tests with fluorocarbon materials are given.

Desau, P. O.↗

NASA NTRS2014

Hot Hydrogen Testing of Tungsten-Uranium Dioxide (W-UO2) CERMET Fuel Materials for Nuclear Thermal Propulsion

CERMET fuel materials are being developed at the NASA Marshall Space Flight Center for a Nuclear Cryogenic Propulsion Stage. Recent work has resulted in the development and demonstration of a Compact Fuel Element Environmental Test (CFEET) System that is capable of subjecting depleted uranium fuel material samples to hot hydrogen. A critical obstacle to the development of an NCPS engine is the high-cost and safety concerns associated with developmental testing in nuclear environments. The purpose of this testing capability is to enable low-cost screening of candidate materials, fabrication processes, and further validation of concepts. The CERMET samples consist of depleted uranium dioxide (UO2) fuel particles in a tungsten metal matrix, which has been demonstrated on previous programs to provide improved performance and retention of fission products1. Numerous past programs have utilized hot hydrogen furnace testing to develop and evaluate fuel materials. The testing provides a reasonable simulation of temperature and thermal stress effects in a flowing hydrogen environment. Though no information is gained about radiation damage, the furnace testing is extremely valuable for development and verification of fuel element materials and processes. The current work includes testing of subscale W-UO2 slugs to evaluate fuel loss and stability. The materials are then fabricated into samples with seven cooling channels to test a more representative section of a fuel element. Several iterations of testing are being performed to evaluate fuel mass loss impacts from density, microstructure, fuel particle size and shape, chemistry, claddings, particle coatings, and stabilizers. The fuel materials and forms being evaluated on this effort have all been demonstrated to control fuel migration and loss. The objective is to verify performance improvements of the various materials and process options prior to expensive full scale fabrication and testing. Post test analysis will include weight percent fuel loss, microscopy, dimensional tolerance, and fuel stability.

Hickman, Robert↗

NASA NTRS2016

Analog Testing of Operations Concepts for Mitigation of Communication Latency During Human Space Exploration

OBJECTIVES: NASA Extreme Environment Mission Operations (NEEMO) is an underwater spaceflight analog that allows a true mission‐like operational environment and uses buoyancy effects and added weight to simulate different gravity levels. Three missions were undertaken from 2014‐2015, NEEMO's 18‐20. All missions were performed at the Aquarius undersea research habitat. During each mission, the effects of varying operations concepts and tasks type and complexity on representative communication latencies associated with Mars missions were studied. METHODS: 12 subjects (4 per mission) were weighed out to simulate near‐zero or partial gravity extravehicular activity (EVA) and evaluated different operations concepts for integration and management of a simulated Earth‐based science backroom team (SBT) to provide input and direction during exploration activities. Exploration traverses were planned in advance based on precursor data collected. Subjects completed science‐related tasks including presampling surveys, geologic‐based sampling, and marine‐based sampling as a portion of their tasks on saturation dives up to 4 hours in duration that were to simulate extravehicular activity (EVA) on Mars or the moons of Mars. One‐way communication latencies, 5 and 10 minutes between space and mission control, were simulated throughout the missions. Objective data included task completion times, total EVA times, crew idle time, translation time, SBT assimilation time (defined as time available for SBT to discuss data/imagery after it has been collected, in addition to the time taken to watch imagery streaming over latency). Subjective data included acceptability, simulation quality, capability assessment ratings, and comments. RESULTS: Precursor data can be used effectively to plan and execute exploration traverse EVAs (plans included detailed location of science sites, high‐fidelity imagery of the sites, and directions to landmarks of interest within a site). Operations concepts that allow for presampling surveys enable efficient traverse execution and meaningful Mission Control Center (MCC) interaction across long communication latencies and can be done with minimal crew idle time. Imagery and information from the EVA crew that is transmitted real‐time to the intravehicular (IV) crewmember(s) can be used to verify that exploration traverse plans are being executed correctly. That same data can be effectively used by MCC (across comm latency) to provide further instructions to the crew from a SBT on sampling priorities, additional tasks, and changes to the plan. Text / data capabilities are preferred over voice capabilities between MCC and IV when executing exploration traverse plans over communication latency. Autonomous crew planning tools can be effective at modifying existing plans if the objectives and constraints are clearly defined.

