Materials for Space Applications
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Space simulation
The National Aeronautics and Space Administration served as a cosponsor of the Sixth Space Simulation Symposium. These proceedings were published as a NASA Special Publication in order to give the participants and attendees of the conference a permanent record of the material presented and to make the technology of space simulation available to others who may find in this technology solutions to problems extant in their respective fields. Space exploration has posed the most challenging technical difficulties man has yet faced and solved. The technology evolved by the space program has relevance to many other fields, especially to the area of environment control and modification. This latter field promises to be one of extreme importance in this decade. The technology of space simulation has evolved many solutions to problems of a similar nature to those now affecting our environment. NASA is pleased to cooperate with the Institute of Environmental Sciences, the American Institute of Aeronautics and Astronautics, and the American Society for Testing and Materials in advancing the frontiers of knowledge in the important area of space simulation and to make these proceedings available to other areas of science and technology.
John F Clark↗
Extreme Spacecraft Charging in Polar Low Earth Orbit
Spacecraft in low altitude, high inclination (including sun -synchronous) orbits are widely used for remote sensing of the Earth fs land surface and oceans, monitoring weather and climate, communications, scientific studies of the upper atmosphere and ionosphere, and a variety of other scientific, commercial, and military applications. These systems episodically charge to frame potentials in the kilovolt range when exposed to space weather environments characterized by a high flux of energetic (approx.10 fs kilovolt) electrons in regions of low background plasma density. Auroral charging conditions are similar in some ways to the space weather conditions in geostationary orbit responsible for spacecraft charging to kilovolt levels. We first review the physics of space environment interactions with spacecraft materials that control auroral charging rates and the anticipated maximum potentials that should be observed on spacecraft surfaces during disturbed space weather conditions. We then describe how the theoretical values compare to the observational history of extreme charging in auroral environments. Finally, a set of extreme DMSP charging events are described varying in maximum negative frame potential from approx.0.6 kV to approx.2 kV, focusing on the characteristics of the charging events that are of importance both to the space system designer and to spacecraft operators. The goal of the presentation is to bridge the gap between scientific studies of auroral charging and the need for engineering teams to understand how space weather impacts both spacecraft design and operations for vehicles on orbital trajectories that traverse auroral charging environments.
Colson, Andrew D.↗
Analysis of Surface Charging for a Candidate Solar Sail Mission Using Nascap-2k
The characterization of the electromagnetic interaction for a solar sail in the solar wind environment and identification of viable charging mitigation strategies are critical solar sail mission design task. Spacecraft charging has important implications both for science applications and for lifetime and reliability issues of sail propulsion systems. To that end, surface charging calculations of a candidate 150-meter-class solar sail spacecraft for the 0.5 AU solar polar and 1.0 AU L1 solar wind environments are performed. A model of the spacecraft with candidate materials having appropriate electrical properties is constructed using Object Toolkit. The spacecraft charging analysis is performed using Nascap-2k, the NASA/AFRL sponsored spacecraft charging analysis tool. Nominal and atypical solar wind environments appropriate for the 0.5 AU and 1.0 AU missions are used to establish current collection of solar wind ions and electrons. Finally, a geostationary orbit environment case is included to demonstrate a bounding example of extreme (negative) charging of a solar sail spacecraft. Results from the charging analyses demonstrate that minimal differential potentials (and resulting threat of electrostatic discharge) occur when the spacecraft is constructed entirely of conducting materials, as anticipated from standard guidelines for mitigation of spacecraft charging issues. Examples with dielectric materials exposed to the space environment exhibit differential potentials ranging from a few volts to extreme potentials in the kilovolt range.
Parker, Linda Neergaard↗
Analysis of Surface Charging for a Candidate Solar Sail Mission Using NASCAP-2K
The characterization of the electromagnetic interaction for a solar sail in the solar wind environment and identification of viable charging mitigation strategies are critical solar sail mission design tasks. Spacecraft charging has important implications both for science applications and for lifetime and reliability issues of sail propulsion systems. To that end, surface charging calculations of a candidate 150-meter-class solar sail spacecraft for the 0.5 AU solar polar and 1.9 AU LI solar wind environments are performed. A model of the spacecraft with candidate materials having appropriate electrical properties is constructed using Object Toolkit. The spacecraft charging analysis is performed using Nascap-2k. the NASA/AFRL sponsored spacecraft charging analysis tool. Nominal and atypical solar wind environments appropriate for the 0.5 AU and 1.0 AU missions are used to establish current collection of solar wind ions and electrons. Finally, a geostationary orbit environment case is included to demonstrate a bounding example of extreme (negative) charging of a solar sail spacecraft. Results from the charging analyses demonstrate that minimal differential potentials (and resulting threat of electrostatic discharge) occur when the spacecraft is constructed entirely of conducting materials, as anticipated from standard guidelines for mitigation of spacecraft charging issues. Examples with dielectric materials exposed to the space environment exhibit differential potentials ranging from a few volts to extreme potentials in the kilovolt range.
