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The continued process development of SiO2 insulators for use in advanced InSb monolithic charge coupled infrared imaging arrays is described. Specific investigations into the use of plasma enhanced chemical vapor deposited (PECVD) SiO2 as a gate insulator for InSb charge coupled devices is discussed, as are investigations of other chemical vapor deposited SiO2 materials.
A viewgraph presentation on the use of Nano-Structured Materials to enable pressure vessel structures for deep atmospheric probes is shown. The topics include: 1) High Temperature/Pressure in Key X-Environments; 2) The Case for Use of Nano-Structured Materials Pressure Vessel Design; 3) Carbon based Nanomaterials; 4) Nanotube production & purification; 5) Nanomechanics of Carbon Nanotubes; 6) CNT-composites: Example (Polymer); 7) Effect of Loading sequence on Composite with 8% by volume; 8) Models for Particulate Reinforced Composites; 9) Fullerene/Ti Composite for High Strength-Insulating Layer; 10) Fullerene/Epoxy Composite for High Strength-Insulating Layer; 11) Models for Continuous Fiber Reinforced Composites; 12) Tensile Strength for Discontinuous Fiber Composite; 13) Ti + SWNT Composites: Thermal/Mechanical; 14) Ti + SWNT Composites: Tensile Strength; and 15) Nano-structured Shell for Pressure Vessels.
Two storage containers are disclosed within which food or biological samples may be stored for transfer in a module by the space shuttle to a space station while maintaining the food or samples at very low temperatures. The container is formed in two parts, each part having an inner shell and an outer shell disposed about the inner shell. The space between the shells is filled with a continuous wrap multi-layer insulation and a getter material. The two parts of the container have interlocking members and when connected together are sealed for preventing leakage from the space between the shells. After the two parts are filled with frozen food or samples they are connected together and a vacuum is drawn in the space between the shells and the container is stored in the module. For the extremely low temperature requirements of biological samples, an internal liner having a phase change material charged by a refrigerant coil is disposed in the space between the shells, and the container is formed from glass fiber material including honeycomb structural elements. All surfaces of the glass fiber which face the vacuum space are lined with a metal foil.
A system and method for detecting damage in an electrical wire, including delivering at least one test electrical signal to an outer electrically conductive material in a continuous or non-continuous layer covering an electrically insulative material layer that covers an electrically conductive wire core. Detecting the test electrical signals in the outer conductive material layer to obtain data that is processed to identify damage in the outer electrically conductive material layer.
During the Hubble Space Telescope (HST) second servicing mission, astronauts noticed that the outer layer of the multilayer insulation (MLI) was cracked in many locations around the telescope. The insulation s outer layer is composed of 5-mil (0.127 mm) Teflon FEP (DuPont; fluorinated ethylene propylene) with vapor-deposited aluminum (VDA) on the backside. The MLI blankets, which are used on over 80 percent of the external surface of the telescope, provide passive thermal control for equipment. Two large cracks were observed on the light shield directly above the high gain antenna. The upper light shield crack propagated from a cut placed in the blanket during installation around a handrail standoff. Two cracks propagated almost normal to each other, with the outer layer curling tightly as the cracks propagated. A second much larger vertical crack had started to curl and lift away from the telescope, as seen in the figure. MLI on the equipment bays was cracked extensively also, and in some areas it had pulled away from the bay. Continued degradation of the equipment bay insulation would potentially cause limited observations because of housekeeping boxes; for example, the data interface unit could overheat during some portions of the year, in certain sun angles.
Flexible intumescent protection sheeting of unusually uniform thickness were prepared from epoxy-polysulfide compositions, containing microfibers and the ammonium salt of 1,4-nitroaniline-2-sulfonic acid, as disclosed in U.S. Pat. No. 3,663,464, except that an ammonium salt particle size in the order of 5 to 8 microns and a fiber size of about 1/128th inch in length and 3 to 5 microns in diameter were found critical to obtain the required density of 1.46 to 1.50 g/cc. The insulation sheeting was prepared by a continuous process involving vacuum mixing, calendering, and curing under very strict conditions which depend to some extent upon the thickness of the sheet produced.
