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NASA NTRS2018

Creating the Required Deep Space Environments for Testing the James Webb Space Telescope (JWST) at NASA Johnson Space Center's Chamber A

NASA is the mission lead for the James Webb Space Telescope (JWST), the next of the "Great Observatories", scheduled for launch in 2021. NASA was directly responsible for the integration and test (I&T) program that culminated in an end-to-end cryo vacuum optical test of the flight telescope and instrument module in Chamber A at NASA Johnson Space Center. Historic Chamber A is the largest thermal vacuum chamber at Johnson Space Center and one of the largest space simulation chambers in the world. Chamber A has undergone a major modernization effort to support the deep cryogenic, vacuum and cleanliness requirements for testing the JWST. This paper will discuss the thermal vacuum test of the Optical Telescope Element (OTE) plus Integrated Science Instrument Module (ISIM) (OTIS) as well as the extensive series of tests that were performed to incrementally validate the operations and performance of the Chamber and Ground Support Equipment (GSE). Each test required a unique thermal vacuum profile for cool down and warm up, steady state operations, GSE testing and contamination control. Select results will be presented on Facility Functional Testing, Chamber Bake-out, GSE Cryo-Proof Testing, Chamber Commissioning, the Optical Ground Support Equipment (OGSE) Test series and the final thermal vacuum test of the OTIS with respect to facility operations to meet JWST program test requirements.

Francis, Andrew↗

NASA NTRSDate not supplied

Analytical Review of Exploration Extravehicular Mobility Unit Heat Rejection Performance

The Primary Thermal Control Loop (PTCL) in the Exploration Extravehicular Mobility Unit (xEMU) uses a Spacesuit Water Membrane Evaporator (SWME) to provide cooling for the crew member and spacesuit avionics. A secondary emergency cooling system, the Auxiliary Thermal Control Loop (ATCL), also uses a smaller version of the SWME, called the Mini-ME, in the event of a failure in the primary system. These are integral to the comfort of the crew member (through heat rejection) during an Extravehicular Activity (EVA). This paper examines the effectiveness of the heat rejection of the PTCL and the ATCL during thermal vacuum testing and the absolute limit of heat rejection to maintain an approximately 10C outlet temperature. During this thermal vacuum test, the PTCL was taken from a heat input of 0W up to 900W, far past the design point, and the ATCL was tested from 0W to 300W. Testing showed that the PTCL and the ATCL can maintain crew member outlet temperature throughout an entire 8-hour thermally controlled EVA environment (hot and cold). The results and effectiveness of the test will be detailed throughout this paper for all EVAs (whether a full mapping profile or a standard continuous heat load).

PLSS↗

NASA NTRS1972

Predicting and analyzing the thermal flux incident on test articles in a simulated space environment

The increase in importance and sophistication of thermal-vacuum testing has accentuated the problem of defining the environment to which the test article was subjected. An adequate definition of the test environment is essential to the verification of test-article thermal models. The technique used for defining the test environment at the NASA Manned Spacecraft Center Space Environment Simulation Laboratory and its application during a recent major thermal-vacuum testing program is discussed.

Wallin, S. P.↗

NASA NTRSDate not supplied

Dual Glovebox Thermal Vacuum Chamber: Testing Capabilities for Spacesuit Arms and Gloves

The development of Extravehicular Activity (EVA) suits and hand mobility EVA tasks are complex, high risk, and difficult to test in a simulated space environment. During the early assembly of the International Space Station, the Crew and Thermal Systems Division’s Systems Test Branch at NASA JSC was tasked to design a chamber that could use two Extravehicular Mobility Unit (EMU) arms in a simulated space environment versus testing with a full suit. The Dual Glove Box (DGB) Chamber was built and served to help develop EVA tools and operations to assist with Return to Flight for the Space Shuttle after the Columbia accident. With the recent development of the Exploration Extravehicular Mobility Unit (xEMU) and new commercial suits through the Extravehicular Activities Services (xEVAS) contract, the DGB can support the need to do suit component testing at thermal extremes and EVA operations without the cost of full suit testing. The DGB can simulate realistic delta pressures, vacuum down to 10^-5 Torr with roughing and cryogenic pumps, and a wide range of shroud temperatures achieved via a combination of Liquid Nitrogen (LN2), conditioned Gaseous Nitrogen (GN2), and Infrared (IR) lamps. Recent developmental work has verified operational status of the chamber and expanded the capabilities of the DGB to include thermal contact testing of suit gloves through the development of 2 temperature-controlled grab bars. This paper will discuss the history and capabilities of the DGB, and the chamber’s future role in the development of new spacesuit systems.

