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Materials and structures

Materials and structures technology covers a wide range of technical areas. Some of the most pertinent issues for the Astrotech 21 missions include dimensionally stable structural materials, advanced composites, dielectric coatings, optical metallic coatings for low scattered light applications, low scattered light surfaces, deployable and inflatable structures (including optical), support structures in 0-g and 1-g environments, cryogenic optics, optical blacks, contamination hardened surfaces, radiation hardened glasses and crystals, mono-metallic telescopes and instruments, and materials characterization. Some specific examples include low coefficients of thermal expansion (CTE) structures (0.01 ppm/K), lightweight thermally stable mirror materials, thermally stable optical assemblies, high reliability/accuracy (1 micron) deployable structures, and characterization of nanometer level behavior of materials/structures for interferometry concepts. Large filled-aperture concepts will require materials with CTE's of 10(exp 9) at 80 K, anti-contamination coatings, deployable and erectable structures, composite materials with CTE's less than 0.01 ppm/K and thermal hysteresis, 0.001 ppm/K. Gravitational detection systems such as LAGOS will require rigid/deployable structures, dimensionally stable components, lightweight materials with low conductivity, and high stability optics. The Materials and Structures panel addressed these issues and the relevance of the Astrotech 21 mission requirements by dividing materials and structures technology into five categories. These categories, the necessary development, and applicable mission/program development phasing are summarized. For each of these areas, technology assessments were made and development plans were defined.

Saito, Theodore T.↗

Effect of Molding and Machining on Neoflon CTFE M400H Polychlorotrifluoroethylene Rod Stock and Valve Seat Properties

Since 1997 numerous fires have been reported to the Food and Drug Administration involving cylinder valves installed on medical use oxygen cylinders sold and operated within the United States. All of the cylinder valves in question had polychlorotrifluoroethylene (PCTFE) valve seats. Subsequent failure analysis showed that the main seat was the primary source of ignition. A review of the incidents involving cylinder valve fires indicated three possible ignition mechanisms: contaminant promotion, flow friction, and resonance. However, gas purity analysis showed that uncombusted, residual oxygen was within specification. Infrared and energy dispersive spectroscopy further showed that no contaminants or organic compounds were present in the remaining, uncombusted valve seat material or on seat plug surfaces. Therefore, contaminant-promoted ignition did not appear to be responsible for the failures. Observations of extruded material along the outer edge of the coined or loaded seat area produced by cylinder overuse or poppet overload led to concerns that accelerated gas flow across a deformed seat surface could generate enough localized heating to ignite the polymeric seat. Low molecular weight or highly amorphous quick-quenched PCTFE grades might be expected to be especially prone to this type of deformation. Such a failure mechanism has been described as flow friction; however, the corresponding mechanistic parameters are poorly understood. Subsequent revelation of low-temperature dimensional instability by thermomechanical analysis (TMA) in a variety of PCTFE sheet and rod stock samples led to new concerns that PCTFE valve seats could undergo excessive expansion or contraction during service. During expansion, additional extrusion and accompanying flow friction could occur. During contraction, a gap between the seal and adjacent metal surfaces could form. Gas flowing past the gap could, in turn, lead to resonance heating and subsequent ignition as described in ASTM Guide for Evaluation Nonmetallic Materials for Oxygen Service (G 63). Attempts to uncover the origins of the observed dimensional instability were hindered by uncertainties about resin grade, process history, and post-process heat history introduced by machining, annealing, and sample preparation. An approach was therefore taken to monitor property changes before and after processing and machining using a single, well-characterized lot of Neoflon CTFE.1 M400H resin. A task group consisting of the current PCTFE resin supplier, two molders, and four valve seat manufacturers was formed, and phased testing on raw resin, intermediate rod stock, and finished valve seats initiated. The effect of processing and machining on the properties of PCTFE rod stock and oxygen gas cylinder valve seats was then determined. Testing focused on two types of extruded rod stock and one type of compression-molded rod stock. To accommodate valve seat manufacturer preferences for certain rod stock diameters, two representative diameters were used (4.8 mm (0.1875 in.) and 19.1 mm (0.75 in.)). To encompass a variety of possible sealing configurations, seven different valve seat types with unique geometries or machining histories were tested. The properties investigated were dimensional stability as determined by TMA, specific gravity, differential scanning calorimetry (DSC), compressive strength, zero strength time, and intrinsic viscosity. Findings are discussed in the context of polymer structure-process-property relationships whenever possible.