Twelve types of prototypes modules for the DOE Photovoltaic Flat Panel Procurement (PRDA 38) were subjected to qualification tests at the Jet Propulsion Laboratory according to a new specification. Environmental exposures were carried out separately and included temperature cycling, humidity, wind simulation, and hail. The most serious problems discovered were reduced insulation resistance to ground and ground continuity of the metal frames, electrical degradation, erratic power readings, and delamination. The electrical and physical characteristics of the newly received modules are also given.
NASA Langley has invented LaRC(exp TM) IA and IAX which are thermoplastic polyimides with good melting, thermal and chemical resistance properties. It was the objective of this contract to prepare and extrude LaRC (exp TM) polyimide onto aircraft wire and evaluate the polymers performance in this critical application. Based on rheology and chemical resistance studies at Imitec, LaRC (exp TM) IAX melts readily in an extruder, facilitating the manufacture of thin wall coatings. The polyimide does not corode the extruder, develop gel particles nor advance in viscosity. The insulated wire was tested according to MiL-W-22759E test specifications. The resulting wire coated with LaRC (exp TM) IAX displayed exceptional properties: surface resistance, non blocking, non burning, hot fluid resistance, impulse dielectric, insulation resistance, low temperature flexibility, thermal aging, wire weight, dimensions, negligible high temperature shrinkage and stripability. The light weight and other properties merit its application in satellites, missiles and aircraft applications. The extruded IAX results in a polyimide aircraft insulation without seams, outstanding moisture resistance, continuous lengths and abrasion resistance.
Westwood Aerogel investigated the reproducible production of an ambiently or electromagnetic spectrum assisted drying of extremely porous aerogel materials. Traditional aerogel processing is limited by low throughput and scalability due to supercritical drying. Westwood Aerogel’s advanced manufacturing process enables commercialization and deployment at scale, making aerogel materials more accessible to a range of industries and applications. We focused on shifting from the lab scale environment to manufacturing prototypes. The initial manufacturing model is based on the float glass process, which is the industry standard for glass window production, and the paper drying process. By incorporating an ambient drying process a continuous line model can be used from start to finish. The project team worked to develop a continuous manufacturing system to scale-up and reduce costs while maintaining the lightweight and insulative properties of aerospace-grade aerogel. While aerogels are extremely insulative, lightweight, and thin materials (making them ideal insulators across application spaces), high costs and stagnant innovation have hampered their wider adoption. Traditional manufacturing of aerogel requires supercritical extraction of pore fluid to obtain highly insulating materials, which is an energy intensive batch process and limits aerogel production output. Westwood Aerogel’s proprietary ambient drying process enables the continuous production of highly insulative aerogel materials without the use of supercritical extraction.
Abstract Electrical signaling is a fundamental mechanism for integrating environmental stimuli and coordinating responses in living organisms. While extensively studied in animals and plants, the role of electrical signaling in fungi remains a largely underexplored field. Early studies suggested that filamentous fungi generate action potential-like signals and electrical currents at hyphal tips, yet their function in intracellular communication remained unclear. Renewed interest in fungal electrical activity has fueled developments such as the hypothesis that mycorrhizal networks facilitate electrical communication between plants and the emerging field of fungal-based electronic materials. Given their continuous plasma membrane, specialized septal pores, and insulating cell wall structures, filamentous fungi possess architectural features that could support electrical signaling over long distances. However, studying electrical phenomena in fungal networks presents unique challenges due to the microscopic dimensions of hyphae, the structural complexity of highly modular mycelial networks, and the limitations of traditional electrophysiological methods. This review synthesizes current evidence for electrical signaling in filamentous fungi, evaluates methodological approaches, and highlights experimental challenges. By addressing these challenges and identifying best practices, we aim to advance research in this field and provide a foundation for future studies exploring the role of electrical signaling in fungal biology.
