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NASA NTRS2011

Monitoring Delamination of Thermal Barrier Coatings During Interrupted High-Heat-Flux Laser Testing using Luminescence Imaging

This presentation showed progress made in extending luminescence-base delamination monitoring to TBCs exposed to high heat fluxes, which is an environment that much better simulates actual turbine engine conditions. This was done by performing upconversion luminescence imaging during interruptions in laser testing, where a high-power CO2 laser was employed to create the desired heat flux. Upconverison luminescence refers to luminescence where the emission is at a higher energy (shorter wavelength) than the excitation. Since there will be negligible background emission at higher energies than the excitation, this methods produces superb contrast. Delamination contrast is produced because both the excitation and emission wavelengths are reflected at delamination cracks so that substantially higher luminescence intensity is observed in regions containing delamination cracks. Erbium was selected as the dopant for luminescence specifically because it exhibits upconversion luminescence. The high power CO2 10.6 micron wavelength laser facility at NASA GRC was used to produce the heat flux in combination with forced air backside cooling. Testing was performed at a lower (95 W/sq cm) and higher (125 W/sq cm) heat flux as well as furnace cycling at 1163C for comparison. The lower heat flux showed the same general behavior as furnace cycling, a gradual, "spotty" increase in luminescence associated with debond progression; however, a significant difference was a pronounced incubation period followed by acceleration delamination progression. These results indicate that extrapolating behavior from furnace cycling measurements will grossly overestimate remaining life under high heat flux conditions. The higher heat flux results were not only accelerated, but much different in character. Extreme bond coat rumpling occurred, and delamination propagation extended over much larger areas before precipitating macroscopic TBC failure. This indicates that under the higher heat flux (and surface & interface temperatures), the TBC was more tolerant of damage. The main conclusions were that high heat flux conditions can not only accelerate TBC debond progression but can also grossly alter the pathway of delamination.

Eldridge, Jeffrey I.↗

NASA NTRS1994

Search of the energetic gamma-ray experiment telescope (EGRET) data for high-energy gamma-ray microsecond bursts

Hawking (1974) and Page & Hawking (1976) investigated theoretically the possibility of detecting high-energy gamma rays produced by the quantum-mechanical decay of a small black hole created in the early universe. They concluded that, at the very end of the life of the small black hole, it would radiate a burst of gamma rays peaked near 250 MeV with a total energy of about 10(exp 34) ergs in the order of a microsecond or less. The characteristics of a black hole are determined by laws of physics beyond the range of current particle accelerators; hence, the search for these short bursts of high-energy gamma rays provides at least the possibility of being the first test of this region of physics. The Compton Observatory Energetic Gamma-Ray Experiment Telescope (EGRET) has the capability of detecting directly the gamma rays from such bursts at a much fainter level than SAS 2, and a search of the EGRET data has led to an upper limit of 5 x 10(exp -2) black hole decays per cu pc per yr, placing constraints on this and other theories predicting microsecond high-energy gamma-ray bursts.

Fichtel, C. E.↗

NASA NTRS1996

Age Life Evaluation of Space Shuttle Crew Escape System Pyrotechnic Components Loaded with Hexanitrostilbene (HNS)

Determining deterioration characteristics of the Space Shuttle crew escape system pyrotechnic components loaded with hexanitrostilbene would enable us to establish a hardware life-limit for these items, so we could better plan our equipment use and, possibly, extend the useful life of the hardware. We subjected components to accelerated-age environments to determine degradation characteristics and established a hardware life-limit based upon observed and calculated trends. We extracted samples using manufacturing lots currently installed in the Space Shuttle crew escape system and from other NASA programs. Hardware included in the study consisted of various forms and ages of mild detonating fuse, linear shaped charge, and flexible confined detonating cord. The hardware types were segregated into 5 groups. One was subjected to detonation velocity testing for a baseline. Two were first subjected to prolonged 155 F heat exposure, and the other two were first subjected to 255 F, before undergoing detonation velocity testing and/or chromatography analysis. Test results showed no measurable changes in performance to allow a prediction of an end of life given the storage and elevated temperature environments the hardware experiences. Given the lack of a definitive performance trend, coupled with previous tests on post-flight Space Shuttle hardware showing no significant changes in chemical purity or detonation velocity, we recommend a safe increase in the useful life of the hardware to 20 years, from the current maximum limits of 10 and 15 years, depending on the hardware.

