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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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NASA NTRS2002

NASA Space Mechanisms Handbook and Reference Guide Expanded Into CD-ROM Set

Several NASA missions suffered failures and anomalies due to problems in applying space mechanisms technology to specific projects. Research shows that engineers often lack either adequate knowledge of mechanism design or sufficient understanding of how mechanisms affect sensitive systems. The Space Mechanisms Project conducted a Lessons Learned study and published a Space Mechanisms Handbook to help space industry engineers avoid recurring design, qualification, and application problems. The Space Mechanisms Handbook written at the NASA Glenn Research Center details the state-of-the-art in space mechanisms design as of 1998. NASA's objective in developing this Space Mechanisms Handbook was to provide readily accessible information on such areas as space mechanisms design, mechanical component availability and use, testing and qualification of mechanical systems, and a listing of worldwide space mechanisms experts and testing facilities in the United States. This handbook has been expanded into a two-volume CD-ROM set in an Adobe Acrobat format. In addition to the handbook, the CD's include (1) the two volume Space Mechanisms Lessons Learned Study, (2) proceedings from all the NASA hosted Aerospace Mechanisms Symposia held through the year 2000, (3) the Space Materials Handbook, (4) the Lubrication Handbook for the Space Industry, (5) the Structural & Mechanical Systems Long-Life Assurance Design Guidelines, (6) the Space Environments and Effects Source-Book, (7) the Spacecraft Deployable Appendages manual, (8) the Fastener Design Manual, (9) A Manual for Pyrotechnic Design, Development and Qualification, (10) the Report on Alternative Devices to Pyrotechnics on Spacecraft, and (11) Gearing (a manual). In addition, numerous other papers on tribology and lubrication are included.This technical summary of the project provides information on how to obtain the handbook and related information.

Fusaro, Robert L.↗
NASA NTRS1983

The 17th Aerospace Mechanisms Symposium

The proceedings of the Aerospace Mechanisms Symposium are reported. Technological areas covered include space lubrication, aerodynamic devices, spacecraft/Shuttle latches, deployment, positioning, and pointing. Devices for spacecraft tether, magnetic bearing suspension, explosive welding, and a deployable/retractable mast are also described.

Source record↗
NASA NTRS2008

Mechanical Description of the Mars Climate Sounder Instrument

This paper introduces the Mars Climate Sounder (MCS) Instrument of the Mars Reconnaissance Orbiter (MRO) spacecraft. The instrument scans the Martian atmosphere almost continuously to systematically acquire weather and climate observations over time. Its primary components are an optical bench that houses dual telescopes with a total of nine channels for visible and infrared sensing, and a two axis gimbal that provides pointing capabilities. Both rotating joints consist of an integrated actuator with a hybrid planetary/harmonic transmission and a twist cap section that enables the electrical wiring to pass through the rotating joint. Micro stepping is used to reduce spacecraft disturbance torques to acceptable levels while driving the stepper motors. To ensure survivability over its four year life span, suitable mechanical components, lubrication, and an active temperature control system were incorporated. Some life test results and lessons learned are provided to serve as design guidelines for actuator parts and flex cables.

rotating joints↗
NASA NTRS1980

Proceedings of the 14th Aerospace Mechanisms Symposium

Technological areas covered include aviation propulsion, aerodynamic devices, and crew safety; space vehicle propulsion, guidance and control; spacecraft deployment, positioning, and pointing; spacecraft bearings, gimbals, and lubricants; and large space structures. Devices for payload deployment, payload retention, and crew extravehicular activity on the space shuttle orbiter are also described.

Source record↗
NASA NTRS1999

Cartridge Bearing System for Space Applications

Conventional spin axis ball bearings have been unreliable in spacecraft, often failing by two heretofore uncontrolled processes: ball retainer instability and lubricant breakdown. The Space Cartridge Bearing System (SCBS) addresses each of these mechanisms directly, leading to a bearing system with absolute freedom from retainer instability and negligible lubricant degradation rate. The result is a reliable plug-in bearing cartridge with a definite design life.

Kingsbury, Edward P.↗
NASA NTRS1967

Wabble gear drive mechanism

The wabble gear principle was applied in the design of a driving mechanism for controlling spacecraft solar panels. The moving elements, other than the output gear, are contained within a hermetically sealed package to prevent escape of lubricants and ingestion of contaminant particles. The driving gear contains one more tooth than the output gear on a concave, conical pitch surface of slightly larger apex angle. The two gears mesh face to face such that engagement takes place at one point along the circumference. The driving gear is not permitted to rotate by virtue of its attachment through the bellows which permits flexure in the pitch and yaw position, but not in roll. As the bearing carrier rotates, the inclined mounting of the bearing causes the driving gear to perform a wabbling, irrotational motion. This wabbling motion causes the contact point between the output gear and the driving gear to traverse around the circumference of the gears once per revolution of the bearing carrier.

Winiarski, F. J.↗
NASA NTRS1973

Current European developments in solar paddle drives

The European Space Research and Technology Centre (ESTEC) is sponsoring the development of a number of critical spacecraft hardware items. The hardware under development includes two competing solar paddle drives which are being produced to similar specifications. Three mechanisms of each type are being produced and will undergo thermal vacuum testing. All mechanisms have lead lubricated bearings.

