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Airtight housing encloses laser for easy alinement and operation in high-vacuum chamber. Beam is transmitted through window into vacuum chamber. Flexible line runs through vacuum chamber to outside, maintaining laser enclosure at atmospheric pressure.
The paper describes a thermal-vacuum space simulator used to assess property changes of fiber-reinforced polymer composite systems. The facility can achieve a vacuum of approximately .0000001 torr with temperatures ranging from -200 to +300 F. Some preliminary experimental results are presented for materials subjected to thermal loading up to 200 F. The tests conducted include the evaluation of matrix modulus and strength, coefficients of thermal expansion, and fracture toughness. Though the experimental program is at an early stage, the data appear to indicate that these parameters are influenced by hard vacuum.
Several vacuum applications of copper foams in the density range 2-5% and pore sizes of 0.5-0.7 mm are discussed, such as a foreline hydrocarbon trap in a mechanical vacuum pump, a molecular-flow resistor, a diffuser, and a water injector. Other suggested applications include the use of foam copper in the form of an externally heated plug to remove traces of oxygen from inert gases bled into a vacuum system through a stainless steel line and the use of the porous surface for minimizing release of secondary electrons from electrodes in the path of charged particle beams.
The solar array drive assemblies for the global positioning satellite (GPS) were built and the need to perform thermal vacuum acceptance testing on at least two complete units simultaneously is emphasized. The safety of the flight hardware is of primary importance. It is found that simultaneous space simulation testing of two complete drive packages requires only minor modification to the high vacuum pump stack. Attention is given to upgrading system safeties for high vacuum operation. Major modifications are designed and implemented for the thermal control system and supporting subsystems. The automated thermal control system and test bed hardware are of primary interest.
Molecular-beam epitaxy and other processes tested with minimal contamination. Vacuum experimental facility for outer space creates vacuums higher than those available in terrestrial vacuum chambers. Facility minimizes contamination of work from walls and allows rapid removal of gases and heat generated by experimental processes. Used for processes such as molecular-beam epitaxy (growing semiconductor superlattices), metal/organic chemical vapor deposition, coating mirrors and other optical components, and ultrapurification.
Vacuum metal-organic-chemical-vapor-deposition (MOCVD) is a new fabrication process with improved safety and easier scalability due to its metal rather than glass construction and its uniform multiport gas injection system. It uses source materials more efficiently than other methods because the vacuum molecular flow conditions allow the high sticking coefficient reactants to reach the substrates as undeflected molecular beams and the hot chamber walls cause the low sticking coefficient reactants to bounce off the walls and interact with the substrates many times. This high source utilization reduces the materials costs power device and substantially decreases the amounts of toxic materials that must be handled as process effluents. The molecular beams allow precise growth control. With improved source purifications, vacuum MOCVD has provided p GaAs layers with 10-micron minority carrier diffusion lengths and GaAs and GaAsSb solar cells with 20% AMO efficiencies at 59X and 99X sunlight concentration ratios. Mechanical stacking has been identified as the quickest, most direct and logical path to stacked multiple-junction solar cells that perform better than the best single-junction devices. The mechanical stack is configured for immediate use in solar arrays and allows interconnections that improve the system end-of-life performance in space.
In order to determine the influence of ductility on the fatigue crack growth rate of aluminum alloys, fatigue tests were carried out on central notched specimens of 2024-T3 and 2024-T8 sheet material. The 2024-T8 material was obtained by an additional heat treatment applied on 2024-T3 (18 hours at 192 C), which increased the static yield strength from 43.6 to 48.9 kgf/sq mm. A change in the ultimate strength was not observed. Fatigue tests were carried out on both materials in humid air and in high vacuum. According to a new crack propagation model, crack extension is supported to be caused by a slip-related process and debonding triggered by the environment. This model predicts an effect of the ductility on the crack growth rate which should be smaller in vacuum than in humid air; however, this was not confirmed. In humid air the crack-growth rate in 2024-T8 was about 2 times faster than in 2024-T3, while in vacuum the ratio was about 2.5. Crack closure measurements gave no indications that crack closure played a significant role in both materials. Some speculative explanations are briefly discussed.
