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The ISS fluid systems are so complex that fluid system cleanliness cannot be verified at the assembly level. A "build clean / maintain clean" approach was used by all major fluid systems: Verify cleanliness at the detail and subassembly level. Maintain cleanliness during assembly.
Currently, NASA uses Dichloropentafluoropropane (HCFC-225), a Class II ozone depleting substance (ODs), to clean contaminated oxygen systems. Starting in 20 15, the Montreal Protocols and Clean Air Act prohibit the production and importation of all hydrochlorofluorocarbons (HCFC), except for limited use in refrigeration applications. Thus, a new non-ozone depleting solvent needs to be developed for use in cleaning. Optimally, such a solvent should also be environmentally benign or green to avoid needing to replace the new solvent with yet another solvent in the future due to other environmental concerns. Work for the first year consisted of two parts. The first part was developing a method of testing the cleaning efficiency of potential solvents. Stainless steel coupons were contaminated with a known weight of various contaminants and contaminant combinations and then immersed in solvent for ten minutes. The coupons were then removed and dried in an oven until all solvent had evaporated. Once dry, the coupons were weighed and the mass of the non-volatile residue (NVR) left on the coupon was determined. The cleaning efficiency of the solvents is reported as percent cleaning, with 100% cleaning being zero NVR left on the test coupon. The second half of the first goal was to use the develop method to perform baseline testing on current solvents. The second part of the work was to begin exploring alternative cleaning solvents. A variety of hydrofluorocarbons (HFCs) were tested. Preliminary testing was also performed with ionic liquids and aqueous surfactant solutions. Once potential solvents were identified, an analysis of the performance and environmental characteristics of each was to be conducted. Four contaminants were specified for use in testing. These are Mil-Spec-H-5606 (5606), a hydraulic fluid, Mil-H-83282B (83282), another hydraulic fluid, diethylhexyl sebacate (Sebacate), and WD-40. The structures of these contaminants are all similar, with long aliphatic hydrocarbon chains of lengths between fifteen and fifty. Contaminants were tested both individually and in combination. All combinations were done with equal weights of the constituent contaminants.
Increasingly strict environmental regulations and the consequent phase out of many effective cleaning solvents has necessitated the development of novel cleaning chemistries and technologies. Among these is vacuum degreasing, a fully enclosed process that eliminates fugitive solvent emissions, thereby reducing cost, environmental, and health related exposure impacts. The effectiveness of vacuum degreasing using modified alcohol for common aerospace contaminants is reported and compared to current and legacy solvents.
In October 2021, NASA Johnson Space Center (JSC) Astromaterials Acquisition and Cu-ration Office in JSC bldg. 31 completed construction and commissioning of the OSIRIS-REx and Hayabusa2cleanroom laboratory suites along with new precision cleaning and advanced curation laboratories: •OSIRIS-REx Curation Cleanroom: ISO Class 5•Hayabusa2 Curation Cleanroom: ISO Class 5•Final Precision Cleaning Cleanroom: ISO Class 5•Advanced Precision Cleaning Cleanroom: ISO Class 6•PreClean Precision Cleaning Cleanroom: ISO Class 6•Advanced Curation Cleanroom: ISO Class 7The new curation facilities are designed for initial receiving, basic characterization, curation processing, and preliminary examination of carbonaceous asteroidal material. The facilities are also designed to enable long-term pristine sample storage to preserve the scientific integrity of each sample to enable decades of future re-search by the international science community. The scientific study of organics in general is critical for both missions. The OSIRIS-REx mission executed a stringent contamination control plan [1] where all sample hardware at time of sample acquisition would be at Level 100 A/2 per IEST-STD-CC1246D (non-volatile residue (NVR) < 500 ng/cm2). In addition, the mission imposed a requirement of <180 ng/cm2 for amino acids (and hydrazine) [1]. Given these mission requirements, long-term storage preservation requirements, and information from the Organic Contamination Baseline Study at JSC [2], the JSC Curation team decided to carefully select cleanroom construction materials that would not hinder the scientific search for amino acids and the study of organics in the samples [3].
Inadequacy of mass loss cleanliness criteria for selection of materials for contamination sensitive uses, and processing of flight hardware for contamination sensitive instruments is discussed. Materials selection for flight hardware is usually based on mass loss (ASTM E-595). However, flight hardware cleanliness (MIL 1246A) is a surface cleanliness assessment. It is possible for materials (e.g. Sil-Pad 2000) to pass ASTM E-595 and fail MIL 1246A class A by orders of magnitude. Conversely, it is possible for small amounts of nonconforming material (Huma-Seal conformal coating) to not present significant cleanliness problems to an optical flight instrument. Effective cleaning (precleaning, precision cleaning, and ultra cleaning) and cleanliness verification are essential for contamination sensitive flight instruments. Polish cleaning of hardware, e.g. vacuum baking for vacuum applications, and storage of clean hardware, e.g. laser optics, is discussed. Silicone materials present special concerns for use in space because of the rapid conversion of the outgassed residues to glass by solar ultraviolet radiation and/or atomic oxygen. Non ozone depleting solvent cleaning and institutional support for cleaning and certification are also discussed.