Several different tests are described which simulated the actual configuration of a cryogenic wind tunnel operating at pressures up to 5 atmospheres (507 kPa) and temperatures from -320 F (78K) to 120 F (322K) in order to determine compatible bolting, adequate sealing, and effective insulating materials. The evaluation of flange attachments (continuous threaded studs) considered bolting based on compatible flanges, attachment materials, and prescribed bolt elongations. Various types of seals and seal configurations were studied to determine suitability and reusability under the imposed pressure and temperature loadings. The temperature profile was established for several materials used for structural supports.
Brief Presenter Biography:Ruth Miller is an aer-ospace systems engineer in the Entry Systems and Ve-hicle Development Branch at NASA Ames Research Center.Introduction:The flexible thermal protection sys-tem (FTPS) on NASA’s Low-Earth Orbit Flight Test of an Inflatable Decelerator (LOFTID) vehicle will be in-strumented with thermocouples (TCs) to measure the in-depth thermal response during entry into Earth’s atmos-phere[1, 2]. Accurate flight temperature measurements are critical for verifying vehicle performance during the flight test and reducing uncertainties in the thermal models.However,the deployable nature of inflatable decelerator technology presents challengesfor integrat-ing TCs, specifically the TCsneed to be compactableand cannot damage the FTPSnor the inflatable structure(IS).Unlike traditional rigid aeroshells, routing TCsthrough the thickness of the FTPS could cause signifi-cant damage during packing of the deployable aeroshellbecause the different layers may shift small amounts in relation to each other imparting strain on the TCsand FTPS materials. The LOFTID TCleads are routed from the measurement location back to the data acquisition system in the vehicle centerbody within the same FTPS layer that they are monitoring the temperature. This ap-proach eliminates the need to put holes in the FTPS lay-ers,butas a consequence,the insulated TCleads travel for an appreciable distance through a region that will expose them to high temperaturesand large thermal gra-dients.LOFTID’s TCswere baselined to be commercially available Type K TCswith a binder impregnated glass braid insulation. These TCswere chosen because they had been used successfully on IRVE-3 and in ground-based arc jet testing. Additionally, these TCsdid notdamage the FTPS nor IS during packing and deploy-ment testing. However, the glass braid insulation is only rated to a maximum continuous use temperature of 482ºC. For reference, the duration of the heat pulse on the LOFTID vehicle is on the order of minutes and themaximum predicted temperaturebeneaththe outermost FTPS layersis 1350ºC.Ground-based testing in a tube furnace at NASA Ames Research Centerwas conducted to determine if the baseline TCsrouted through FTPS samples would survive and provide accurate temperature measure-mentsat LOFTID flight-relevant temperatures[3].The test results showed large measurement errors occurred beginning at approximately 400°C due to conductive deposits on the TCinsulation electrically shorting the TCleads.The conductive deposits and thus electrical shorting weredetermined to be caused by twoerror sources:1.The organic binder on the TCinsulation carbon-izingin a high temperature, low oxygen envi-ronment2.Decomposition products from the FTPSperme-atingthe braided TC insulationFurther testing in the tube furnace demonstrated that heat cleaning the TCinsulation effectivelyremovedthe organic binder andeliminatedthe first error source.The second error sourcewas shown to be mitigated by the addition of amica wraparound each individual TCleadtoact as an impermeable barrier.To understand the applicability of theground-based tube furnace test results to flight,anarc jet testseriesat Boeing’s Large Core Arc Tunnel (LCAT) facilitywas conducted[4].The error sourcesand mitigation strate-giesidentified in the tube furnace testing were substan-tiatedin the arc jet testing.However, the arc jet testing also revealed three new error sources:1.Glass TCinsulation meltingwhich resultsin electrical shorting of the TCeither through di-rect contact between the two leads or through the electrically conductive FTPS materials2.TCwire meltingwhich results in a noisy and/or open-loop TCresponse3.Type K TCwire green-rotwhich results in large calibration errors Scope of the Presentation:This presentation will include a brief discussion onthe effect of electrical shorting on the output of a TC(i.e. how to identify elec-trical shorting in TCdataand what the associated erroris).The tube furnace and arc jet test resultswill be dis-cussedand the solutions LOFTID is implementing to mitigate the error sourcesidentified in the tube furnace and arc jet testingwill be presented.Additionally, futureresearch and development work to eliminateTCerror sourcesfor future missionswill be recommended.