Kaixin Cui↗

NASA NTRS1972

Preparation, verification, and operational control of a large space-environment-simulation chamber for contamination sensitive tests

A 2-year program to prepare chamber A at the NASA Manned Spacecraft Center for Apollo telescope mount thermal-vacuum tests is discussed. This program covers modification to existing chamber systems, the development of facility and chamber operating procedures, the selection of chamber cleaning and control methods, and the development and evaluation of diagnostic instrumentation. Extensive efforts to ensure a minimum contamination environment for the Apollo telescope mount test series are illustrated. Recent thermal-vacuum tests of this chamber at progressive stages of cleanliness have demonstrated the success achieved in reducing the particulate and molecular contamination levels of the basic chamber interior.

Visentine, J. T.↗

NASA NTRS2008

Overview of the Orion Vibroacoustic Test Capability at NASA Glenn Research Center

In order to support the environmental test needs for our new Orion and Constellation program, NASA is developing unique world-class test facilities. To optimize this testing of spaceflight hardware while minimizing transportation issues, a one-stop, under one roof test capability is being developed at the Space Power Facility at the NASA Glenn Research Center's Plum Brook Station. This facility will provide the capability to perform the following environmental testing: (1) reverberation acoustic testing, (2) mechanical base-shake sine testing, (3) modal testing, (4) thermal-vacuum testing, and (5) EMI/EMC (electromagnetic interference and compatibility) testing. An overview of this test capability will be provided in this presentation, with special focus on the two new vibroacoustic test facilities currently being designed and built, the Reverberant Acoustic Test Facility (RATF) and the Mechanical Vibration Facility (MVF). Testing of the engineering developmental hardware and qualification hardware of the Orion (Crew Exploration Vehicle) will commence shortly after the facilities are commissioned.

Hughes, William O.↗

NASA NTRS2013

Space Power Facility-Capabilities for Space Environmental Testing Within a Single Facility

The purpose of this paper is to describe the current and near-term environmental test capabilities of the NASA Glenn Research Center's Space Power Facility (SPF) located at Sandusky, Ohio. The paper will present current and near-term capabilities for conducting electromagnetic interference and compatibility testing, base-shake sinusoidal vibration testing, reverberant acoustic testing, and thermal-vacuum testing. The paper will also present modes of transportation, handling, ambient environments, and operations within the facility to conduct those tests. The SPF is in the midst of completing and activating new or refurbished capabilities which, when completed, will provide the ability to conduct most or all required full-scale end-assembly space simulation tests at a single test location. It is envisioned that the capabilities will allow a customer to perform a wide range of space simulation tests in one facility at reasonable cost.

Sorge, Richard N.↗

NASA NTRS2020

Case Study of Using Flocad to Model a Ground Test Station Ln2 Heat Exchanger

This paper presents a case study of using FLOCAD to model the heat transfer and boiling flow behavior of a Liquid Nitrogen (LN2) ground station equipment heat exchanger. The unique aspect of this work is that is one of very few studies documenting the use of FLOCAD in the spacecraft thermal control community. The results of the simulations described herein were used to guide and plan the execution of thermal vacuum testing spacecraft hardware using a ground test heat exchanger such as the one modeled herein. The paper will review the theory of two-phase boiling flow and correlations used by SINDA/FLUINT as well as the terminology and nomenclature used within Thermal Desktop / FLOCAD regarding two-phase boiling flow heat transfer modeling and simulation. Results for using the ground station heat exchanger as a heat sink in a thermal vacuum test set up are shown in order to demonstrate the set-up and execution of a typical FLOCAD model. Results indicate that properly modeling of the two-phase behavior is critical in order to ascertain the time constant associated with the heat exchanger, as well as understanding the temperature distribution across the test equipment and prediction of required LN2 flowrates to be used during testing. The paper is meant to augment the FLOCAD user’s manual and serve as a tutorial for thermal engineers and analysts wishing to learn and apply FLOCAD to industrial problems.