Bentall, R. H.↗
NASA NTRS1984

Microwelding of various metallic materials under ultravacuum (A0138-10)

In the space vacuum environment, the spacecraft mechanisms are liable to sustain damaging effects from microwelds due to molecular diffusion of the spacecraft constituent metals. Such microwelds result in a continuing increase in the friction factors and are even liable to jam the mechanisms altogether. The object of this experiment is to check the metal surfaces representative of the mechanism constituent metals (treated or untreated, lubricated or unlubricated) for microwelds afater an extended stay in the space environment. The experimental approach is to passively expose inert metal specimens to the space vacuum and to conduct end-of-mission verification of the significance of microwelds between various pairs of metal washers. The experiment will be located in one of the FRECOPA boxes in a 12-in. -deep peripheral tray that contains nine other experiments from France.

Assie, J. P.↗
NASA NTRS1974

Magnetic tape transport for high reliability in space

Studies of tape recorder failure modes in spacecraft tape-recorder applications reveal that failures within the mechanical transport package far outnumber those of the associated electronics. It would, therefore, be desirable to simplify the transport mechanism and to separate the moving parts with a continuously fresh supply of a single inert lubricant medium. The suggestion is made to replace the ball bearings with hydrostatically pressurized fluid film bearings.

Hoffman, J. K.↗
NASA NTRS2000

A New Apparatus to Evaluate Lubricants for Space Applications: The Spiral Orbit Tribometer (SOT)

Lubricants used in space mechanisms must be thoroughly tested prior to their selection for critical applications. Traditionally, two types of tests have been used: accelerated and full-scale. Accelerated tests are rapid, economical, and provide useful information for gross screening of candidate lubricants. Although full-scale tests are more believable, because they mimic actual spacecraft conditions, they are expensive and time consuming. The spiral orbit tribometer compromises between the two extremes. It rapidly determines the rate of tribochemically induced lubricant consumption, which leads to finite test times, under realistic rolling/pivoting conditions that occur in angular contact bearings.

Jones, William R., Jr.↗
NASA NTRS1973

Extendible-retractable electric field measurement antenna for IMP J

An antenna dispenser mechanism for the IMP J spacecraft was designed, fabricated, and tested. Upon command the mechanism deploys or retracts a conductor for use as a receiving antenna for an electric field measurement experiment. Five identical units were fabricated and tested to the IMP H & J environmental test specification. Of these, four are designated for flight on the IMP J spacecraft and one as a prototype flight spare. The testing program was successfully completed although certain design modifications were required as problems were uncovered by the testing; particularly thermal vacuum operation. The antenna mechanism functions well under the expected environmental and loading conditions. The wear life and load capability of the dry molybdenum disulphide lubricant originally used on the heavily loaded worm and gear pair were disappointing and a substitute material was applied. The lubricant finally applied performed well; although other problems were generated.

Larrick, W.↗
NASA NTRS1992

Deployment and retrieval mechanism redesigned for Spartan spacecraft on the STS

The Spartan Release Engage Mechanism (REM) is a system designed to restrain the Spartan spacecraft during Space Transportation System (STS) launch and landing. The mechanism is designed to allow deployment and retrieval of the Spartan free flyer spacecraft from the shuttle payload bay. Because current Spartan spacecraft payloads are much heavier than payloads intended for the original REM, an extensive redesign, analysis, and test program was necessary. Also, increased emphasis on safety in the post-Challenger era prompted a reevaluation of possible failures. Much of the design effort focused on improving the latch mechanism gearbox. Key concerns were effective gear lubrication, thermal gradients at the gearbox mounts, operation at thermal extremes, and gear-train failure contingencies. Increased concern for reliability led to the design of an Extra Vehicular Activity (EVA) backup latch system.

Galloway, Greg↗
NASA NTRS2016

The International Space Station (ISS) Solar Alpha Rotary Joint (SARJ): Materials & Processes (M&P) Lessons Learned for a Large, Spacecraft Rotating Mechanism

The ISS utilizes two large rotating mechanisms, the SARJ, as part of the solar arrays alignment system for more efficient power generation. The SARJ is a 10.3m circumference, nitrided 15-5PH steel race ring of triangular cross-section, with 12 sets of trundle bearing assemblies transferring load across the rolling joint. The SARJ mechanism rotates continuously and slowly - once every orbit, or every 90 minutes. In 2008, the starboard SARJ suffered a lubrication failure, resulting in severe damage (spalling) of one of the race ring surfaces. Extensive effort was conducted to prevent the port SARJ from suffering the same failure, and fortunately was ultimately successful in recovering the functionality of the starboard SARJ. The M&P function was key in determining the cause of failure and the means for mechanism recovery. From a M&P lessons-learned perspective, observations are made concerning the original SARJ design parameters (boundary conditions), the perceived need for nitriding the race ring, the test conditions employed during qualification, the environmental controls used for the hardware preflight, and the lubrication robustness necessary for complex kinematic mechanisms expecting high-reliability and long-life.