Composite materials offer unique benefits in aerospace applications, including high strength-to-weight ratio, and are becoming increasingly used by industry manufacturers. Current manufacturing and processing methods can lead to defects in the composites, which are identified after fabrication using inspection methods. This study utilized a high-temperature ultrasonic inspection system to detect process-induced porosity in an out-of-autoclave (OOA) composite panel during cure. In order to perform ultrasonic scans in-situ during cure, the system needed to be able to operate at oven temperatures up to 200 °C. There are no commercially available ultrasonic scanning systems that can operate continuously at these temperatures, so an enclosure was fabricated to insulate the ultrasonic system in the curing oven. The enclosure housed a MISTRAS® motorized X-Y raster scanner and contact transducer (Olympus® X2002). The Olympus® X2002 contact transducer is a continuous high-temperature delay line transducer with a center frequency of 2.25 MHz. In order to prevent the inside of the enclosure from reaching high temperatures, a sparge pipe inside the cooling enclosure was connected to a liquid nitrogen (LN2) tank outside of the oven via insulated hoses. The cooling system was automatically controlled by a temperature controller that was programmed to open a solenoid valve along the hose at 31 ℃ and close at 28 ℃ inside the cooling enclosure. When the solenoid valve was open, LN2 would flow from the LN2 tank and vaporize prior to reaching cooling enclosure. A U-shaped sparge pipe had holes drilled along its length to uniformly introduce cold nitrogen gas into the cooling enclosure. This prevented the motors from ever reaching the maximum desired operating temperature of 38 ℃. In the bottom of the enclosure, the tool plate was placed with the composite facing the outside of the enclosure, exposing it to the temperatures of the oven. The tool plate was 63.5 mm thick borosilicate glass, which was chosen for its low ultrasonic attenuation and moderate thermal conductivity. A thin layer of ultrasonic couplant was placed on the tool plate. The transducer sent and received ultrasonic waves through the tool plate into the composite. A MISTRAS® Remote UT System performed all wave generation, analog to digital conversion, and data acquisition and processing. The transducer was connected directly to the Remote UT System via a high-temperature BNC cable (CD International, RG-316). Polyimide insulated copper wire was used to connect the scanner to a 2-axis motor drive, which was connected to the Remote UT System. The motor drive and Remote UT System were located outside the industrial oven. A diagram of the ultrasonic system is shown in Figure 1. Figure 1: Diagram of ultrasonic in-situ defect detection system. In this study, a porosity gradient was introduced into the carbon fiber reinforced polymer (CFRP) composite through a misfit of the part and caul plate. A 24-ply quasi-isotropic ([0/90, ±45]12S) composite panel was laid up using Newport® AS4C-M/NB321 out-of-autoclave (OOA) plain weave (PW) prepreg (42% resin content, 195 g/m2). The first 16 plies were 203 mm × 203 mm. Ply drops were incorporated into the panel by decreasing the length of plies 17-24. The sizes of each ply are included in Table 1. All plies were centered along their length (x-axis) creating a trapezoidal type cross-section. Table 1: Ply sizes Plies Length (mm) Width (mm) 1-16 203 203 17-18 102 203 19-20 85 203 21-22 68 203 23-24 51 203 A 15-5 stainless steel caul plate (Size: 203 × 203 × 1.2 mm) was placed on the laminate. The composite and caul plate were vacuum bagged to the tool plate. Per the product datasheet, Newport 321 can be cured between 121 °C and 149 °C, depending on service temperature, with a hold for 90-120 minutes. Based on prior thermal testing of the cooling enclosure, the desired composite temperature cycle could be attained when the air temperature of the oven was ramped to 160 °C at a rate of 1.7 °C/min with a 3 hour hold. The extended hold was not necessary to cure the composite, but did allow for additional scans at the cure temperature during preliminary testing. The composite panel was under vacuum pressure