Hoffman, William C., III↗

NASA NTRS1976

Long-life mission reliability for outer planet atmospheric entry probes

The results of a literature analysis on the effects of prolonged exposure to deep space environment on the properties of outer planet atmospheric entry probe components are presented. Materials considered included elastomers and plastics, pyrotechnic devices, thermal control components, metal springs and electronic components. The rates of degradation of each component were determined and extrapolation techniques were used to predict the effects of exposure for up to eight years to deep space. Pyrotechnic devices were aged under accelerated conditions to an equivalent of eight years in space and functionally tested. Results of the literature analysis of the selected components and testing of the devices indicated that no severe degradation should be expected during an eight year space mission.

Mccall, M. T.↗

NASA NTRS1978

Accelerated/abbreviated test methods for predicting life of solar cell encapsulants to Jet Propulsion Laboratory California Institute of Technology for the encapsulation task of the low-cost solar array project

An important principle is that encapsulants should be tested in a total array system allowing realistic interaction of components. Therefore, micromodule test specimens were fabricated with a variety of encapsulants, substrates, and types of circuitry. One common failure mode was corrosion of circuitry and solar cell metallization due to moisture penetration. Another was darkening and/or opacification of encapsulant. A test program plan was proposed. It includes multicondition accelerated exposure. Another method was hyperaccelerated photochemical exposure using a solar concentrator. It simulates 20 year of sunlight exposure in a short period of one to two weeks. The study was beneficial in identifying some cost effective encapsulants and array designs.

Kolyer, J. M.↗

NASA NTRS1992

Microbial biofilm studies of the environmental control and life support system water recovery test for Space Station Freedom

NASA is developing a water recovery system (WRS) for Space Station Freedom to reclaim human waste water for reuse by astronauts as hygiene or potable water. A water recovery test (WRT) currently in progress investigates the performance of a prototype of the WRS. Analysis of biofilm accumulation, the potential for microbially influenced corrosion (MIC) in the WRT, and studies of iodine disinfection of biofilm are reported. Analysis of WRT components indicated the presence of organic deposits and biofilms in selected tubing. Water samples for the WRT contained acid-producing and sulfate-reducing organisms implicated in corrosion processes. Corrosion of an aluminum alloy was accelerated in the presence of these water samples; however, stainless steel corrosion rates were not accelerated. Biofilm iodine sensitivity tests using an experimental laboratory scale recycled water system containing a microbial check valve (MCV) demonstrated that an iodine concentration of 1 to 2 mg/L was ineffective in eliminating microbial biofilm. For complete disinfection, an initial concentration of 16 mg/L was required, which was gradually reduced by the MCV over 4 to 8 hours to 1 to 2 mg/L. This treatment may be useful in controlling biofilm formation.

Rodgers, E. B.↗

NASA NTRS1993

SATCOM simulator speeds MSS deployment and lowers costs

Mobile satellite systems (MSS) are being proposed and licensed at an accelerating rate. How can the design, manufacture, and performance of these systems be optimized at costs that allow a reasonable return on investment? The answer is the use of system simulation techniques beginning early in the system design and continuing through integration, pre- and post-launch monitoring, and in-orbit monitoring. This paper focuses on using commercially available, validated simulation instruments to deliver accurate, repeatable, and cost effective measurements throughout the life of a typical mobile satellite system. A satellite communications test set is discussed that provides complete parametric test capability with a significant improvement in measurement speed for manufacturing, integration, and pre-launch and in-orbit testing. The test set can simulate actual up and down link traffic conditions to evaluate the effects of system impairments, propagation and multipath on bit error rate (BER), channel capacity and transponder and system load balancing. Using a standard set of commercial instruments to deliver accurate, verifiable measurements anywhere in the world speeds deployment, generates measurement confidence, and lowers total system cost.