Parker, Linda Neergaard↗
Extreme Spacecraft Charging in Polar Low Earth Orbit
Spacecraft in low altitude, high inclination (including sun-synchronous) orbits are widely used for remote sensing of the Earth's land surface and oceans, monitoring weather and climate, communications, scientific studies of the upper atmosphere and ionosphere, and a variety of other scientific, commercial, and military applications. These systems episodically charge to frame potentials in the kilovolt range when exposed to space weather environments characterized by a high flux of energetic (~10 s kilovolt) electrons in regions of low background plasma density which is similar in some ways to the space weather conditions in geostationary orbit responsible for spacecraft charging to kilovolt levels. We first review the physics of space environment interactions with spacecraft materials that control auroral charging rates and the anticipated maximum potentials that should be observed on spacecraft surfaces during disturbed space weather conditions. We then describe how the theoretical values compare to the observational history of extreme charging in auroral environments. Finally, a set of extreme DMSP charging events are described varying in maximum negative frame potential from ~0.6 kV to ~2 kV, focusing on the characteristics of the charging events that are of importance both to the space system designer and to spacecraft operators. The goal of the presentation is to bridge the gap between scientific studies of auroral charging and the need for engineering teams to understand how space weather impacts both spacecraft design and operations for vehicles on orbital trajectories that traverse auroral charging environments.
Colson, Andrew D.↗
Hybrid Modeling Study on Grain Evolution in the Metal Welding Process and Its Potential Lunar Application
Metal is most commonly used structural material in a wide range of spacecraft, and welding is the principal method for joining metal components into functional systems. However, conducting welding experiments under extreme environments—such as microgravity or vacuum conditions in space—is prohibitively expensive and experimentally challenging. To overcome these limitations, multi-physics computational welding models provide a cost-effective and versatile alternative. In this work, the authors have developed a coupled thermal (fluid) microstructure simulation framework to model metal welding under varying gravity conditions. The framework integrates a mixed-mode heat transfer formulation (conduction, convection, and radiation) with molten pool fluid dynamics, enabling accurate prediction of temperature fields and weld-pool geometry. A grain growth model is further incorporated to capture the spatial and temporal evolution of microstructure, including grain size distribution and morphological transitions during solidification. This approach provides detailed insight into molten pool evolution and grain-level microstructure development throughout the welding process. By explicitly parameterizing environmental conditions, the model supports extrapolation to off-Earth manufacturing scenarios such as welding on the lunar surface. Tantalum—chosen in this study due to its high melting point, oxidation resistance, and mechanical stability at elevated temperatures—serves as the material system for model demonstration. Beyond Tantalum, the integrated multi-physics framework offers broad applicability for predictive welding simulations of various structural and refractory metals or alloys used in extreme terrestrial or extraterrestrial environments.
kinetic Monte Carlo (SPPARKS)↗
Post-Launch Calibration and Testing of Space Weather Instruments on GOES-R Satellite
The Geostationary Operational Environmental Satellite - R (GOES-R) is the first of a series of satellites to be launched, with the first launch scheduled for October 2016. The three instruments - Solar Ultra Violet Imager (SUVI), Extreme ultraviolet and X-ray Irradiance Sensor (EXIS), and Space Environment In-Situ Suite (SEISS) provide the data needed as inputs for the product updates National Oceanic and Atmospheric Administration (NOAA) provides to the public. SUVI is a full-disk extreme ultraviolet imager enabling Active Region characterization, filament eruption, and flare detection. EXIS provides inputs to solar backgrounds/events impacting climate models. SEISS provides particle measurements over a wide energy-and-flux range that varies by several orders of magnitude and these data enable updates to spacecraft charge models for electrostatic discharge. EXIS and SEISS have been tested and calibrated end-to-end in ground test facilities around the United States. Due to the complexity of the SUVI design, data from component tests were used in a model to predict on-orbit performance. The ground tests and model updates provided inputs for designing the on-orbit calibration tests. A series of such tests have been planned for the Post-Launch Testing (PLT) of each of these instruments, and specific parameters have been identified that will be updated in the Ground Processing Algorithms, on-orbit parameter tables, or both. Some of SUVI and EXIS calibrations require slewing them off the Sun, while no such maneuvers are needed for SEISS. After a six-month PLT period the GOES-R is expected to be operational. The calibration details are presented in this paper.