Waller, Jess M.↗

Spheres of Earth: An Introduction to Making Observations of Earth Using an Earth System's Science Approach. Student Guide

Scientists from the Image Science and Analysis Laboratory (ISAL) at NASA's Johnson Space Center (JSC) work with astronauts onboard the International Space Station (ISS) who take images of Earth. Astronaut photographs, sometimes referred to as Crew Earth Observations, are taken using hand-held digital cameras onboard the ISS. These digital images allow scientists to study our Earth from the unique perspective of space. Astronauts have taken images of Earth since the 1960s. There is a database of over 900,000 astronaut photographs available at http://eol.jsc.nasa.gov . Images are requested by ISAL scientists at JSC and astronauts in space personally frame and acquire them from the Destiny Laboratory or other windows in the ISS. By having astronauts take images, they can specifically frame them according to a given request and need. For example, they can choose to use different lenses to vary the amount of area (field of view) an image will cover. Images can be taken at different times of the day which allows different lighting conditions to bring out or highlight certain features. The viewing angle at which an image is acquired can also be varied to show the same area from different perspectives. Pointing the camera straight down gives you a nadir shot. Pointing the camera at an angle to get a view across an area would be considered an oblique shot. Being able to change these variables makes astronaut photographs a unique and useful data set. Astronaut photographs are taken from the ISS from altitudes of 300 - 400 km (~185 to 250 miles). One of the current cameras being used, the Nikon D3X digital camera, can take images using a 50, 100, 250, 400 or 800mm lens. These different lenses allow for a wider or narrower field of view. The higher the focal length (800mm for example) the narrower the field of view (less area will be covered). Higher focal lengths also show greater detail of the area on the surface being imaged. Scientists from the Image Science and Analysis Laboratory (ISAL) at NASA s Johnson Space Center (JSC) work with astronauts onboard the International Space Station (ISS) who take images of Earth. Astronaut photographs, sometimes referred to as Crew Earth Observations, are taken using hand-held digital cameras onboard the ISS. These digital images allow scientists to study our Earth from the unique perspective of space. Astronauts have taken images of Earth since the 1960s. There is a database of over 900,000 astronaut photographs available at http://eol.jsc.nasa.gov . Images are requested by ISAL scientists at JSC and astronauts in space personally frame and acquire them from the Destiny Laboratory or other windows in the ISS. By having astronauts take images, they can specifically frame them according to a given request and need. For example, they can choose to use different lenses to vary the amount of area (field of view) an image will cover. Images can be taken at different times of the day which allows different lighting conditions to bring out or highlight certain features. The viewing angle at which an image is acquired can also be varied to show the same area from different perspectives. Pointing the camera straight down gives you a nadir shot. Pointing the camera at an angle to get a view across an area would be considered an oblique shot. Being able to change these variables makes astronaut photographs a unique and useful data set. Astronaut photographs are taken from the ISS from altitudes of 300 - 400 km (approx.185 to 250 miles). One of the current cameras being used, the Nikon D3X digital camera, can take images using a 50, 100, 250, 400 or 800mm lens. These different lenses allow for a wider or narrower field of view. The higher the focal length (800mm for example) the narrower the field of view (less area will be covered). Higher focal lengths also show greater detail of the area on the surface being imaged. There are four major systems or spheres of Earth. They are: Atmosphere, Biosphere, Hydrosphe, and Litho/Geosphere.