Carey, Tim↗

NASA NTRS1992

Low-Isp derated ion thruster operation

The performance and lifetime expectations of 30 cm xenon ion thruster technology at low values of specific impulse were evaluated, with emphasis on 1000-2500 s operation. Power levels of up to 2.0 kW, appropriate for auxiliary and orbit maneuvering propulsion, were processed at thrust-to-power ratios up to 57 mN/kW. These tests were conducted using a derated 30 cm ion thruster with high-perveance design two-grid ion optics with xenon propellent. Lifetime projections were made based on a simple analysis of critical component erosion rates, and it was found that a strong correlation exists with the ratio of the specific impulse-to-input power. Under all operating conditions for which the projected thruster lifetime is less than 10,000 hrs, the life-limiting component of this technology is erosion of the accelerator grid due to charge-exchange ions. The use of alternative grid materials such as carbon is estimated to increase useful thruster lifetimes by as much as an order of magnitude and may enable long-life high thrust-density, sub-2500 s Isp operation. The performance and life of the derated thruster appears similar to that of the Russian SPT-100 thruster in the 1.0-2.0 kW, 1600-2000 s operational envelope.

Patterson, Michael J.↗

NASA NTRS1992

Low-Isp derated ion thruster operation

The performance and lifetime expectations of 30 cm xenon ion thruster technology at low values of specific impulse were evaluated, with emphasis on 1000-2500 s operation. Power levels of up to 2.0 kW, appropriate for auxiliary and orbit maneuvering propulsion, were processed at thrust-to-power ratios up to 57 mN/kW. These tests were conducted using a derated 30 cm ion thruster with high-perveance design two-grid ion optics with xenon propellant. Lifetime projections were made based on a simple analysis of critical component erosion rates, and it was found that a strong correlation exists with the ratio of the specific impulse-to-input power. Under all operating conditions for which the projected thruster lifetime is less than 10,000 hrs, the life-limiting component of this technology is erosion of the accelerator grid due to charge-exchange ions. The use of alternative grid materials such as carbon is estimated to increase useful thruster lifetimes by as much as an order of magnitude and may enable long-life high thrust-density, sub-2500 s Isp operation. The performance and life of the derated thruster appears similar to that of the Russian SPT-100 thruster in the 1.0-2.0 kW, 1600-2000 s operational envelope.

Patterson, Michael J.↗

NASA NTRS2001

Effects of via-conductor geometry in the electromigration failure of Al:Cu wires

Electromigration (EM) experiments conducted using two types of via/plug to conductor alignment indicate a geometrical dependence of electromigration failure in Al:Cu conductors. The resistance vs time curves show distinctive steps when the alignment is parallel. This is explained by a successive loss of conductivity through the plug due to void formation. In the perpendicular via/conductor arrangement, resistance increases by smaller and closely spaced steps. EM experiments without vias, found that the conductor life under stress increases by at least an order of magnitude. Kinetic studies at four temperatures between 180-240 C found activation energies to be 1.0 plus or minus 0.1eV.

Al:Cu accelerated testing electromigration activat↗

NASA NTRS1977

Investigation of test methods, material properties and processes for solar cell encapsulants

The potentially useful encapsulating materials for Task 3 of the Low-Cost Silicon Solar Array project were studied to identify, evaluate, and recommend encapsulant materials and processes for the production of cost-effective, long-life solar cell modules. Materials for study were chosen on the basis of existing knowledge of generic chemical types having high resistance to environmental weathering. The materials varied from rubbers to thermoplastics and presented a broad range of mechanical properties and processing requirements. Basic physical and optical properties were measured on the polymers and were redetermined after exposure to indoor artificial accelerated aging conditions covering four time periods. Strengths and weaknesses of the various materials were revealed and data was accumulated for the development of predictive methodologies. To date, silicone rubbers, fluorocarbons, and acrylic polymers appear to have the most promising combination of characteristics. The fluorocarbons may be used only as films, however, because of their high cost.