On-orbit Calibration↗
Post-Launch Calibration and Testing of Space Weather Instruments on GOES-R Satellite
The Geostationary Operational Environmental Satellite - R (GOES-R) is the first of a series of satellites to be launched, with the first launch scheduled for October 2016. The three instruments Solar UltraViolet Imager (SUVI), Extreme ultraviolet and X-ray Irradiance Sensor (EXIS), and Space Environment In-Situ Suite (SEISS) provide the data needed as inputs for the product updates National Oceanic and Atmospheric Administration (NOAA) provides to the public. SUVI is a full-disk extreme ultraviolet imager enabling Active Region characterization, filament eruption, and flare detection. EXIS provides inputs to solar back-ground-sevents impacting climate models. SEISS provides particle measurements over a wide energy-and-flux range that varies by several orders of magnitude and these data enable updates to spacecraft charge models for electrostatic discharge. EXIS and SEISS have been tested and calibrated end-to-end in ground test facilities around the United States. Due to the complexity of the SUVI design, data from component tests were used in a model to predict on-orbit performance. The ground tests and model updates provided inputs for designing the on-orbit calibration tests. A series of such tests have been planned for the Post-Launch Testing (PLT) of each of these instruments, and specific parameters have been identified that will be updated in the Ground Processing Algorithms, on-orbit parameter tables, or both. Some of SUVI and EXIS calibrations require slewing them off the Sun, while no such maneuvers are needed for SEISS. After a six-month PLT period the GOES-R is expected to be operational. The calibration details are presented in this paper.
On-orbit Calibration↗
Analysis of Arc Welding Process in Space
This work is motivated by NASA plans to conduct welding experiments on the ISS. It is expected that deployment of welding and additive manufacturing technologies in the space environment has the potential to revolutionise how orbiting platforms are designed, manufactured, and assembled. However, the structure, composition and quality of a weld is extremely dependent on the environment and can be difficult to control in space. Shielding gases would also be tough to manage as gases behave differently in zero gravity and airless environments. Additional points of concern are related to the spatter and sparks dynamics in space. Therefore, there is a need for a more basic understanding of welding processes by computational modelling. To provide such an insight we developed state of art models of the ARC torch, droplet detachment and transfer, and the melt pool build up using magnetohydrodynamics approximation and level set method for two-phase liquid metal/-gas flow modelling. Two finite element models were built using 2D axisymmetric geometry in COMSOL Multiphysics®: (i) stationary model of the ARC torch and (ii) dynamical model of droplet detachment and transfer. Both models demonstrate reasonable agreement with earlier experimental observations and high sensitivity to the temperature dependence of the thermophysical parameters on the system materials. The models were used to provide physical insight into ARC welding in various environments and geometries. It was shown, in particular, that there is a significant probability of gas bubbles trapping in the meltpool and a possibility of unbounded wondering of sparks in the welding chamber in zero gravity. In addition, we estimated metal evaporation rate that may be hazardous in the confined environment of the ISS. These issues raise concern of quality of the weld and safety for ISS applications.