Chappell, Steven P.↗

NASA NTRSDate not supplied

Measurement of Material Recession and Shock Standoff in Plasma Windtunnel using Neural Nets

Arcjets are plasma wind tunnels used to test the performance of heatshield materials for spacecraft atmospheric entry. These facilities present an extremely harsh flow environment with heat fluxes up to 109 W/m2 for up to 30 minutes. The plasma is low-temperature (∼1 eV) but high pressure (> 10 kPa) creating high-enthalpy supersonic flows similar to atmospheric entry conditions. Typically, material samples are measured before and after a test to characterize the total recession. However, this does not capture time-dependent effects such as material expansion and non-linear recession. This work will present new analysis of arcjet test videos which measure both the time-dependent 2D recession of the material samples and the shock standoff distance. The results show non-linear time-dependent effects are present for some conditions. The material and shock edges are extracted from the videos by training and applying a convolutional neural network. Due to the consistent camera settings, the machine learning model achieves high accuracy (± 2 px) relative to manually segmented images with only a small number of training frames (80).

Neural network↗

NASA NTRSDate not supplied

Thermal Vacuum and Vibration Testing of the Differential Thermal Expansion Thermal Switch

The Extended Stroke, Reverse Operation, Differential Expansion Thermal Switch for Extreme Variable Environments uses materials with both positive and negative coefficients of thermal expansion (CTE) arranged in concentric cylinders so that the thermal switch (TS) operates passively, opening a gap between interfaces to create a low thermal contact when cold, and closing the gap between interfaces to create a high thermal contact when hot. This paper details the testing of the TS at Marshall Space Flight Center including the pre-vibe thermal vacuum cycle test, vibration test, post-vibe thermal vacuum cycle test, and long duration thermal vacuum cycle test. The pre- and post-vibe thermal cycle and the long duration cycle test tested to hot and cold plateau initial temperatures of 40 °C, and -173 °C, respectively. The pre- and post-vibe tests required plateau holds of at least 2 hours, whereas the long duration cycle test required plateau holds of at least 20 hours. The tests each used a rate of temperature change of < 2 °C/min when transitioning between plateaus. The data collected from each thermal test is compared to show the operation of the TS both before and after the vibration test to GEVS levels, and throughout the long duration cycle test. From the data collected, the total conductance through the TS interfaces is calculated for both on (TS closed – during hot plateau) and off (TS open – during cold plateau) configurations, and the turndown ratio is also calculated. Challenges and lessons learned from the testing are also discussed.

thermal control technology↗

NASA NTRSDate not supplied

Validation of Multisystem Countermeasures Protocol for Spaceflight during Antarctica Winter-over at Palmer Station (Palmer Countermeasures)