Willis, P. B.↗

NASA NTRS1988

Successful completion of a cyclic ground test of a mercury ion auxiliary propulsion system

An engineering model Ion Auxiliary Propulsion System (IAPS) 8-cm thruster (S/N 905) has completed a life test at NASA Lewis Research Center. The mercury ion thruster successfully completed and exceeded the test goals of 2557 on/off cycles and 7057 hr of operation at full thrust. The final 1200 cycles and 3600 hr of the life test were conducted using an engineering model of the IAPS power electronics unit (PEU) and breadboard digital controller and interface unit (DCIU). This portion of the test is described in this paper with a charted history of thruster operating parameters and off-normal events. Performance and operating characteristics were constant throughout the test with only minor variations. The engineering model power electronics unit operated without malfunction; the flight software in the digital controller and interface unit was exercised and verified. Post-test inspection of the thruster revealed facility enhanced accelerator grid erosion but overall the thruster was in good condition. It was concluded that the thruster performance was not drastically degraded by time or cycles. Additional cyclic testing is currently under consideration.

Francisco, David R.↗

NASA NTRS1988

Successful completion of a cyclic ground test of a mercury Ion Auxiliary Propulsion System

Francisco, David R.↗

NASA NTRS1971

Performance of a 10 mlb biowaste resistojet.

Description of the thrusting performance of a 10-mlb thrust, concentric-tubes biowaste resistojet, which was life tested on hydrogen and ammonia propellants for 8000 hours. Thrusting performance is presented for H2, H2O, CH4, and CO2 as well as typical biopropellant mixtures CO2-CH4, H2O-CH4 and CO2-H2O. Using Pt-Ir alloy heater tubes, 235 and 575 seconds were obtained for water and hydrogen propellants. Overall total power efficiencies were 66%, which includes losses for a preevaporator close-coupled for the water tests. Vibration to 1.0 sq q/Hz with an overall G rms of 36, shock at 30 g's and acceleration to 8 g's simulating a launch were passed by the thrustor.

Phillips, D. G.↗

NASA NTRS1993

Benefits gained and lessons learned from NASA's Small Explorer (SMEX) Program

NASA's Small Explorer Program (SMEX) is a sustained program of scientific satellites limited in mass to 200-300 kg (depending on orbital inclination) for a 500-km circular orbit. The SMEX program was undertaken to obtain the benefits of scientific yield, short development time, and high flight rate, with the goal to launch a mission every year. NASA also uses the program to train engineers and managers in designing and developing spacecraft. The phases of a SMEX mission life cycle are described including the competitive selection of missions through announcement of opportunity and evaluation of proposals, the definition of mission and system requirements, design and development of the spacecraft, testing, launch, and operations. Program content of some SMEX missions is then reviewed. The first SMEX mission was the Solar, Anomalous, and Magnetospheric Particle Explorer, which confirmed that anomalous cosmic rays are only partially ionized atoms. The Fast Auroral Snapshot Explorer was intended to measure the electric, magnetic, and time-variable fields and to record particle flow in the auroral acceleration region. A future mission is the Submillimeter Wave Astronomy Satellite to examine low-level molecular transitions.