Graff, Paige Valderrama↗

Testing Protocol Development for the Fracture Toughness of Parts Built with Big Area Additive Manufacturing

The mechanical testing of additively manufactured parts has largely relied on the existing standards developed for traditional manufacturing. While this approach leverages the investment made in current standards development, it inaccurately assumes that the mechanical response of additive manufacturing (AM) parts is identical to that of parts manufactured through traditional processes. When considering thermoplastic, material extrusion AM, the differences in response can be attributed to an AM part’s inherent inhomogeneity caused by porosity, interlayer zones, and surface texture. Additionally, the interlayer bonding of parts printed with large-scale AM is difficult to adequately assess, as much testing is performed such that stress is distributed across many layer interfaces; therefore, the lack of AM-specific standards to assess interlayer bonding is a significant research gap. To quantify interlayer bonding via fracture toughness, double cantilever beam (DCB) testing has been used for some AM materials, and DCB has been generally used for a variety of materials including metal, wood, and laminates. Mode I DCB testing was performed on thermoplastic matrix composites printed with Big Area Additive Manufacturing (BAAM). Of particular interest was the notch shape and deflection speed during testing. The results examine the differences when using two notch types and three deflection speeds. The testing method introduced by the following paper differentiates itself from the ones described in the standards used by modernizing the methodology. This was conducted with the introduction of Digital Image Correlation (DIC) to gather displacement and load data simultaneously without human intervention.

Polymer Science↗

An Evaluation of AI Models’ Performance for Three Geothermal Sites

Current artificial intelligence (AI) applications in geothermal exploration are tailored to specific geothermal sites, limiting their transferability and broader applicability. This study aims to develop a globally applicable and transferable geothermal AI model to empower the exploration of geothermal resources. This study presents a methodology for adopting geothermal AI that utilizes known indicators of geothermal areas, including mineral markers, land surface temperature (LST), and faults. The proposed methodology involves a comparative analysis of three distinct geothermal sites—Brady, Desert Peak, and Coso. The research plan includes self-testing to understand the unique characteristics of each site, followed by dependent and independent tests to assess cross-compatibility and model transferability. The results indicate that Desert Peak and Coso geothermal sites are cross-compatible due to their similar geothermal characteristics, allowing the AI model to be transferable between these sites. However, Brady is found to be incompatible with both Desert Peak and Coso. The geothermal AI model developed in this study demonstrates the potential for transferability and applicability to other geothermal sites with similar characteristics, enhancing the efficiency and effectiveness of geothermal resource exploration. This advancement in geothermal AI modeling can significantly contribute to the global expansion of geothermal energy, supporting sustainable energy goals.

Energy & Fuels↗

Reconstruction of the Mesoscale Velocity Shear Seaward of Coastal Upwelling Regions from the Refraction of the Surface Wave Field

The objective of this project is to study fronts that develop at the boundary between cold water recently upwelled to the surface through Ekman divergence, and warmer surrounding waters. This specific objective was suggested by studying the small scale structure of upwelling fronts (coastal, island, and equatorial) through shipboard surveys and infrared satellite images. Constraints on the shuttle equator crossing imposed by other land sites precluded a coverage of the area targeted in the initial SIR-C proposal, the California Current. The site was then relocated to the Equatorial Pacific upwelling tongue, that can be satisfactorily imaged for a wide range of longitudes of the equator crossing. Some limited data was nevertheless obtained over coastal upwelling off California in 1989, using the JPL AIRSAR in multifrequency mode, and over island upwelling off Hawaii in 1990, using the radar in along-track interferometric mode.

Flament, Pierre↗

Preliminary Results from the Confined Helium Experiment

We describe the preliminary results from an experiment to measure the heat capacity of helium confined within a stack of evenly spaced silicon plates at temperatures very close to the superfluid transition. The resolution of the heat capacity measurements was generally about 5x10 (exp -9)K, allowing the finite size peak to be mapped in detail. In addition, wide range data containing information on the behavior of the surface specific heat was collected. The preliminary analysis shows fair agreement with theory, but some discrepancies. The results can also be combined with related ground measurements on smaller length scales to perform additional tests of scaling predictions for cross-over to lower dimensional behavior. Some results in this area are also presented.