for the entire cure cycle. Under vacuum, the caul plate deformed causing high and low pressure regions. The low-pressure regions formed high porosity in the composite part. The ultrasonic data collected showed that the inspection system was able to monitor the evolution of porosity within the composite throughout the cure cycle. Fifty scans of a 203 mm × 51 mm (8 in. × 2 in.) area of the composite were completed throughout the cure cycle. The scan speed was set to 43 mm/s in the x-direction and 36 mm/s in the y-direction, with a 1.0 mm/pixel resolution in both directions. Each scan took approximately five minutes to complete. Figure 2 shows C-scan amplitude data (top view) from one scan during the cure cycle. The color map indicates the maximum amplitude (%) measured with a time gate that contains reflections from the back surface (furthest from the transducer in contact with the caul plate) of the composite. Because porosity in the composite increases the ultrasonic attenuation in the composite part, a higher amplitude (red) indicates low porosity and a lower amplitude (blue) indicates high porosity. The regions where the caul plate was applying increased pressure (center and ends of the panel) resulted in reduced porosity, whereas the ply drop regions had reduced pressure and thus had higher porosity. Figure 2: Amplitude C-scan (top view) of OOA composite from one scan during the 160 °C temperature hold. Higher amplitude (red) indicates low porosity. Lower amplitude (blue) indicates high porosity. A B-scan is a two-dimensional image plotting the ultrasonic signals from a single y-position at every x-location of the composite panel. The travel time (μs) of the ultrasonic wave (representing the through-thickness location) is plotted along the y-axis, and the ultrasonic wave signal is represented as a contour map. Based on the B-scan data, the location of the defects with respect to the composite thickness was able to be determined. The ply drop regions had high porosity near the front (tool plate) surface of the composite (Figure 3). Figure 3: B-scan (cross-section view) of OOA composite from one scan during the 160 °C temperature hold. Using the data obtained from amplitude C-scans and B-scans throughout the cure cycle, the high and low porosity regions within the composite laminate were detected and localized with high spatial resolution. This paper will discuss the evolution of porosity content in the OOA composite during cure. OOA tests aided the transition of this system to an autoclave, which is the primary method of curing aerospace-grade thermoset composites.
Four very large (900Kgal) cryogenic liquid hydrogen and oxygen storage tanks at Kennedy Space Center's LC-39 launch pads were constructed in 1965 to support the Apollo/Saturn V Program and continue to support the Space Shuttle Program. These double-walled spherical tanks with powdered insulation in the annular region, have received minimal refurbishment or even inspection over the years. Intrusively inspecting these tanks would mean a significant down time to the program as the cryogenic liquid and the perlite insulation would have to be removed which would be a significant task and long-term schedule disruption. A study of the tanks was performed to determine the extent to which performance and structural information could be revealed without intrusive inspection. Thermal images of the tanks were taken over a variety of environmental conditions to determine the best conditions under which to compare and use thermography as a health monitoring technique as the tanks continue to age. The settling and subsequent compaction of insulation is a serious concern for cryogenic tanks. Comparison of images from the tanks reveals significant variations in the insulation in the annual regions and point to the use of thermography as a way to monitor for insulation migration and possible compaction. These measurements, when combined with mathematical models of historical boil-off data provide key insight to the condition of the vessels. Acceptance testing methods for new tanks, before they are filled with cryogenic commodity (and thereby thermally cycled), are needed and we explore how thermography can be used to accomplish this.