Gilman, David↗

NASA NTRS2005

Non-contact Creep Resistance Measurement for Ultra-high temperature Materials

Continuing pressures for higher performance and efficiency in propulsion are driving ever more demanding needs for high-temperature materials. Some immediate applications in spaceflight include combustion chambers for advanced chemical rockets and turbomachinery for jet engines and power conversion in nuclear-electric propulsion. In the case of rockets, the combination of high stresses and high temperatures make the characterization of creep properties very important. Creep is even more important in the turbomachinery, where a long service life is an additional constraint. Some very high-temperature materials are being developed, including platinum group metals, carbides, borides, and silicides. But the measurement of creep properties at very high temperatures is itself problematic, because the testing instrument must operate at such high temperatures. Conventional techniques are limited to about 1700 C. A new, containerless technique for measuring creep deformation has been developed. This technique is based on electrostatic levitation (ESL) of a spherical sample, which is heated to the measurement temperature and rotated at a rate such that the centrifugal acceleration causes creep deformation. Creep of samples has been demonstrated at up to 2300 C in the ESL facility at NASA MSFC, while ESL itself has been applied at over 3000 C, and has no theoretical maximum temperature. The preliminary results and future directions of this NASA-funded research collaboration will be presented.

Hyers, Robert W.↗

NASA NTRS2016

A Fly-Through Mission Strategy Targeting Peptide as a Signature of Chemical Evolution and Possible Life in Enceladus Plumes

In situ detection of organic molecules in the extraterrestrial environment provides a key step towards better understanding the variety and the distribution of building blocks of life and it may ultimately lead to finding extraterrestrial life within the Solar System. Here we present combined results of two separate experiments that enable us to realize such in situ life signature detection from the deep habitats of the "Ocean World": a hydrothermal reactor experiment simulating complex organic synthesis and a simulated fly-through capture experiment of organic-bearing microparticles using silica aerogels, followed by subsequent analysis. Both experiments employ peptide as a plausible organics existing in Encleadus plume particles produced in its subsurface ocean. Recent laboratory hydrothermal experiments and a theoretical model on silica saturation indicated an on going hydrothermal reactions in subsurface Enceladus ocean. Given the porous chondritic origin of the core, it is likely that organic compounds originated by radiation chemistry such as amino acid precursors could have been provided, leached, and altered through widespread water-rock interactions. By using the same laboratory experimental setup from the latest water-rock interaction study, we performed amino acid polymerization experiments for 144 days and monitored the organic complexity changing over time. So far over 3,000 peaks up to the size of greater than 600 MW were observed through the analysis of capillary electrophoresis time-of-flight mass spectrometry (CE-TOF-MS) with an indication of amino acid derivatives and short peptides. Generally abiotic polymerization of enantiomeric amino acids results in forming stereoisomeric peptides with identical molecular weight and formula as opposed to homochiral biopolymers. Assuming Enceladus plume particles may contain a mixture of stereoisomeric peptides, we were able to distinguish 16 of the 17 stereoisomeric tripeptides as a test sample using capillary electrophoresis (CE) under optimized conditions. We further conducted Enceladus plume fly-through capture experiment by accelerating peptides soaked in rock particles up to a speed of 5.7 km/s and capturing with originally developed hydrophobic silica aerogels. Direct peptide extraction with acetonitrile-water followed by CE analysis led to detection of only but two stereoisomeric acidic peptide peaks, presenting the first run-through hypervelocuty impact sample analysis targeting peptides as key molecule to to understand the ongoing astrobiology on Enceladus.

organic molecules↗

NASA NTRS2002

Comparison of Several Different Sputtered Molybdenum Disulfide Coatings for Use in Space Applications

Tribology experiments on different types of sputtered molybdenum disulfide (MoS2) coatings (obtained from different vendors) using accelerated testing techniques were conducted. The purpose was to determine which would be the best coating for use with auxiliary journal bearings for spacecraft energy storage flywheels. Experiments were conducted in moist air (50% relative humidity) and in dry air (<100 PPM water vapor content) on a Pin-on-Disk Tribometer to determine how well the coatings would perform in air. Experiments were also conducted on a Block-on-Ring Tribometer in dry nitrogen (<100 PPM water vapor) to simulate how well the coatings would perform in vacuum. Friction, counterface wear, coating wear, endurance life and surface morphology were investigated.

Fusaro, Robert L.↗