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The development and characteristics of flame resistant polymers and composite materials for use in spacecraft structures are discussed. The requirement for the material to be nonflammable in the oxygen enriched atmosphere of the spacecraft is examined. The properties of various materials are tabulated and compared. Specific applications of various materials are presented.
In our NIAC Phase I study, awarded September 2011, the MIT Space Systems Lab (MIT SSL) began investigating a new structural and mechanical technique aimed at reducing the mass and increasing the stowed-to-deployed ratio of spacecraft systems. This technique uses the magnetic fields from current passing through coils of high temperature superconductors (HTSs) to support spacecraft structures and deploy them to operational configurations from their positions as stowed inside a launch vehicle fairing. These electromagnetic coils are tethered or hinged together in such a way that their motion in some directions or around some axes is constrained, as in Figure 1. Our Phase II study,awarded in Fall 2012, continued this work on electromagnetic structures, with an added focus on developing a new thermal system, investigating additional, non-structural electromagnet functions, and creating a maturation roadmap and plan for addressing barriers to feasibility of the technology. We now call the project MAGESTIC, or Magnetically Enabled STructures using Interacting Coils.
Lockheed Martin Skunk Works, is taking the next step towards economical low-Earth-orbit (LEO) operations with NASA's X-33 technology demonstrator, that uses composite tanks for liquid hydrogen (LH sub2) fuel storage and structural support, The X-33 is a 53% scale model of the VentureStar single-stage-to-orbit (SSTO) reusable launch vehicle(RLV) projected to orbit payloads at a rate, of $1,000 per pound beginning in 2004 In order to make VentureStar completely reusable and economical engineers are using composite materials throughout the spacecrafts structure. The first test of the design comes in 1999 on the X-33 technology demonstrator. Two of the primary structures that engineers will be evaluating are the carbon fiber/epoxy LH2 fuel tanks. The 29-ft long by 18-ft wide tanks, which fill two-thirds of the X-33's interior, serve a dual purpose carrying fuel and providing structural support to the walls of the spacecraft. Fiber placement makes it possible to build the fuel tanks, large, light and strong enough to satisfy X33's requirements. Lockheed Martin choose the fabrication technology to produce the eight sections of each tank because of fiber placement's ability to handle complex surfaces, speed and repeatability.
Spacecraft designs are driven by the payloads and mission requirements that they support. Many of the payload characteristics, such as mass, power requirements, communication requirements, moving parts, and so forth directly affect the choices for the spacecraft structural configuration and its subsystem design and component selection. The conceptual design process, which translates mission requirements into early spacecraft concepts, must be tolerant of frequent changes in the payload complement and resource requirements. A computer data base was designed and implemented for the purposes of containing the payload characteristics pertinent for spacecraft conceptual design, tracking the evolution of these payloads over time, and enabling the integration of the payload data with engineering analysis programs for improving the efficiency in producing spacecraft designs. In-house tools were used for constructing the data base and for performing the actual integration with an existing program for optimizing payload mass locations on the spacecraft.
Increased application of polymer matrix composite (PMC) materials in large vehicle structures requires consideration of non-autoclave manufacturing technology. The NASA Composites for Exploration project, and its predecessor, Lightweight Spacecraft Structures and Materials project, were tasked with the development of materials and manufacturing processes for structures that will perform in a heavy-lift-launch vehicle environment. Both autoclave and out of autoclave processable materials were considered. Large PMC structures envisioned for such a vehicle included the payload shroud and the interstage connector. In this study, composite sandwich panels representing 1/16th segments of the barrel section of the Ares V rocket fairing were prepared as 1.8 m x 2.4 m sections of the 10 m diameter arc segment. IM7/977-3 was used as the face-sheet prepreg of the autoclave processed panels and T40-800B/5320-1 for the out of autoclave panels. The core was 49.7 kilograms per square meters (3.1 pounds per cubic feet (pcf)) aluminum honeycomb. Face-sheets were fabricated by automated tape laying 153 mm wide unidirectional tape. This work details analysis of the manufactured panels where face-sheet quality was characterized by optical microscopy, cured ply thickness measurements, acid digestion, and thermal analysis.