Anderson, Kevin R.↗

NASA NTRS2016

Thermal Management and Thermal Protection Systems

During my internship in the Thermal Design Branch (ES3), I contributed to two main projects: i) novel passive thermal management system for future human exploration, ii) AVCOAT undercut thermal analysis. i) As NASA prepares to further expand human and robotic presence in space, it is well known that spacecraft architectures will be challenged with unprecedented thermal environments. Future exploration activities will have the need of thermal management systems that can provide higher reliability, mass and power reduction and increased performance. In an effort to start addressing the current technical gaps the NASA Johnson Space Center Passive Thermal Discipline has engaged in technology development activities. One of these activities was done through an in-house Passive Thermal Management System (PTMS) design for a lunar lander. The proposed PTMS, functional in both microgravity and gravity environments, consists of three main components: a heat spreader, a novel hybrid wick Variable Conductance Heat Pipe (VCHP), and a radiator. The aim of this PTMS is to keep electronics on a vehicle within their temperature limits (0 and 50 C for the current design) during all mission phases including multiple lunar day/night cycles. The VCHP was tested to verify its thermal performance. I created a thermal math model using Thermal Desktop (TD) and analyzed it to predict the PTMS performance. After testing, the test data provided a means to correlate the thermal math model. This correlation took into account conduction and convection heat transfer, representing the actual benchtop test. Since this PTMS is proposed for space missions, a vacuum test will be taking place to provide confidence that the system is functional in space environments. Therefore, the model was modified to include a vacuum chamber with a liquid nitrogen shroud while taking into account conduction and radiation heat transfer. Infrared Lamps were modelled and introduced into the model to simulate the sun's rays directly impinging on the system. Heating rate of the lamps were calculated by knowing fraction of emitted energy in a wavelength interval and the filament temperature. This version of the model can be used to predict performance of the system under vacuum with extreme cold or hot conditions. Initial testing of the PTMS showed promise, and the thermal math model predicts even better performance in thermal vacuum testing. ii) Thermal Protection Systems (TPS) are required for vehicles which enter earth's atmosphere to protect from aerodynamic heating caused by the friction between the vehicle and atmospheric gases. Orion's heat shield design has two aspects which needed to be analyzed thermally: i) a small excess of adhesive used to bond the outer AVCOAT layer to the inner composite structure tends to seep from under the AVCOAT and form a small bead in between two bricks of AVCOAT, ii) a silicone rubber with different thermophysical properties than AVCOAT fills the gap between two bricks of AVCOAT. I created a thermal model using TD to determine temperature differences that are caused by these two features. To prevent false results, all TD models must be verified against something known. In this case, the TD model was correlated to CHAR, an ablation modelling software used to analyze TPS. Analyzing a node far from the concerning features, we saw that the TD model data match CHAR data, verifying the TD model. Next, the temperature of the silicone rubber as well as the bead of adhesive were analyzed to determine if they exceeded allowable temperatures. It was determined that these two features do not have a significant effect on the max temperature of the heat shield. This model can be modified to check temperatures at various locations of the heat shield where the composite thickness varies.

Hasnain, Aqib↗

NASA NTRS2016

Regolith Volatile Recovery at Simulated Lunar Environments

Lunar Polar Volatiles: Permanently shadowed craters at the lunar poles contain water, 5 wt according to LCROSS. Interest in water for ISRU applications. Desire to ground truth water using surface prospecting e.g. Resource Prospector and RESOLVE. How to access subsurface water resources and accurately measure quantity. Excavation operations and exposure to lunar environment may affect the results. Volatile capture tests: A series a ground based dirty thermal vacuum tests are being conducted to better understand the subsurface sampling operations. Sample removal and transfer. Volatiles loss during sampling operations. Concept of operations, Instrumentation. This presentation is a progress report on volatiles capture results from these tests with lunar polar drill prototype hardware.

thermal vacuum tests↗

NASA NTRS1999

Pre-Launch Noise Characterization of the Landsat-7 Enhanced Thematic Mapper Plus (ETM Plus)