In a continual mass optimization effort for the Orion vehicle by NASA and its prime contractor Lockheed Martin Space, along with the European Space Agency (ESA) and its contractors Airbus and Thales Alenia Space-Italy (TAS-I), a series of shield characterization shots have been performed to quantify the ballistic enhancement of a single-layer of Kevlar® in multi-layer insulation (MLI). This enhanced MLI is part of Orion’s propulsion subsystem, and it is planned to replace a double-layer Kevlar® configuration starting at the Artemis IV mission. This effort has included fifty-two shield characterization shots for five different shield configurations over the four Orion propellant storage vessels. These storage vessels are located in the European Service Module (ESM). This shield characterization has been managed by the Hypervelocity Impact Technology (HVIT) group in NASA Astromaterials Research and Exploration Sciences at Johnson Space Center (JSC) for the NASA Engineering and Safety Center (NESC) and the Multi-Purpose Crew Vehicle (MPCV) program office in coordination with Lockheed Martin Space and Thales Alenia Space-Italy (TAS-I). The shield characterization has used the two-stage, light-gas-gun at the Remote Hypervelocity Test Laboratory (RHTL) of NASA JSC White Sands Test Facility (WSTF) for acceleration of projectiles to representative orbital impact speeds. From this shield characterization effort, a revised ballistic limiting equation (BLE) has been developed for each of the five representative shielding configurations of the ESM pressure vessels. This document provides a brief description of the shield configurations considered for the Orion program and the shield characterization findings. These results are compared to the assumed BLE for each configuration going into the Artemis missions that utilize this version of ballistic enhanced MLI. The models are integrated into a fourteen day High Lunar Orbit (HLO) mission as a representative reliability prediction impact for Orion, and it has been found that the predicted risk of a loss-of-crew (LOC) event is actually a little less than half of the assumed value that launched this design modification opportunity.
The recovery of the Solid Rocket Boosters presented a major challenge. The SRB represents the largest payload ever recovered and presents the added complication that it is continually emitting hot gases and burning particles of insulation and other debris. Some items, such as portions of the nozzle, are large enough to burn through the nylon parachute material. The SRB Decelerator Subsystem program was highly successful in that no SRB has been lost as a result of inadequate performance of the DSS.
An effort to provide inspection of the bondlines in the Space Shuttle Solid Rocket Motor (SRM) is discussed. Investigation of the bondlines in the membrane region of the SRM has centered on representative samples provided by Morton Thiokol. These samples have pull-tabs, or in one case grafoil inserts, to simulate delaminations at various points in the multilayer structure of steel case, liner, insulation, liner, and propellant. Discussed here is the continuing approach to examining these defects which is predicated on a model of an ultrasonic wave propagating in a lossy multilayer resonant structure, the experimental arrangements used, and the results of these experiments.
The current Space Launch System (SLS) internal solid rocket motor insulation, polybenzimidazole acrylonitrile butadiene rubber (PBI-NBR), is a new insulation that replaced asbestos-based insulations found in Space Shuttle heritage solid rocket boosters. PBI-NBR has some outstanding characteristics such as an excellent thermal erosion resistance, low thermal conductivity, and low density. PBI-NBR also has some significant challenges associated with its use: Air entrainment/entrapment during manufacture and lay-up/cure and low mechanical properties such as tensile strength, modulus, and fracture toughness. This technology development attempted to overcome these challenges by testing various reformulated versions of booster insulation. The results suggest the SLS program should continue to investigate material alternatives for potential block upgrades or use an entirely new, more advanced booster. The experimental design was composed of a logic path that performs iterative formulation and testing in order to maximize the effort. A lab mixing baseline was developed and documented for the Rubber Laboratory in Bldg. 4602/Room 1178.