Historically, many subscale and full-scale rocket motors have employed environmentally and physiologically harmful chemicals during the manufacturing process. This program examines the synergy and interdependency between environmentally acceptable materials for solid rocket motor insulation applications, bonding, corrosion inhibiting, painting, priming, and cleaning, and then implements new materials and processes in subscale motors. Tests have been conducted to eliminate or minimize hazardous chemicals used in the manufacture of modified-NASA materials test motor (MNASA) components and identify alternate materials and/or processes following NASA Operational Environmental Team (NOET) priorities. This presentation describes implementation of high pressure water refurbishment cleaning, aqueous precision cleaning using both Brulin 815 GD and Jettacin, and insulation case bonding using ozone depleting chemical (ODC) compliant primers and adhesives.
A study was conducted to evaluate ultrasonic cleaning systems for precision cleaning effectiveness for oxygen service hardware. This evaluation was specific for Rocketdyne Division of Rockwell Aerospace alloys and machining soils. Machining lubricants and hydraulic fluid were applied as soils to standardized complex test specimens designed to simulate typical hardware. The study consisted of tests which included 20, 25, 30, 40, 50, and 65 kHz ultrasonic cleaning systems. Two size categories of cleaning systems were evaluated, 3- to 10-gal laboratory size tanks and 35- to 320-gal industrial size tanks. The system properties of cavitation, frequency vs. cleaning effectiveness, the two types of transducers, and the power level of the system vs. size of the cleaning tank were investigated. The data obtained from this study was used to select the ultrasonic tanks for the aqueous fine clean facility installed at Rocketdyne.
A study was conducted to evaluate ultrasonic cleaning systems for precision cleaning effectiveness for oxygen service hardware. This evaluation was specific for Rocketdyne Div. of Rockwell Aerospace alloys and machining soils. Machining lubricants and hydraulic fluid were applied as soils to standardized complex test specimens designed to simulate typical hardware. The study consisted of tests which included 20, 25, 30, 40, 50, and 65 kHz ultrasonic cleaning systems. Two size categories of cleaning systems were evaluated, 3- to 10-gal laboratory size tanks and 35- to 320-gal industrial size tanks. The system properties of cavitation; frequency vs. cleaning effectiveness; the two types of transducers; and the power level of the system vs. size of the cleaning tank were investigated. The data obtained from this study was used to select the ultrasonic tanks for the aqueous fine clean facility installed at Rocketdyne.
A study was done to characterize the cleanliness level achievable when using a rudimentary cleaning process, and results were compared to JPR 5322.1G Level 300A. While it is not ideal to clean in a shop environment, some situations (e.g., field combat operations) require oxygen system hardware to be maintained and cleaned to prevent a fire hazard, even though it cannot be sent back to a precision cleaning facility. This study measured the effectiveness of basic shop cleaning. Initially, three items representing parts of an oxygen system were contaminated: a metal plate, valve body, and metal oxygen bottle. The contaminants chosen were those most likely to be introduced to the system during normal use: oil, lubricant, metal shavings/powder, sand, fingerprints, tape, lip balm, and hand lotion. The cleaning process used hot water, soap, various brushes, gaseous nitrogen, water nozzle, plastic trays, scouring pads, and a controlled shop environment. Test subjects were classified into three groups: technical professionals having an appreciation for oxygen hazards; professional precision cleaners; and a group with no previous professional knowledge of oxygen or precision cleaning. Three test subjects were in each group, and each was provided with standard cleaning equipment, a cleaning procedure, and one of each of the three test items to clean. The results indicated that the achievable cleanliness level was independent of the technical knowledge or proficiency of the personnel cleaning the items. Results also showed that achieving a Level 300 particle count was more difficult than achieving a Level A nonvolatile residue amount.
Future missions that return astromaterials with trace carbonaceous signatures will require strict protocols for reducing and controlling terrestrial carbon contamination. Adventitious carbon (AC) on primary sample containers and related hardware is an important source of that contamination. AC is a thin film layer or heterogeneously dispersed carbonaceous material that naturally accrues from the environment on the surface of atmospheric exposed metal parts. To test basic cleaning techniques for AC control, metal surfaces commonly used for flight hardware and curating astromaterials at JSC were cleaned using a basic cleaning protocol and characterized for AC residue. Two electropolished stainless steel 316L (SS- 316L) and two Al 6061 (Al-6061) test coupons (2.5 cm diameter by 0.3 cm thick) were subjected to precision cleaning in the JSC Genesis ISO class 4 cleanroom Precision Cleaning Laboratory. Afterwards, the samples were analyzed by X-ray photoelectron spectroscopy (XPS) and Raman spectroscopy.