Thermal control and vacuum sealing achieved while contamination avoided. Simple, relatively inexpensive molecular-hydrogen dissociator for atomic-hydrogen masers used on Earth or in vacuum of space. No air cooling required, and absence of elastomeric O-ring seals prevents contamination. In-vacuum dissociator for atomic hydrogen masers, hydrogen gas in glass dissociator dissociated by radio-frequency signal transmitted from surrounding 3-turn coil. Heat in glass conducted away by contacting metal surfaces.
In improved furnace concept for heat-treating thin films, vacuum ports in vacuum plate(s) hold films connected together in zones so vacuum applied separately to each zone. Allows material being held to shrink or expand while still being held in place. Unclamped zones expand or contract , relieving local stresses so entire sheet accommades thermally induced changes without cracking. Applications include manufacture of thin semiconductor films for solar cells and of membranes for electrolytic production of oxygen.
A form of sulfur that is white at room temperature and very fluffy in texture has been found in laboratory experiments on the effects of vacuum sublimation (evaporation) on solid sulfur. This work is an outgrowth of proton sputtering experiments on sulfur directed toward understanding Jovian magnetospheric effects on the surface of Io. Fluffy white sulfur is formed on the surface of solid yellow, tan, or brown sulfur melt freezes in vacuum by differential (fractional) evaporation of two or more sulfur molecular species present in the original sulfur; S(8) ring sulfur is thought to be the dominant sublimination phase lost to the vacuum sink, and polymeric chain sulfur S(u) the dominant residual phase that remains in place, forming the residual fluffy surface layer. The reflectance spectrum of the original sulfur surface is greaty modified by formation of the fluffy layer: the blue absorption band-edge and shoulder move 0.05 to 0.06 microns toward shorter wavelengths resulting in a permanent increase in reflectivity near 0.42 to 0.46 microns; the UV reflectivity below 0.40 microns is reduced. This form of sulfur should exist in large quantity on the surface of Io, especially in hotspot regions if there is solid free sulfur there that has solidified from a melt. Its color and spectra will indicate relative crystallization age on a scale of days to months and/or surface temperature distribution history.
Vacuum sublimation effects on solid sulfur yield a form of the element that is white at room temperature, is fluffy in texture, and forms on frozen sulfur in vacuum through differential evaporation of molecular species in the solid. This vacuum sulfur should exist in large quantity on Io, if the solid free sulfur there has solidified from a melt; a sulfur volcanism model for Io is accordingly developed on this basis which implies that the color and spectra of different sulfur regions of Io could indicate their relative crystallization ages and cooling histories. The flux of sublimating hotspot sulfur appears consistent with estimated turnover rates of the Io surface.
Report describes tests of lubricating properties of 10 polymer-based materials - in particular, polyimides - in vacuum. Commercially available materials, in forms of solid bodies and films on metals, were tested on pin-on-disk apparatus in vacuum. Best low-wear, low-friction material was 80 PMDA/20 BTDA solid-body polyimide. Friction and wear properties of most polyimides so good in vacuum that solid-lubricant additives not necessary.
Coatings are presently applied to Space Shuttle Main Engine (SSME) turbine blades for protection against the harsh environment realized in the engine during lift off-to-orbit. High performance nickel, chromium, aluminum, and yttrium (NiCrAlY) alloy coatings, which are applied by atmospheric plasma spraying, crack and spall off because of the severe thermal shock experienced during start-up and shut-down of the engine. Ceramic coatings of yttria stabilized zirconia (ZrO2-Y2O3) were applied initially as a thermal barrier over coating to the NiCrAlY but were removed because of even greater spalling. Utilizing a vacuum plasma spraying process, bond coatings of NiCrAlY were applied in a low pressure atmosphere of argon/helium, producing significantly improved coating-to-blade bonding. The improved coatings showed no spalling after 40 MSFC burner rig thermal shock cycles, cycling between 1700 and -423 F. The current atmospheric plasma NiCrAlY coatings spalled during 25 test cycles. Subsequently, a process was developed for applying a durable thermal barrier coating of ZrO2-Y2O3 to the turbine blades of first stage high-pressure fuel turbopumps utilizing the vacuum plasma process. The improved thermal barrier coating has successfully passed 40 burner rig thermal shock cycles without spalling. Hot firing in an SSME turbine engine is scheduled for the blades. Tooling was installed in preparation for vacuum plasma spray coating other SSME hardware, e.g., the titanium main fuel valve housing (MFVH) and the fuel turbopump nozzle/stator.