Increased application of polymer matrix composite (PMC) materials in large vehicle structures requires consideration of non-autoclave manufacturing technology. The NASA Composites for Exploration project, and its predecessor, Lightweight Spacecraft Structures and Materials project, were tasked with the development of materials and manufacturing processes for structures that will perform in a heavy-lift-launch vehicle environment. Both autoclave and out of autoclave processable materials were considered. Large PMC structures envisioned for such a vehicle included the payload shroud and the interstage connector. In this study, composite sandwich panels representing 1/16th segments of the barrel section of the Ares V rocket fairing were prepared as 1.8 m x 2.4 m sections of the 10 m diameter arc segment. IM7/977-3 was used as the face-sheet prepreg of the autoclave processed panels and T40-800B/5320-1 for the out of autoclave panels. The core was 49.7 kg/sq m (3.1 lb/cu ft (pcf)) aluminum honeycomb. Face-sheets were fabricated by automated tape laying 153 mm wide unidirectional tape. This work details analysis of the manufactured panels where face-sheet quality was characterized by optical microscopy, cured ply thickness measurements, acid digestion, and thermal analysis.
As the optical performance requirements of space telescopes get more stringent, the need to analyze all possible error sources early in the mission design becomes critical. One large telescope with tight performance requirements is the Large Ultraviolet / Optical / Infrared Surveyor (LUVOIR) concept. The LUVOIR concept includes a 15-meter-diameter segmented-aperture telescope with a suite of serviceable instruments operating over a range of wavelengths between 100nm to 2.5um. Using an isolation architecture that involves no mechanical contact between the telescope and the host spacecraft structure allows for tighter performance metrics than current space-based telescopes being flown. Because of this separation, the spacecraft disturbances can be greatly reduced and disturbances on the telescope payload contribute more to the optical performance error. A portion of the optical performance error comes from the disturbances generated from the motion of the Fast Steering Mirror (FSM) on the payload. Characterizing the effects of this disturbance gives insight into the specifications on the FSM needed to achieve the tight optical performance requirements of the overall system. Through analysis of the LUVOIR finite element model and linear optical model given a range of input disturbances at the FSM, the optical performance of the telescope and recommendations for FSM specifications can be determined. The LUVOIR observatory control strategy consists of a multi-loop control architecture including the spacecraft Attitude Control System (ACS), Vibration Isolation and Precision Pointing System (VIPPS), and FSM. This paper focuses on the control loop containing the FSM disturbances and their effects on the telescope optical performance.
A proposed family of devices for inducing fatigue in bolts in order to break the bolts would incorporate piezoelectric actuators into resonant fixtures as in ultrasonic/ sonic drills/corers and similar devices described in numerous prior NASA Tech Briefs articles. These devices were originally intended primarily for use as safer, more-reliable, more-versatile alternatives to explosive bolts heretofore used to fasten spacecraft structures that must subsequently be separated from each other quickly on command during flight. On Earth, these devices could be used for accelerated fatigue testing of bolts. Fatigue theory suggests that a bolt subjected to both a constant-amplitude dynamic (that is, oscillatory) stress and a static tensile stress below the ultimate strength of the bolt material will fail faster than will a bolt subjected to only the dynamic stress. This suggestion would be applied in a device of the proposed type. The device would be designed so that the device and the bolt to be fatigue-tested or broken would be integral parts of an assembly (see figure). The static tension in the tightened bolt would apply not only the clamping force to hold the joined structures (if any) together but also the compression necessary for proper operation of the piezoelectric actuators as parts of a resonant structural assembly. The constant-amplitude dynamic stress would be applied to the bolt by driving the piezoelectric actuators with a sinusoidal voltage at the resonance frequency of longitudinal vibration of the assembly. The amplitude of the excitation would be made large enough so that the vibration would induce fatigue in the bolt within an acceptably short time. In the spacecraft applications or in similar terrestrial structural-separation applications, devices of the proposed type would offer several advantages over explosive bolts: Unlike explosive bolts, the proposed devices would be reusable, could be tested before final use, and would not be subject to catastrophic misfire. In fatigue-testing applications, devices of the proposed type would offer advantages of compactness and low cost, relative to conventional fatigue- testing apparatuses. In both structural- separation and fatigue-testing applications, bolts to be broken or tested could be instrumented with additional ultrasonic transducers for monitoring of pertinent physical properties and of fatigue failure processes.
Nuclear-electric spacecraft configurations for Jupiter mission discussing radiation shielding, heat rejection radiator, spacecraft structure, etc
For the future space systems, on-orbit identification (ID) capability will be required to complement on-orbit control, due to the fact that the dynamics of large space structures, spacecrafts, and antennas will not be known sufficiently from ground modeling and testing. The computational requirements for ID of flexible structures such as the space station (SS) or the large deployable reflectors (LDR) are however, extensive due to the large number of modes, sensors, and actuators. For these systems the ID algorithm operations need not be computed in real-time, only in near real-time, or an appropriate mission time. Consequently the space systems will need advanced processors and efficient parallel processing algorithm design and architectures to implement the identification algorithms in near real-time. The MAX computer currently being developed may handle such computational requirements. The purpose is to specify the on-board computational requirements for dynamic and static identification for large space structures. The computational requirements for six ID algorithms are presented in the context of three examples: the JPL/AFAL ground antenna facility, the space station (SS), and the large deployable reflector (LDR).