Components in the aerospace industry must perform with accuracy and precision under extreme conditions, and surface contamination can be detrimental to the desired performance, especially in cases when the components come into contact with strong oxidizers such as liquid oxygen. Therefore, precision cleaning is an important part of a components preparation prior to utilization in aerospace applications. Current cleaning technologies employ a variety of cleaning agents, many of which are halogenated solvents that are either toxic or cause environmental damage. Thus, this project seeks to identify alternative precision cleaning solvents and technologies, including use of less harmful cleaning solvents, ultrasonic and megasonic agitation, low-pressure plasma cleaning techniques, and supercritical carbon dioxide extraction. Please review all data content found in the Public Data tab located at: https:techport.nasa.govview11697public
NASA's Kennedy Space Center has developed two solvent-free precision cleaning techniques: plasma cleaning and supercritical carbon dioxide (SCCO2), that has equal performance, cost parity, and no environmental liability, as compared to existing solvent cleaning methods.
The Mars Sample Return mission has the goal to drill, break off, and retain rock core samples. After some results gained from rock core mechanics testing, the realization that scoring teeth would cleanly break off the core after only a few millimeters of penetration, and noting that rocks are weak in tension, the idea was developed to use symmetric wedging teeth in compression to weaken and then break the core at the contact plane. This concept was developed as a response to the break-off and retention requirements. The wedges wrap around the estimated average diameter of the core to get as many contact locations as possible, and are then pushed inward, radially, through the core towards one another. This starts a crack and begins to apply opposing forces inside the core to propagate the crack across the plane of contact. The advantage is in the simplicity. Only two teeth are needed to break five varieties of Mars-like rock cores with limited penetration and reasonable forces. Its major advantage is that it does not require any length of rock to be attached to the parent in order to break the core at the desired location. Test data shows that some rocks break off on their own into segments or break off into discs. This idea would grab and retain a disc, push some discs upward and others out, or grab a segment, break it at the contact plane, and retain the portion inside of the device. It also does this with few moving parts in a simple, space-efficient design. This discovery could be implemented into a coring drill bit to precisely break off and retain any size rock core.
This NASA Engineering and Safety Center (NESC) Technical Assessment Report addresses the urgent need to identify, test, and qualify replacement cleaning solvents and technologies following 3M’s decision to discontinue production of hydrofluoroether (HFE) products, including Novec HFE-7100, by the end of 2025. HFE-7100 is widely used across NASA for precision cleaning of ground and flight hardware, especially in oxygen system components, and as a heat transfer fluid in high-power-density thermal control systems. The assessment evaluates commercially available replacement solvents, alternative cleaning technologies, and their compatibility with NASA’s operational requirements. Key findings include the identification of viable solvent replacements, their performance in contaminant removal, materials compatibility, and oxygen system safety. The report also explores novel cleaning approaches, including aqueous, supercritical CO₂, cryogenic aerosol, plasma, UV-ozone, magnetically optimized fluids, and induced charge active filtration, highlighting their merits, limitations, and readiness for NASA adoption. The NESC provides recommendations for solvent selection, facility adaptation, and continued technology maturation to ensure mission continuity and regulatory compliance.
Precision cleaning and cleanliness verification techniques are examined as a subset of a comprehensive contamination control strategy for a Mars sample return mission. Additional information is contained in the original extended abstract.
A self contained, single use hose and tubing cleaning module which utilizes available water supplies without requiring access to precision cleaning facilities is presented. The module is attached to the water source at the inlet side and to the hose or tubing to be cleaned at the outlet side. The water flows through a water purification zone, a detergent dispensing zone, a filtration zone before the detergent laden water flows into the tubing to clean the tubing walls. The module contains an embedded pad which is impregnated with a pH indicator to indicate to the user when the detergent has dissolved and rinsing of the tubing begins.
This paper presents the mechanical design and analysis work completed on the Lunar Orbiter Laser Altimeter (LOLA). LOLA is one of six instruments on the Lunar Reconnaissance Orbiter (LRO), scheduled to launch in 2008. LOLA's main objective is to produce a high-resolution global lunar topographic model to aid in safe landings and enhance surface mobility in future exploration missions. LOLA will also look for evidence of ice water in the permanently shadowed regions around the lunar poles. Beryllium was chosen as the primary material for the LOLA Optical Transmitter Assembly to take advantage of the material's low mass density for light weight optical instrument design and for CTE matching of the refractive optical components. In addition, the thermal conductivity and specific heat of beryllium minimizes thermal gradients and thermal excursions. Special consideration must be made for the planning and preparation to fabricate beryllium components, as well as the preparation and cleaning of the components for gold plating. Assembly challenges include handling, precision cleaning and integration and testing. Structural analysis considerations include following General Environmental Verification Specification (GEVS) guidelines for GSFC payloads. The GEVS random environment for LOLA has an acceptance level of 10.0 Grms, which was analyzed for higher frequency transients. The low frequency transients were analyzed using a Mass Acceleration Curve to obtain an equivalent static loading. In addition, Structural-Thermal-Optical analysis, commonly referred to as STOP analysis, was completed to predict optical performance under the instrument's operational thermal environment. This included stress and distortion analysis on the receiver telescope lens.