Golden, Johnny L.↗
NASA NTRS1969

Space Materials Handbook, 3rd ed.

This edition is the result of an extensive revision and reworking of the second edition of the Space Materials Handbook along with the incorporation of entirely new subject matter coverage and new materials data. All of the most significant material, phenomena, properties, and principles covered in the original Handbook are presented and expanded in this revised and updated version. However, treatment of theoretical aspects has been condensed in order that more emphasis could be placed on the extensive new materials knowledge and data obtained from the design and successful launching of a wide variety of space systems. The handbook is organized into four parts, namely: space environment, effect of space environment on materials, materials in space, and biological interaction with spacecraft materials. Information on mechanical, physical, and chemical properties and characteristics is given for a wide variety of metallic and nonmetallic materials. The effects of natural and induced environments on materials are appraised. Materials categories include coverage of thermal control materials, optical materials, adhesives, organic structural materials, inorganic structural materials, electronic components and materials, materials for sealing applications, and lubrication materials. In addition, a comprehensive multiple citation index is incorporated which gives ready access to information on specific subject areas with regard to their locations within the Handbook.

John B Rittenhouse↗
NASA NTRS2016

The International Space Station (ISS) Solar Alpha Rotary Joint (SARJ): Materials & Processes (M&P) Lessons Learned for a Large, Rotating Spacecraft Mechanism

The International Space Station (ISS) utilizes two large rotating mechanisms, the solar alpha rotary joints (SARJs), as part of the solar arrays' alignment system for more efficient power generation. Each SARJ is a 10.3m circumference, nitrided 15-5PH steel race ring of triangular cross-section, with 12 sets of trundle bearing assemblies transferring load across the rolling joint. The SARJ mechanism rotates continuously and slowly - once every orbit, or every 90 minutes. In 2007, the starboard SARJ suffered a lubrication failure, resulting in severe damage (spalling) to one of the race ring surfaces. Extensive effort was conducted to prevent the port SARJ from suffering the same failure, and fortunately that effort was ultimately successful in also recovering the functionality of the starboard SARJ. The M&P engineering function was key in determining the cause of failure and the means for mechanism recovery. From a M&P lessons-learned perspective, observations are made concerning the original SARJ design parameters (boundary conditions), the perceived need for nitriding the race ring, the test conditions employed during qualification, the environmental controls used for the hardware preflight, and the lubrication robustness necessary for complex kinematic mechanisms expecting high-reliability and long-life.

Golden, Johnny L.↗
NASA NTRS2008

Wear and Tear - Mechanical

The focus of this chapter is on the long term wear and tear, or aging, of the mechanical subsystem of a spacecraft. The mechanical subsystem is herein considered to be the primary support structure (as in a skeleton or exoskeleton) upon which all other spacecraft systems rest, and the associated mechanisms. Mechanisms are devices which have some component that moves at least once, in response to some type of passive or active control system. For the structure, aging may proceed as a gradual degradation of mechanical properties and/or function, possibly leading to complete structural failure over an extended period of time. However, over the 50 years of the Space Age such failures appear to be unusual. In contrast, failures for mechanisms are much more frequent and may have a very serious effect on mission performance. Just as on Earth, all moving devices are subject to normal (and possibly accelerated) degradation from mechanical wear due to loss or breakdown of lubricant, misalignment, temperature cycling effects, improper design/selection of materials, fatigue, and a variety of other effects. In space, such environmental factors as severe temperature swings (possibly 100's of degrees C while going in and out of direct solar exposure), hard vacuum, micrometeoroids, wear from operation in a dusty or contaminated environment, and materials degradation from radiation can be much worse. In addition, there are some ground handling issues such as humidity, long term storage, and ground transport which may be of concern. This chapter addresses the elements of the mechanical subsystem subject to wear, and identifies possible causes. The potential impact of such degradation is addressed, albeit with the recognition that the impact of such wear often depends on when it occurs and on what specific components. Most structural elements of the mechanical system typically are conservatively designed (often to a safety factor of greater than approximately 1.25 on yield for unmanned spacecraft) but do not have backup structure due to the added mass this would impose, and also due to the fact that structural elements can be accurately modeled mathematically and in test. Critical mechanisms or devices may have backups, or alternate work-arounds, since characterization of these systems in a 1g environment is less accurate than structure, and repair in-space is often impossible.

Swanson, Theodore↗
NASA NTRS1990

Liquid lubrication in space

The requirement for long-term, reliable operation of aerospace mechanisms has, with a few exceptions, pushed the state of the art in tribology. Space mission life requirements in the early 1960s were generally 6 months to a year. The proposed U.S. space station schedule to be launched in the 1990s must be continuously usable for 10 to 20 years. Liquid lubrication systems are generally used for mission life requirements longer than a year. Although most spacecraft or satellites have reached their required lifetimes without a lubrication-related failure, the application of liquid lubricants in the space environment presents unique challenges. The state of the art of liquid lubrication in space as well as the problems and their solutions are reviewed.

Zaretsky, Erwin V.↗