ARC welding↗
Simulation Based Studies of Low Latency Teleoperations for NASA Exploration Missions
Human exploration of Mars will involve both crewed and robotic systems. Many mission concepts involve the deployment and assembly of mission support assets prior to crew arrival on the surface. Some of these deployment and assembly activities will be performed autonomously while others will be performed using teleoperations. However, significant communications latencies between the Earth and Mars make teleoperations challenging. Alternatively, low latency teleoperations are possible from locations in Mars orbit like Mars' moons Phobos and Deimos. To explore these latency opportunities, NASA is conducting a series of studies to investigate the effects of latency on telerobotic deployment and assembly activities. These studies are being conducted in laboratory environments at NASA's Johnson Space Center (JSC), the Human Exploration Research Analog (HERA) at JSC and the NASA Extreme Environment Mission Operations (NEEMO) underwater habitat off the coast of Florida. The studies involve two human-in-the-loop interactive simulations developed by the NASA Exploration Systems Simulations (NExSyS) team at JSC. The first simulation investigates manipulation related activities while the second simulation investigates mobility related activities. The first simulation provides a simple real-time operator interface with displays and controls for a simulated 6 degree of freedom end effector. The initial version of the simulation uses a simple control mode to decouple the robotic kinematic constraints and a communications delay to model latency effects. This provides the basis for early testing with more detailed manipulation simulations planned for the future. Subjects are tested using five operating latencies that represent teleoperation conditions from local surface operations to orbital operations at Phobos, Deimos and ultimately high Martian orbit. Subject performance is measured and correlated with three distance-to-target zones of interest. Each zone represents a target distance ranging from beyond 10m in Zone 1, through 1 cm to contact in Zone 5 with a step size factor of 10. Collected data consists of both objective simulation data (time, distance, hand controller inputs, velocity) and subjective questionnaire data. The second simulation provides a simple real-time operator interface with displays and control of a simulated surface rover. The rover traverses a synthetic Mars-like terrain and must be maneuvered to avoid obstacles while progressing to its destination. Like the manipulator simulation, subjects are tested using five operating latencies that represent teleoperation conditions from local surface operations to orbital operations at Phobos, Deimos and ultimately high Martian orbit. The rover is also operated at three different traverse speeds to assess the correlation between latency and speed. Collected data consisted of both objective simulation data (time, distance, hand controller inputs, braking) and subjective questionnaire data. These studies are exploring relationships between task complexity, operating speeds, operator efficiencies, and communications latencies for low latency teleoperations in support of human planetary exploration. This paper presents early results from these studies along with the current observations and conclusions. These and planned future studies will help to inform NASA on the potential for low latency teleoperations to support human exploration of Mars and inform the design of robotic systems and exploration missions.
Gernhardt, Michael L.↗
Introduction
Probable climatic extremes of terrestrial environment data specifically applicable for NASA space vehicles and associated equipment development are considered. Design guideline values are established for the following environmental parameters: (1) Thermal (temperature and solar radiation); (2) humidity; (3) precipitation; (4) winds; (5) pressure; (6) density; (7) electricity (atmospheric); (8) corrosion (atmospheric); (9) sand and dust; (10) fungi and bacteria; (11) atmospheric oxidants; (12) composition of the atmosphere; and (13) inflight thermodynamic properties.
Daniels, G. E.↗
Fiber optic experiment for the Shuttle long-duration exposure facility
The present investigation is concerned with an active fiber-optic data transmission experiment which has been under development for a planned orbital exposure on the Shuttle Long Duration Exposure Facility (LDEF) and subsequent recovery for laboratory evaluation. The LDEF is a space shuttle payload which is designed to carry a large number of independent tray-mounted experiments into low earth orbit for exposure to the space environment. The LDEF is then to be recovered by a later shuttle flight for postflight examination. Data is stored on a tape recorder within the experiment tray; no telemetry is provided. A description is given of two independent experiment trays which are being prepared. The experiments are to be conducted to gain experience in the design of a complete fiber link for the space environment and to confirm that the effects of the critical environments in space, in particular particle radiation and temperature extremes, are not detrimental to satisfactory link operation.
Johnston, A. R.↗
Summary of Research Issues in Behavior and Performance in Isolated and Confined Extreme (ICE) Environments
The papers presented in this section describe changes in behavior and performance in various isolated and confined extreme (ICE) environments, including Antarctic expeditions and research stations, space simulators and isolation chambers, and submarines. Each of these environments possesses characteristics that are in some way analogous to those found on long-duration space missions. Despite differences in length of mission, characteristics of mission personnel or crew, and characteristics in the physical environment, the various ICE environments described in this collection of papers appear to produce similar changes in behavior and performance. These changes include increased disturbances of mood, increased rates of psychiatric disorder, increased interpersonal tension, and a disruption of circadian rhythms. However, these environments do not inherently produce decrements in performance. Palinkas and colleagues suggest that prolonged exposure to the isolation and confinement in the Antarctic can actually have positive or "salutogenic" effects as well, evidenced by a decrease in mood disturbances and increase in performance measures.