The use of vacuum resources is integral to a number of proposed concepts for gas disposal from Space Staton Freedom. These include both direct overboard venting and onboard collection and storage of waste gases. A methodology is presented for determining flowrates through proposed vacuum lines. The flowrates through overboard vents are used to calculate number column densities, which are compared with current Freedom program requirements. The results are combined with discussions about the relative merits of some proposed and alternate concepts for providing vacuum resources.
The mass losses and the outgassing rates per unit area of three thermal blankets consisting of various combinations of Mylar and Kapton, with interposed Dacron nets, were measured with a microbalance using two methods. The blankets at 25 deg C were either outgassed in vacuum for 20 hours, or were purged with a dry nitrogen flow of 3 cu. ft. per hour at 25 deg C for 20 hours. The two methods were compared for their effectiveness in cleaning the blankets for their use in space applications. The measurements were carried out using blanket strips and rolled-up blanket samples fitting the microbalance cylindrical plenum. Also, temperature scanning tests were carried out to indicate the optimum temperature for purging and vacuum cleaning. The data indicate that the purging for 20 hours with the above N2 flow can accomplish the same level of cleaning provided by the vacuum with the blankets at 25 deg C for 20 hours, In both cases, the rate of outgassing after 20 hours is reduced by 3 orders of magnitude, and the weight losses are in the range of 10E-4 gr/sq cm. Equivalent mass loss time constants, regained mass in air as a function of time, and other parameters were obtained for those blankets.
The construction of a turnkey cryogenic vacuum test facility was recently completed. The facility will be used to measure and record the surface profile of large diameter and 540 kg optics under simulated space conditions. The vacuum test chamber is a vertical stainless steel cylinder with a 3.5 diameter and a 7 m tangent length. The chamber was designed to maximize optical testing quality by minimizing the vibrations between the laser interferometer and the test specimen. This was accomplished by designing the chamber for a high natural frequency and vibration isolating the chamber. An optical test specimen is mounted on a movable presentation stage. During thermal vacuum testing, the specimen may be positioned to + or - 0.00025 cm accuracy with a fine adjustment mechanism. The chamber is evacuated by a close coupled Roots-type blower and rotary vane pump package and two cryopumps. The chamber is equipped with an optically dense gaseous nitrogen cooled thermal shroud. The thermal shroud is used to cool or warm the optical test specimen at a controlled rate. A control system is provided to automatically evacuate the chamber and cooldown the test specimen to the selected control temperature.
A systems level mechanisms test was conducted on the Orbital Sciences Corp.'s Transfer Orbit Stage (TOS). The TOS is a unique partially reusable transfer vehicle which will boost a satellite into its operational orbit from the Space Shuttle's cargo bay. The mechanical cradle and tilt assemblies will return to earth with the Space Shuttle while the Solid Rocket Motor (SRM) and avionics package are expended. A mechanisms test was performed on the forward cradle and aft tilting assemblies of the TOS under thermal vacuum conditions. Actuating these assemblies under a 1 g environment and thermal vacuum conditions proved to be a complex task. Pneumatic test fixturing was used to lift the forward cradle, and tilt the SRM, and avionics package. Clinometers, linear voltage displacement transducers, and load cells were used in the thermal vacuum chamber to measure the performance and characteristics of the TOS mechanism assembly. Incorporation of the instrumentation and pneumatic system into the test setup was not routine since pneumatic actuation of flight hardware had not been previously performed in the facility. The methods used are presented along with the problems experienced during the design, setup and test phases.
The National Space Exploration Initiative, specifically the Lunar component, has major requirements for technology development of critical systems, one of which is electrical power. The availability of significant electrical power on the surface of the Moon is a principal driver defining the complexity of the lunar base. Proposals to generate power on the Moon include both nuclear and solar (photovoltaic) systems. A more efficient approach is to attempt utilization of the existing lunar resources to generate the power systems. Synergism may occur from the fact that there have already been lunar materials processing techniques proposed for the extraction of oxygen that would have, as by-products, materials that could be specifically used to generate solar cells. The lunar environment is a vacuum with pressures generally in the 1 x 10(exp -10) torr range. Such conditions provide an ideal environment for direct vacuum deposition of thin film solar cells using the waste silicon, iron, and TiO2 available from the lunar regolith processing meant to extract oxygen. It is proposed, therefore, to grow by vacuum deposition, thin film silicon solar cells from the improved regolith processing by-products.