Lipa, J. A.↗

Flexible Models for Solar Sail Control

Solar sails employ a unique form of propulsion, gaining momentum from incident and reflected photons. However, the momentum transferred by an individual photon is extremely small. Consequently, a solar sail must have an extremely large surface area and also be extremely light. The flexibility of the sail then must be considered when designing or evaluating control laws. In this paper, solar sail flexibility and its influence on control effectiveness is considered using idealized two-dimensional models to represent physical phenomena rather than a specific design. Differential equations of motion are derived for a distributed parameter model of a flexible solar sail idealized as a rotating central hub with two opposing flexible booms. This idealization is appropriate for solar sail designs in which the vibrational modes of the sail and supporting booms move together allowing the sail mass to be distributed along the booms in the idealized model. A reduced analytical model of the flexible response is considered. Linear feedback torque control is applied at the central hub. Two translational disturbances and a torque disturbance also act at the central hub representing the equivalent effect of deflecting sail shape about a reference line. Transient simulations explore different control designs and their effectiveness for controlling orientation, for reducing flexible motion and for disturbance rejection. A second model also is developed as a two-dimensional "pathfinder" model to calculate the effect of solar sail shape on the resultant thrust, in-plane force and torque at the hub. The analysis is then extended to larger models using the finite element method. The finite element modeling approach is verified by comparing results from a two-dimensional finite element model with those from the analytical model. The utility of the finite element modeling approach for this application is then illustrated through examples based on a full finite element model.

Weaver Smith, Suzanne↗

Pre- and post-annealing of mechanical damage in silicon wafers

Basic properties of mechanical damage in silicon consisting of cracks and abrasion were studied using transmission electron microscopy. The crystallographic structure of mechanical damage was determined before and after high temperature annealing. The main findings include that stresses in silicon around crack tips are not plastically relieved at room temperature and that abrasion at room temperature introduces shear loops into the silicon. It was also found that cracks of micron size can be annealed out, specifically, if cleavage occurs on 111 planes. The healing products of such cracks are 60 deg and 90 deg dislocations. Submicron cracks transform into stacking faults during annealing. Likewise high concentrations of shear loops due abrasion were found to anneal into stacking faults. A one to one correlation between surface areas containing small cracks and stacking faults was made. Measurements of damage removal on silicon surfaces through chemical-mechanical etching techniques are presented. It is shown that silicon dioxide repolishes damaged silicon surfaces most effectively.

Schwottke, G. H.↗

Radar and infrared remote sensing of geothermal features at Pilgrim Springs, Alaska

High-altitude radar and thermal imagery collected by the NASA research aircraft WB57F were used to examine the structural setting and distribution of radiant temperatures of geothermal anomalies in the Pilgrim Springs, Alaska area. Like-polarized radar imagery with perpendicular look directions provides the best structural data for lineament analysis, although more than half the mapped lineaments are easily detectable on conventional aerial photography. Radiometer data and imagery from a thermal scanner were used to evaluate radiant surface temperatures, which ranged from 3 to 17 C. The evening imagery, which utilized density-slicing techniques, detected thermal anomalies associated with geothermal heat sources. The study indicates that high-altitude predawn thermal imagery may be able to locate relatively large areas of hot ground in site-specific studies in the vegetated Alaskan terrain. This imagery will probably not detect gentle lateral gradients.

Dean, K. G.↗

Sensors for ceramic components in advanced propulsion systems: Summary of literature survey and concept analysis, task 3 report

The results of a literature survey and concept analysis related to sensing techniques for measuring of surface temperature, strain, and heat flux for (non-specific) ceramic materials exposed to elevated temperatures (to 2200 K) are summarized. Concepts capable of functioning in a gas turbine hot section environment are favored but others are reviewed also. Recommendation are made for sensor development in each of the three areas.