Palinkas, Lawrence A.↗
Augmentation of blood circulation to the fingers by warming distant body areas
Future activities in space will require greater periods of time in extreme environments in which the body periphery will be vulnerable to chilling. Maintaining the hands and fingers in comfortable conditions enhances finger flexibility and dexterity, and thus effects better work performance. We have evaluated the efficacy of promoting heat transfer and release by the extremities by increasing the blood flow to the periphery from more distant parts of the body. The experimental garment paradigm developed by the investigators was used to manipulate the temperature of different body areas. Six subjects, two females and four males, were evaluated in a stage-1 baseline condition, with the inlet temperature of the circulating water in the liquid cooling/warming garment (LCWG) at 33 degrees C. At stage 2 the total LCWG water inlet temperature was cooled to 8 degrees C, and at stage 3 the inlet water temperature in specific segments of the LCWG was warmed (according to protocol) to 45 degrees C, while the inlet temperature in the rest of the LCWG was maintained at 8 degrees C. The following four body-area-warming conditions were studied in separate sessions: (1) head, (2) upper torso/arm, (3) upper torso/arm/head, and (4) legs/feet. Skin temperature, heat flux and blood perfusion of the fingers, and subjective perception of thermal sensations and overall physical comfort were assessed. Finger temperature (T(fing)) analyses showed a statistically significant condition x stage interaction. Post-hoc comparisons (T(fing)) indicated that at stage 3, the upper torso/arm/head warming condition was significantly different from the head, upper torso/arm and legs/feet conditions, showing an increase in T(fing). There was a significant increase in blood perfusion in the fingers at stage 3 in all conditions. Subjective perception of hand warmth, and overall physical comfort level significantly increased in the stage 3 upper torso/arm/head condition. The findings indicate that physiological methods to enhance heat transfer by the blood to the periphery within protective clothing provide an additional tool for increasing total and local human comfort in extreme environments.
NASA Discipline Life Sciences Technologies↗
Performance of Rad Hard quad receivers at extreme temperatures
We characterize the electrical performance and reliabilities as potential space electronic parts under extreme low and high temperature environments extending nominal device specifications.
Rad-Hard Quad Receivers electrical performance↗
Vibration Considerations for Cryogenic Tanks Using Glass Bubbles Insulation
The use of glass bubbles as an efficient and practical thermal insulation system has been previously demonstrated in cryogenic storage tanks. One such example is a spherical, vacuum-jacketed liquid hydrogen vessel of 218,000 liter capacity where the boiloff rate has been reduced by approximately 50 percent. Further applications may include non-stationary tanks such as mobile tankers and tanks with extreme duty cycles or exposed to significant vibration environments. Space rocket launch events and mobile tanker life cycles represent two harsh cases of mechanical vibration exposure. A number of bulk fill insulation materials including glass bubbles, perlite powders, and aerogel granules were tested for vibration effects and mechanical behavior using a custom design holding fixture subjected to random vibration on an Electrodynamic Shaker. The settling effects for mixtures of insulation materials were also investigated. The vibration test results and granular particle analysis are presented with considerations and implications for future cryogenic tank applications. A thermal performance update on field demonstration testing of a 218,000 L liquid hydrogen storage tank, retrofitted with glass bubbles, is presented. KEYWORDS: Glass bubble, perlite, aerogel, insulation, liquid hydrogen, storage tank, mobile tanker, vibration.
Werlink, Rudolph J.↗
Channel Wall Nozzle Manufacturing and Hot-Fire Testing Using a Laser Wire Direct Closeout Technique for Liquid Rocket Engines
A regeneratively-cooled nozzle for liquid rocket engine applications is a significant cost of the overall engine due to the complexities of manufacturing a large thin-walled structure that must operate in extreme temperature and pressure environments. The National Aeronautics and Space Administration (NASA) has been investigating and advancing methods for fabrication of liquid rocket engine channel wall nozzles to realize further cost and schedule improvements over traditional techniques. The methods being evaluated are targeting increased scale required for current NASA and commercial space programs. Several advanced rapid fabrication methods are being investigated for forming of the inner liner, producing the coolant channels, closeout of the coolant channels, and fabrication of the manifolds. NASA's Marshall Space Flight Center (MSFC) has completed process development and subscale hot-fire testing of a series of these advanced fabrication channel wall nozzle technologies to gather performance data in a relevant environment. The primary fabrication technique being discussed in this paper is Laser Wire Direct Closeout (LWDC). This process has been developed to significantly reduce the time required for closeouts of regeneratively-cooled slotted liners. It allows for channel closeout to be formed in place in addition to the structural jacket without the need for channel fillers or complex tooling. Additional technologies were also tested as part of this program including water jet milling and arc-based additive manufacturing deposition. Each nozzle included different fabrication features, materials, and methods to demonstrate durability in a hot-fire environment. The results of design, fabrication, and hot-fire testing are discussed in this paper.
Gradl, Paul R.↗