A noise characterization of the Landsat-7 Enhanced Thematic Mapper Plus (ETM+) instrument was performed as part of a near-real time performance assessment and health monitoring program. Perl'ormance data for the integrated Landsat-7 spacecraft and ETM+ were collected before, during, and after the spacecraft thermal vacuum testing program at the Lockheed Martin Missiles and Space (LMMS) facilities in Valley Forge, PA. The Landsat-7 spacecraft and ETM+ instrument were successfully launched on April 15, 1999. The spacecraft and ETM+ are now nearing the end of the on orbit engineering checkout phase, and Landsat-7 is expected to be declared operational on or about July 15, 1999. A preliminary post-launch noise characterization was performed and compared with the pre-launch characterization. In general the overall noise levels in the ETM+ are at or below the specification levels. Coherent noise is seen in most bands, but is only operationally significant when imaging in (he panchromatic band (band 8). This coherent noise has an amplitude as high as approximately 3 DN (peak-to-peak, high gain) at the Nyquist rate of 104 kHz, and causes the noise levels in panchromatic band images at times to exceed the total noise specification by up to approximately 10%. However, this 104 kHz noise is now much weaker than it was prior to the successful repair of the ETM+ power supplies that was completed in May 1998. Weak and stable coherent noise at approximately 5 kHz is seen in all bands in the prime focal plane (bands 1-4 and 8) with the prime (side A) electronics. Very strong coherent noise at approximately 20 kHz is seen in a few detectors of bands 1 and 8, but this noise is almost entirely in the turn-around region between scans when the ETM+ is not imaging the Earth. Strong coherent noise was seen in 2 detectors of band 5 during some of the pre-launch testing; however, this noise seems to be temperature dependent, and has not been seen in the current on orbit environment. Strong 91 kHz coherent noise was observed in the redundant (side B) panchromatic band data after the completion of spacecraft thermal vacuum testing. The cause of this coherent noise was identified as a failed capacitor that was replaced prior to launch, and this noise has not been seen on orbit.

Pedelty, J. A.↗

NASA NTRS1985

Performance of the Spacelab Astro-1 mission heat pipe radiator

This paper describes the design and performance of the Astro Integrated Radiator System (IRS). The system was recently ground tested and proven successful in rejecting approximately 400 watts of heat. The radiator was constructed from an aluminum panel configured to form two orthogonal planes. Heat pipes were adhesively bonded and riveted to the radiator to isothermalize the surface. The IRS was subjected to a full thermal vacuum test to validate the thermal math model and to qualify the radiator for space flight. The thermal performance met prescribed temperature limits with margins at both extremes, and no mechanical failures occurred.

Humphries, W. R.↗

NASA NTRSDate not supplied

Development of a Thermal Vacuum Chamber for Lunar Surface Simulation

Simulating the lunar surface environment is a critical component in advancing the Technology Readiness Level (TRL) of newly developed lunar surface exploration systems and understanding regolith dynamics. Developing systems with the ability to simulate the lunar surface environment presents unique challenges associated with both the hardware requirements of the system and the uniqueness of the lunar environment. Additionally, many thermal vacuum testing systems are large and expensive to maintain and operate, increasing the cost for the end users. Many low TRL prototypes are small-scale and low-cost, making it unfeasible and unnecessary to utilize larger scale testing facilities. A small-scale, modular, and easily reconfigurable chamber with a quick testing turnaround time could allow rapid TRL advancement with minimal costs and time commitments relative to many of the current testing facilities. Here, we introduce a thermal vacuum chamber system that will support experimentation and rapid testing and maturation of small-scale hardware systems and subsystems for lunar surface exploration.