Bennethum, W. H.↗

Space Shuttle production verification motor 1 (PV-1) field joint protection system, volume 7

The performance of the field joint protection system (FJPS) of the Space Shuttle Production Verification Motor 1 (PV-1), as evaluated by postfire hardware inspection. Compliance with the specifications is shown for the FJPS assembly and components. The simplified FJPS and field joint heaters performed nominally, maintaining all joint seal temperatures within the required range. One anomally was noted on the igniter-to-case joint heater during postfire inspection. The heater buckled off the surface in two areas, resulting in two hot spots on the heater and darkened heater insulation. The condition did not affect heater performance during ignition countdown and all igniter seals were maintained within required temperature limits.

Wilkinson, J. P.↗

Mapping Surface Cover Parameters Using Aggregation Rules and Remotely Sensed Cover Classes

A coupled model, which combines the Biosphere-Atmosphere Transfer Scheme (BATS) with an advanced atmospheric boundary-layer model, was used to validate hypothetical aggregation rules for BATS-specific surface cover parameters. The model was initialized and tested with observations from the Anglo-Brazilian Amazonian Climate Observational Study and used to simulate surface fluxes for rain forest and pasture mixes at a site near Manaus in Brazil. The aggregation rules are shown to estimate parameters which give area-average surface fluxes similar to those calculated with explicit representation of forest and pasture patches for a range of meteorological and surface conditions relevant to this site, but the agreement deteriorates somewhat when there are large patch-to-patch differences in soil moisture. The aggregation rules, validated as above, were then applied to remotely sensed 1 km land cover data set to obtain grid-average values of BATS vegetation parameters for 2.8 deg x 2.8 deg and 1 deg x 1 deg grids within the conterminous United States. There are significant differences in key vegetation parameters (aerodynamic roughness length, albedo, leaf area index, and stomatal resistance) when aggregate parameters are compared to parameters for the single, dominant cover within the grid. However, the surface energy fluxes calculated by stand-alone BATS with the 2-year forcing, data from the International Satellite Land Surface Climatology Project (ISLSCP) CDROM were reasonably similar using aggregate-vegetation parameters and dominant-cover parameters, but there were some significant differences, particularly in the western USA.

Arain, Altaf M.↗

Computational Investigation of Powered Descent for Human-Scale Mars Landers

NASA human-scale Mars entry, descent, and landing vehicles currently under consideration have system requirements beyond the current state of the art. Specifically, heritage approaches for deceleration using parachutes and initiating engines at subsonic speeds are not adequate to land these large vehicles (50-60 metric ton entry mass) precisely (within 50 meters of a surface target). Therefore, the present approach for landing humans on Mars utilizes entry vehicles with large aerodynamic surface areas that transition to the descent and landing phase by initiating retropropulsion at supersonic speeds. Vehicle performance, including stability and control, depends on accurate characterization of the aerodynamic-propulsive interference effects, especially at engine initiation, when the vehicles are transitioning from an entry attitude to that suitable for descent and landing. This paper summarizes the human Mars entry vehicle configurations, retropropulsion integration, performance assumptions, and expected flight environment at engine initiation. Cases spanning supersonic, transonic, and subsonic conditions during powered descent are analyzed using four computational fluid dynamics codes, all of which have been previously applied to supersonic retropropulsion at varying scales and conditions. The results of the analysis are used to develop an aerodynamic-propulsive interference model that has since been applied in trajectory simulations to augment the fidelity of human-scale Mars entry vehicle performance.