A series of seven gravity-gradient dynamics experiments is proposed utilizing the Radio Astronomy Explorer (RAE-B) spacecraft in lunar orbit. It is believed that none of the experiments will impair the spacecraft structure or adversely affect the continuation of the scientific mission of the satellite. The first experiment is designed to investigate the spacecraft dynamical behavior in the absence of libration damper action and inertia. It requires stable gravity-gradient capture of the spacecraft in lunar orbit with small amplitude attitude librations as a prerequisite. Four subsequent experiments involve partial retraction, ultimately followed by full redeployment, of one or two of the 230-meter booms forming the lunar-directed Vee-antenna. These boom length change operations will induce moderate amplitude angular librations of the spacecraft.
Interplanetary spacecraft are exposed to meteoroid fluxes with characteristics far exceeding the physical simulation capabilities of test facilities for predicting the likelihood that a meteoroid will penetrate a spacecraft’s critical systems. Accurate risk predictions are crucial to ensuring that important interplanetary missions, such as sample returns, can survive years of exposure to the meteoroid environment and safely reenter the Earth’s atmosphere with their scientific cargo. In this paper, we summarize a series of meteoroid impact damage computational simulations into two types of spacecraft composite protective structures using the Smooth Particle Hydrodynamics Code. We consider the effects of both meteoric materials and non-meteoric materials on a shielded forebody thermal protection system (TPS) for an extreme entry environment and on an unshielded aftbody TPS that is similar to the material covering the space shuttle’s external tank.
Spacecraft structures such as antennas, solar arrays and radiator panels significantly respond to high acoustic levels seen at lift-off. Some future spacecraft may utilize nuclear electric propulsion that require large radiator panels to reject waste heat. A vibroacoustic assessment was performed for two different radiator panel designs. Results from the analysis of the two designs using different analytical approaches are presented and discussed.
Metallic foams are a relatively new class of materials with low density and novel physical, mechanical, thermal, electrical and acoustic properties. Although incompletely characterized, they offer comparable mechanical performance to traditional spacecraft structural materials (i.e. honeycomb sandwich panels) without detrimental through-thickness channeling cells. There are two competing types of metallic foams: open cell and closed cell. Open cell foams are considered the more promising technology due to their lower weight and higher degree of homogeneity. Leading micrometeoroid and orbital debris shields (MMOD) incorporate thin plates separated by a void space (i.e. Whipple shield). Inclusion of intermediate fabric layers, or multiple bumper plates have led to significant performance enhancements, yet these shields require additional non-ballistic mass for installation (fasteners, supports, etc.) that can consume up to 35% of the total shield weight [1]. Structural panels, such as open cell foam core sandwich panels, that are also capable of providing sufficient MMOD protection, represent a significant potential for increased efficiency in hypervelocity impact shielding from a systems perspective through a reduction in required non-ballistic mass. In this paper, the results of an extensive impact test program on aluminum foam core sandwich panels are reported. The effect of pore density, and core thickness on shielding performance have been evaluated over impact velocities ranging from 2.2 - 9.3 km/s at various angles. A number of additional tests on alternate sandwich panel configurations of comparable-weight have also been performed, including aluminum honeycomb sandwich panels (see Figure 1), Nomex honeycomb core sandwich panels, and 3D aluminum honeycomb sandwich panels. A total of 70 hypervelocity impact tests are reported, from which an empirical ballistic limit equation (BLE) has been derived. The BLE is in the standard form suitable for implementation in risk analysis software, and includes the effect of panel thickness, core density, and facesheet material properties. A comparison between the shielding performance of foam core sandwich panel structures and common MMOD shielding configurations is made for both conservative (additional 35% non-ballistic mass) and optimistic (additional mass equal to 30% of bumper mass) considerations. Suggestions to improve the shielding performance of foam core sandwich panels are made, including the use of outer mesh layers, intermediate fabric/composite layers, and varying pore density.