Thermal Vacuum Chamber↗

NASA NTRSDate not supplied

Solid-state Laser Development for the in Situ Spectroscopic Europa Explorer Instrument

The in Situ Spectroscopic Europa Explorer (iSEE) instrument is an ultra-compact laser-enabled Raman spectrometer instrument that meets the top-level science requirements for multiple future planetary in situ missions to explore the surface and atmospheric chemistry of planetary bodies across the Solar System. Enceladus, Europa, the Moon, Mars, and Venus are some of the primary targets for future NASA missions to search for extraterrestrial life and potentially habitable environments beyond Earth, further our understanding of the timing and formation of the Solar System and identify potentially viable economic resources such as water and/or valuable metal assets. We report on the advancement and space flight qualification of a compact, robust, solid-state laser operating at 515 nm that serves as the excitation source for the iSEE investigation. The iSEE instrument is being developed under a NASA Maturation of Instruments for Solar System Exploration (MatISSE) program. The iSEE laser is a diode pumped 1030 nm Yb:YAG microchip laser with a second harmonic generator to achieve an output wavelength of 515 nm and coupled to a multi-mode fiber for delivery to the Raman spectrometer probe. The fundamental 1030 nm laser operates at a pulse repetition frequency (PRF) of 1-10 kHz with pulse energy of 95 μJ and ~800 ps pulse width. A 15 mm long Type II KTP crystal is used for second harmonic generation from 1030 nm to 515 nm. The residual fundamental 1030 nm is separated from the 515 nm beam using a pair of dichroic filters. A focusing lens couples the 515 nm beam to the optical fiber to produce an output laser pulse energy of 20 μJ. A custom vacuum fiber feedthrough assembly was designed with two 105 μm core fibers, and two 200 μm core fibers. One fiber is needed for coupling the laser to the iSEE instrument, and the additionally fibers provide redundancy and design flexibility. The laser enclosure is pressurized with >1 atm of clean dry air. The laser has been designed to minimize the size, weight, and power (SWaP) for a lander instrument with minimal resources. The laser will go through environmental testing including vibration and thermal vacuum testing for space flight qualification. Here we discuss the design, trade studies, performance, and environmental qualificationtesting of the iSEE laser.

Solid state laser, Raman spectrometer, visible las↗

NASA NTRS2023

NASA Passive Thermal Control Engineering Guidebook

The NASA Passive Thermal Control Engineering Guidebook provides recommendations, including best practices and lessons learned, related to the passive thermal control engineering discipline. Topics include analysis (including documentation and review), thermal hardware (design/selection, vendors, and integration), testing, and flight operations. The passive thermal discipline includes thermal control and thermal protection systems. The passive thermal control discipline, which is addressed in this Guidebook, is broad and covers internal and external systems, component passive thermal analysis, vehicle on-orbit attitude timeline analysis, integrated thermal analysis, various thermal control apparatus (heaters and controls, coatings, blankets and insulations, isolators, geometric design for view factors, materials emissivity/absorptivity properties), passive cooling of avionics, purge, vent, and drain for vehicle cavities and compartments, thermal model development and correlation, thermal cycle and thermal-vacuum testing. Topics related to thermal protection systems (TPS) are not within the scope of this document. The Guidebook provides a consolidated reference for early career as well as experienced engineers embarking on a new task. Leveraging the experience of the group minimizes the learning curve that exists at the start of new projects, reduces the risk of repeating mistakes, and improves the organization’s ability to deliver high-quality products efficiently. The intent of this document is to provide guidance based on collective experience, and is not intended impose constraints on project work. Best practices can vary substantially and it is important to apply judgment wisely based on careful consideration of the specific design and requirements. Implementation of the methods described will vary from project to project and should be applied in conjunction with the judgment of the thermal engineers performing and reviewing the work. The recommendations in this document are not intended to replace program, project, branch, Center, or NASA requirements and/or policies.

thermal↗

NASA NTRS2023

NASA Passive Thermal Control Engineering Guidebook

thermal↗

NASA NTRS1970

Optical contamination during thermal testing in vacuum

Comparative tests are described for optical degradation in vacuum systems served by oil-type or ion-type pumping operation. Results show that degradation occurs only during ultraviolet irradiation in vacuum systems with oil-type pumping systems and that it increases with exposure time. Degradation does not occur with ion systems.

Zwiener, J. M.↗

NASA NTRS1981

The heat pipe thermal canister

The thermal canister represents a new approach to instrument thermal control for Shuttle experiments which require tight temperature control. The canister substitutes a known, benign thermal environment for the variable and uncertain environment of space, the space environment being neutralized by a system of feedback controlled variable conductance heat pipes. A proto-flight unit has been fabricated and this paper describes the acceptance thermal vacuum test results of the thermal canister experiment which will fly on an early Space Shuttle flight.

Harwell, W.↗