Ashley M Korzun↗

Using Open Innovation in Reducing Risk to Crews

In the exploration of destinations outside of Earth's neighborhood, specifically Mars, scientific and engineering inquiries have occurred by two means; observations from satellites and observations by landed spacecraft. Satellite observations (Mariner, MRO, Mars Odyssey, provide global-scale spatial and temporal data while landed spacecraft (Viking, Mars Pathfinder, Spirit, Opportunity, Phoenix Mars Lander) investigate highly localized areas of the surface of the planet. In preparation for human exploration, extensive knowledge of the surface and atmospheric environments should be known before the first human leaves Earth. The primary goal of performing reconnaissance on Mars on a sub-global scale is to know as much as possible about the environment to which crews will be subjected. At the current rate of launching and landing probes to Mars, it will take a very long time to understand the surface and atmospheric conditions associated with the regions where prospective crews may land. Meanwhile electronics and electrical systems are rapidly getting smaller. One can argue that to acquire the knowledge of the region, one must take hundreds, maybe thousands of measurements simultaneously. One means to perform such a task is to deploy a swarm of sensors. Such a swarm would perform an in-situ assessment of the region. Imagine a close flyby mission to Mars for example, where mini- to micro-sensors are deposited into the atmosphere over half an orbit or more. The sensors, captured by the atmospheric drag and Martian gravity slowly descend buffeted about by Martian winds and weather until they settle on the surface a great time later (think of how long dust takes to settle). As they descend they communicate a vast array of data; temperature, chemistry, pressure, radiation dose, electric or magnetic properties from a region of the planet and an individual sensor need not measure the same quantity as its neighbors. Initially, they could move at the whim of the environment but later versions could have locomotion or propulsion mechanisms. Humans wouldn't need to decide where the sensors go, the sensors do that for themselves. This is a key strength of a sensor swarm. The intelligence relies on the group not on a decision maker on earth. Real time sensor inputs direct what the swarm considers most interesting to investigate resulting in emergent behavior. We issued a $20,000 challenge to the global innovators to provide solutions as to how such a swarm could be initialized and by what protocols and methodologies by which they operate. Over 400 innovators from 49 countries took a look at the problem, with three receiving partial awards for solutions.

Mel Ferebee↗

Atmospheric effects on radiometric imaging from satellites under low optical thickness conditions

The interference that the atmosphere poses to analyzing the imagery taken by satellite-borne instruments is discussed, assuming a cloud-free, planar, and horizontally uniform atmosphere. An approximate explicit formula is derived for the earth-atmosphere system nadir-beam reflectivity in terms of the atmospheric parameters, object pixel reflectivity and surrounding area reflectivity, for the limiting case of an optically thin atmosphere. The concepts of the forward-scattering and the backward-scattering optical thickness are introduced, and it is shown that the atmospheric effects in a spectral band depend in a specific fashion on these atmospheric parameters and on the surface spectral reflectivity. In addition, contrast transmittance through the atmosphere, which affects the possibilities of photointerpretation, is discussed.

Otterman, J.↗

Exploration of crustal/mantle material for the earth and moon using reflectance spectroscopy

Near-infrared reflectance spectra have been acquired (1) for Moses Rock diatreme in SE Utah using an airborne imaging spectrometer (AIS) and (2) for small areas in and around the large lunar impact crater Copernicus using a spectrometer on earth-based telescopes. The high spectral resolution and precision of these data allow several mineral components of surface material to be identified and analyzed in a spatial context. The derived mineralogical information is used to address specific geological problems. For the terrestrial study the distribution of the measured abundance of mantle derived ultramafic microbreccia across Moses Rock dike indicates that flow stabilized into a few channels during the violent eruption. For the lunar study the variety of rock types identified in crustal material of deep-seated origin is distinct from the dominant rock types sampled from the upper lunar crust and suggests a complex crustal evolution.

Pieters, Carle M.↗

Detailed examination of LDEF's frame and the A0178 thermal blankets by the meteoroid and debris special investigations group

A responsibility of the group is to define the hypervelocity particle environment encountered by LDEF during its stay in low Earth orbit. LDEF's 6061-T6 aluminum frame and the 'Teflon silver-inconel paint' thermal blankets represent large surface areas that were widely distributed around the spacecraft. The results are reported of high resolution scans of approx. 0.36 and approx. 0.31 sq m for the intercostals and thermal blankets, respectively. The findings are in qualitative agreement with existing model predictions that suggest high differential bombardment histories for surfaces pointing into specific directions relative to the velocity vector of a non-spinning platform in LEO. The production rate for craters greater than or = 50 microns in diameter in aluminum and penetration holes greater than or = 100 microns in diameter in thin foil materials differ by more than a factor of 10 between forward and rearward facing surfaces. These are substantial differences that must be considered during the design of future long duration space platforms in LEO.

See, Thomas H.↗