Exploration-class missions beyond the Van Allen belt to the Moon and then Mars will begin soon. Low-Earth orbital spaceflight results in the persistent perturbation of the human immune system, characterized by reductions in T and NK cell function, altered cytokine profiles, and the reactivation of latent herpesviruses. While these alterations have not caused widespread clinical issues, some crewmembers experience immune-related adverse events, including manifestations of symptomatic herpes viral reactivation, allergy, and respiratory distress. Because future deep-space exploration missions will be of unprecedented duration, it is reasonable to hypothesize that the immune perturbations observed aboard International Space Station (ISS) will intensify during longer missions in deep space, thereby placing crewmembers at elevated clinical risk. Thus, it is imperative to preserve the immune vigilance of astronauts by developing a countermeasure strategy. Of all the Earth analogs studied to date, an Antarctica winter-over (AWO) mission most closely reproduces the spaceflight experience: prolonged deployment, extreme environment, circadian misalignment, isolation, station lifestyle, and personal risk. The US maintains three primary stations in Antarctica: South Pole Station, McMurdo, and Palmer. Previous studies suggest that stations located near the interior of Antarctica (South Pole, McMurdo) have confounding effects on the immune system due to persistent hypobaric hypoxia. Thus, it was hypothesized that winter-over at a coastal station (Palmer) would be more akin to spaceflight due to its normoxic but still extreme environment. Therefore, AWO at Palmer Station was chosen as the platform for testing and validating the effectiveness of a NASA multi-system countermeasures protocol designed for deep space missions. The array of countermeasure protocols and monitoring methods deployed for each AWO will consist of diet modifications, nutritional supplementation, prescribed aerobic and resistive exercise, and a protocol of stress relieving virtual reality exercises. A multitude of biological sample types, including blood, saliva, and hair will be collected in tandem with the countermeasures in order to examine the combined effectiveness of the countermeasures. Samples and logs from subjects will be transported from Palmer Station to Johnson Space Center for further processing and distribution to co-investigators at the end of each winter-over. Extracted samples will be analyzed by appropriate testing platforms (Multiplex, qPCR, ELISA, etc.) to monitor alterations in leukocyte distribution, T cell and NK function, cytokine profiles, reactivation of latent herpesviruses, and nutritional factors. The data collected will be compared to a control year in which no countermeasures were deployed to evaluate the overall effectiveness of the analog and to validate the candidate immune countermeasure strategy. With the completion of the Antarctica Winter-Over (WO) 2022 control year, samples for 13 subjects have been successfully returned from Antarctica to NASA/JSC for further processing and distribution to Co-Investigators. WO 2023, the first countermeasure year, has also commenced with 11 subject consenting and performing their base line data collections (BDC) held in Chile. Another 5 subjects, who were already stationed at Palmer Station, Antarctica, joined as participates in the investigation. These 5 subjects were consented, but no BDC was able to be collected due to their joining in-mission. Therefore, there will be a total of 16 subjects participating in Antarctica's 2023 Winter-Over.

Cody L Gutierrez↗

NASA NTRSDate not supplied

Multiscale and Multifidelity Modeling of a 3D Woven Composite Thermal Protection System

Complex three-dimensional (3D) woven composites have been considered by multiple NASA projects in recent years as a means of offering improved mechanical and thermal performance over traditional laminated composite systems. Parallel efforts have focused on developing simulation capabilities for these systems, which have traditionally and heavily relied on experimental testing to evaluate composite performance. One system is the Heatshield for Extreme Entry Environment Technology (HEEET), which is being considered for the thermal protection system on reentry spacecraft. Optical microscopy was used to characterize the blended carbon and phenolic fiber tows. A section of HEEET insulation layer was imaged with high-resolution micro-computed tomography (microCT) and segmented to separate individual tows, porous matrix, and voids. These data were used to develop multiscale thermomechanical computational models within the NASA Multiscale Analysis Tool (NASMAT). Two NASMAT modeling approaches were considered to capture the details of the 3D woven architecture: a coarse model appropriate for inclusion in multiscale structural analyses and a high-fidelity model created by downsampling the microCT data. Both elastic and thermal properties were computed and compared. The feasibility and challenges associated with modeling complex, hybrid 3D woven composites were also addressed.

NASMAT↗

NASA NTRS2016

James Webb Space Telescope Integrated Science Instrument Module Thermal Vacuum Thermal Balance Test Campaign at NASA's Goddard Space Flight Center

The James Webb Space Telescope is a large infrared telescope with a 6.5-meter primary mirror, designed as a successor to the Hubble Space Telescope when launched in 2018. Three of the four science instruments contained within the Integrated Science Instrument Module (ISIM) are passively cooled to their operational temperature range of 36K to 40K with radiators, and the fourth instrument is actively cooled to its operational temperature of approximately 6K. Thermal-vacuum testing of the flight science instruments at the ISIM element level has taken place in three separate highly challenging and extremely complex thermal tests within a gaseous helium-cooled shroud inside Goddard Space Flight Centers Space Environment Simulator. Special data acquisition software was developed for these tests to monitor over 1700 flight and test sensor measurements, track over 50 gradients, component rates, and temperature limits in real time against defined constraints and limitations, and guide the complex transition from ambient to final cryogenic temperatures and back. This extremely flexible system has proven highly successful in safeguarding the nearly $2B science payload during the 3.5-month-long thermal tests. Heat flow measurement instrumentation, or Q-meters, were also specially developed for these tests. These devices provide thermal boundaries o the flight hardware while measuring instrument heat loads up to 600 mW with an estimated uncertainty of 2 mW in test, enabling accurate thermal model correlation, hardware design validation, and workmanship verification. The high accuracy heat load measurements provided first evidence of a potentially serious hardware design issue that was subsequently corrected. This paper provides an overview of the ISIM-level thermal-vacuum tests and thermal objectives; explains the thermal test configuration and thermal balances; describes special measurement instrumentation and monitoring and control software; presents key test thermal results; lists problems encountered during testing and lessons learned.