Anodized aluminum samples representative of Space Station Freedom structural material were tested for electrical breakdown under space plasma conditions. In space, this potential arises across the insulating anodized coating when the spacecraft structure is driven to a negative bias relative to the external plasma potential due to plasma-surface interaction phenomena. For anodized materials used in the tests, it was found that breakdown voltage varied from 100 to 2000 volts depending on the sample. The current in the arcs depended on the sample, the capacitor, and the voltage. The level of the arc currents varied from 60 to 1000 amperes. The plasma number density varied from 3 x 10 exp 6 to 10 exp 3 ions per cc. The time between arcs increased as the number density was lowered. Corona testing of anodized samples revealed that samples with higher corona inception voltage had higher arcing inception voltages. From this it is concluded that corona testing may provide a method of screening the samples.
The FLUKA nuclear transport and reaction code can be developed into a practical tool for calculation of spacecraft and planetary surface asset SEE and TID environments. Nuclear reactions and secondary particle shower effects can be estimated with acceptable accuracy both in-flight and in test. More detailed electronic device and/or spacecraft geometries than are reported here are possible using standard FLUKA geometry utilities. Spacecraft structure and shielding mass. Effects of high Z elements in microelectronic structure as reported previously. Median shielding mass in a generic slab or concentric sphere target geometry are at least approximately applicable to more complex spacecraft shapes. Need the spacecraft shielding mass distribution function applicable to the microelectronic system of interest. SEE environment effects can be calculated for a wide range of spacecraft and microelectronic materials with complete nuclear physics. Evaluate benefits of low Z shielding mass can be evaluated relative to aluminum. Evaluate effects of high Z elements as constituents of microelectronic devices. The principal limitation on the accuracy of the FLUKA based method reported here are found in the limited accuracy and incomplete character of affordable heavy ion test data. To support accurate rate estimates with any calculation method, the aspect ratio of the sensitive volume(s) and the dependence must be better characterized.
The Taurus Lightweight Manned Spacecraft (LMS) was developed by students of the University of Maryland's Aerospace Engineering course in Space Vehicle Design. That course required students to design an Alternative Manned Spacecraft (AMS) to augment or replace the Space Transportation System and meet the following design requirements: (1) launch on the Taurus Booster being developed by Orbital Sciences Corporation; (2) 99.9 percent assured crew survival rate; (3) technology cutoff data of 1 Jan. 1991; (4) compatibility with current space administration infrastructure; and (5) first flight by May 1995. The Taurus LMS design meets the above requirements and represents an initial step towards larger and more complex spacecraft. The Taurus LMS has a very limited application when compared to the Space Shuttle, but it demonstrates that the U.S. can have a safe, reliable, and low cost space system. The Taurus LMS is a short mission duration spacecraft designed to place one man into low earth orbit (LEO). The driving factor for this design was the low payload carrying capabilities of the Taurus Booster--1300 kg to a 300 km orbit. The Taurus LMS design is divided into six major design sections. The human factors system deals with the problems of life support and spacecraft cooling. The propulsion section contains the abort system, the Orbital Maneuvering System (OMS), the Reaction Control System (RCS), and power generation. The thermal protection systems and spacecraft structure are contained in the structures section. The avionics section includes navigation, attitude determination, data processing, communication systems, and sensors. The mission analysis section was responsible for ground processing and spacecraft astrodynamics. The systems integration section pulled the above sections together into one spacecraft and addressed costing and reliability.
The Taurus Lightweight Manned Spacecraft (LMS) was developed by students of the University of Maryland's Aerospace Engineering course in Space Vehicle Design. That course required students to design an Alternative Manned Spacecraft (AMS) to augment or replace the Space Transportation System and meet the following design requirements: (1) launch on the Taurus Booster being developed by Orbital Sciences Corporation; (2) 99.9 percent assured crew survival rate; (3) technology cutoff date of 1 Jan. 1991; (4) compatibility with current space administration infrastructure; and (5) first flight by May 1995. The Taurus LMS design meets the above requirements and represents an initial step toward larger and more complex spacecraft. The Taurus LMS has a very limited application when compared to the space shuttle, but it demonstrates that the U.S. can have a safe, reliable, and low-cost space system. The Taurus LMS is a short mission duration spacecraft designed to place one man into low Earth orbit (LEO). The driving factor for this design was the low payload carrying capabilities of the Taurus Booster - 1300 kg to a 300-km orbit. The Taurus LMS design is divided into six major design sections. The Human Factors section deals with the problems of life support and spacecraft cooling. The Propulsion section contains the Abort System, the Orbital Maneuvering System (OMS), the Reaction Control System (RCS), and Power Generation. The thermal protection systems and spacecraft structure are contained in the Structures section. The Avionics section includes Navigation, Attitude Determination, Data Processing, Communication systems, and Sensors. The Mission Analysis section was responsible for ground processing and spacecraft astrodynamics. The Systems Integration Section pulled the above sections together into one spacecraft, and addressed costing and reliability.