JWST ISIM Thermal↗

NASA NTRSDate not supplied

Measurement of material recession and shock standoff in plasma windtunnel using neural nets

Arcjets are plasma wind tunnels used to test the performance of heatshield materials for spacecraft atmospheric entry. These facilities present an extremely harsh flow environment with heat fluxes up to 10^9 W/m^2 for up to 30 minutes. The plasma is low-temperature (~1 eV) but high pressure (> 10 kPa) creating high-enthalpy supersonic flows similar to atmospheric entry conditions. Typically, material samples are measured before and after a test to characterize the total recession. However, this does not capture time-dependent effects such as material expansion and non-linear recession. This work will present new analysis of arcjet test videos which measure both the time-dependent 2D recession of the material samples and the shock standoff distance. New results showing non-linear material erosion rates will be highlighted. The material and shock edges are extracted from the videos by training and applying a convolutional neural network. Due to the consistent camera settings, the machine learning model achieves high accuracy (~99%) on new data with only a small number of training frames (~80). The new results will be discussed in the context of temperature dependent plasma-surface interaction.

Magnus A Haw↗

NASA NTRSDate not supplied

Powering the Lunar Surface: Managing Dust, Extreme Environments, and Power Needs

Power availability remains one of the primary constraints for lunar surface science. This talk reviews power requirements from previously flown instruments to help prepare future payloads for upcoming CLPS opportunities and highlights the testing and environmental simulation capabilities at NASA JSC that enable reliable lunar payload development. It also outlines the power needs, environmental challenges, and emerging technologies required to support sustained human and robotic operations on the lunar surface as part of NASA’s Moon to Mars strategy. Key challenges include variable solar illumination at polar and equatorial regions, extreme thermal environments, and dust driven degradation that limit current surface power systems. The science data needed for resource identification and landing site planning will allow for the successful preparation of crewed Artemis activities and long-term presence. Building on recent missions, current test infrastructure, and emerging power technology pathways, this presentation equips industry, academia, and government teams with the information needed to design robust lunar payloads, reduce development risk, and fully leverage the increasing cadence of CLPS missions. These developments will form a critical technical foundation for long duration lunar presence and future Mars exploration.

Anastasia Ford↗

NASA NTRSDate not supplied

Powering the Lunar Surface: Managing Dust, Extreme Environments, and Power Needs

lunar power↗

NASA NTRS2000

Comparison of Dynamic Characteristics for an Inflatable Solar Concentrator in Atmospheric and Thermal Vacuum Conditions

Dynamic testing of an inflatable solar concentrator structure in a thermal vacuum chamber as well as in ambient laboratory conditions is described in detail. Unique aspects of modal testing for the extremely lightweight inflatable are identified, including the use of a noncontacting laser vibrometer measurement system. For the thermal vacuum environment, mode shapes and frequency response functions are compared for three different test article inflation pressures at room temperature. Modes that persist through all the inflation pressure regimes are identified, as well as modes that are unique for each pressure. In atmospheric pressure and room temperature conditions, dynamic measurements were obtained for the expected operational inflation pressure of 0.5 psig. Experimental mode shapes and frequency response functions for ambient conditions are described and compared to the 0.5 psig results from the thermal vacuum tests. Only a few mode shapes were identified that occurred in both vacuum and atmospheric environments. This somewhat surprising result is discussed in detail, and attributed at least partly to 1.) large differences in modal damping, and 2.) significant differences in the mass of air contained by the structure, in the two environments. Results of this investigation point out the necessity of testing inflatable space structures in vacuum conditions before they can be launched. Ground testing in atmospheric pressure is not sufficient for predicting on-orbit dynamics of non-rigidized inflatable systems.

Slade, Kara N.↗