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NASA NTRS2016

Conceive, Believe and Achieve; A Path to Miniaturization, COTS Infusion, and Size Weight and Power Realization for Flight

JPL along with other aerospace agencies such as the US Air Force Space Pro-grams and a packaging technology innovator, i3 Electronics, Inc., are evaluating the use of state-of-the-art (SOA) commercial off-the-shelf (COTS) and alternative packaging technologies for future high performance and high reliability space applications. Utilization of SOA COTS technologies have resulted in large scale reduction in electronics volume, weight, power, cost and schedule with outstanding electrical performance and high reliability. We will share JPL’s joint design, architectural approach, alternative substrate materials selection, associated processes, and mission assurance role in identifying reliability and qualification risks, as part of the three year Heterogeneous Packaging/Device Integration effort under the guidance and leadership of JPL’s Mission Assurance Directorate.

Hunter, Don J.↗

NASA NTRS2019

History of NASA's Determination of Offgassed Products (Test 7)

NASA's Determination of Offgassed Products (Test 7) from materials and assembled articles for spaceflight has evolved since the Apollo program for over 50 years to meet various habitable spacecraft nonmetallic programmatic requirements. Now mandated by NASA STD-6016A, Standard Materials and Processes Requirements for Spacecraft, all nonmetallic materials used in habitable flight compartments, with the exception of ceramics, metal oxides, inorganic glasses, and materials used in sealed containers, must meet the offgassing requirements in NASA-STD-6001B Test 7. This manuscript presents the history of Test 7, beginning with the Apollo spacecraft nonmetallic materials selection guidelines and test requirements in 1967, in which tests were performed in mostly oxygen atmospheres. It progresses through Skylab, Space Shuttle, International Space Station nonmetals testing, and acceptance requirements with milder test environments. This review of the history of Test 7 presents the reader with a perspective on the development and changes undergone since inception to the present. Related NASA standard tests (some now former, discontinued, combined, or supplemental) including Test 6, Odor Assessment, Test 16, Determination of Offgassed Products from Assembled Articles, and Test 12, Total Spacecraft Cabin Offgassing, are discussed in context

Greene, Benjamin↗

NASA NTRS2019

History of NASA's Determination of Offgassed Products (Test 7)

Greene, Benjamin↗

NASA NTRS2020

Space Flight LiDARs, Navigation & Science Instrument Implementations: Lasers, Optoelectronics, Integrated Photonics, Fiber Optic Subsystems and Components

For the past 25 years, the National Aeronautics and Space Administration (NASA) Goddard Space Flight Center's Photonics Group in the Engineering Directorate has been substantially contributing to the flight design, development, production, testing and integration of many science and navigational instruments. The Moon to Mars initiative will rely heavily upon utilizing commercial technologies for instrumentation with aggressive schedule deadlines. The group has an extensive background in screening, qualifying, development and integration of commercial components for spaceflight applications. By remaining adaptable and employing a rigorous approach to component and instrument development, they have forged and fostered relationships with industry partners. They have been willing to communicate lessons learned in packaging, part construction, materials selection, testing, and other facets of the design and production process critical to implementation for high-reliability systems. As a result, this successful collaboration with industry vendors and component suppliers has enabled a history of mission success from the Moon to Mars (and beyond) while balancing cost, schedule, and risk postures. In cases where no commercial components exist, the group works closely with other teams at Goddard Space Flight Center and other NASA field centers to fabricate and produce flight hardware for science, remote sensing, and navigation applications. Summarized here is the last ten years of instrumentation development lessons learned and data collected from the subsystems down to the optoelectronic component level.

Detectors↗

NASA NTRS2018

Numerical and Experimental Study of Local Resin Pressure for the Manufacturing of Composite Structures and Their Effect on Porosity

Porosity can have significant impact on the mechanical performance of composite structures. The primary sources of voids during the cure of composites include air entrapped during lay-up, bag or tool leaks, and the off gassing of volatiles. Capturing the physics of void evolution during composite processing is a challenge due to the number of sources and changing phenomena that give rise to voids as the resin cures. Local changes in resin pressure due to geometric features or cure shrinkage have been experimentally linked to a higher likelihood of void formation. In this work, a preliminary model was developed to predict local resin pressure which can be used to identify regions more susceptible to porosity. Experiments were conducted to validate the model accuracy. Ultimately, this model can be used as a tool to minimize the likelihood of porosity by optimizing the material selection, part design, layup, and cure process.

Bedayat, Houman↗

NASA NTRSDate not supplied

History of NASAâ€™s Odor Assessment (Test 6)

NASA's Odor Assessment (Test 6) for nonmetallic materials and assembled articles for spacecraft has evolved since the Apollo program in 1966 to meet various habitable spacecraft nonmetallic programmatic requirements. The purpose of Test 6 is to determine if the odor from a material or assembled article is objectionable or revolting on an odor-characteristic scale of 0 to 4. Samples of the toxicity-screened test atmosphere from a conditioned specimen container are administered to an Odor Panel of qualified human research subject volunteers using a syringe and mask, and are assigned a scored odor characteristic of undetectable (0), barely detectable (1), easily detectable (2), objectionable (3), or revolting (4). The odor from a material or assembled article is objectionable or revolting if an average rating of 2.5 or higher is assigned by an Odor Panel. This manuscript presents the history of Test 6, beginning with the Apollo spacecraft nonmetallic materials selection guidelines and test requirements from 1966, in which tests were performed in oxygen atmospheres, and follows the odor test through Skylab, Space Shuttle, International Space Station, and Orion nonmetals testing, and acceptance requirements.

Benjamin Greene↗

NASA NTRSDate not supplied

Photonics for Space Flight Instruments

For the past 25 years, the National Aeronautics and Space Administration (NASA) Goddard Space Flight Center’s Photonics Group in the Engineering Directorate has been substantially contributing to the flight design, development, production, testing and integration of many science and navigational instruments. The group has an extensive background in screening, qualifying, development and integration of commercial components for spaceflight applications. They have been willing to communicate lessons learned in packaging, part construction, materials selection, testing, and other facets of the design and production process critical to implementation for high-reliability systems. Summarized here is the last ten years of instrumentation development lessons learned and data collected from the subsystems down to the optoelectronic component level.

Spaceflight↗

NASA NTRSDate not supplied

Aerothermal Effects of Hypersonic Shock Impingement on a Highly Swept Leading Edge

A numerical study is conducted to investigate aerothermal implications of oblique shock impingement on a highly swept leading edge in hypersonic flow, with flow conditions and geometry relevant to non-propulsive leading edge heating on hypersonic cruise vehicles. In contrast to propulsive inlet leading edge shock impingement, which has been subject to extensive historical study, bow shock impingement on a highly swept wing leading edge has received comparatively little attention in the literature. Distinguishing characteristics of this type of flow include a potentially dominant surface heating contribution from crossflow-induced viscous dissipation, possible wall velocity slip and temperature jump effects, and various modes of shock layer thermal nonequilibrium that can interact with shock impingement flowfield structures. One overall goal of this work is to assess the impact of bow shock impingement and related nonequilibrium phenomena for wing leading edge design, materials selection and thermal management. Another goal is to improve understanding – and thereby reduce associated design margins – for the physical processes and mechanisms that may influence wing leading edge heating in the presence of an impinging shock. A combination of direct simulation Monte Carlo and Reynolds-averaged Navier-Stokes analysis is used to assess surface and flowfield characteristics for a series of hypersonic shock impingement problems, based on historical ground tests and related flight conditions. Favorable comparisons are performed with experimental data, and various thermal nonequilibrium effects are quantified.

direct simulation Monte Carlo↗

NASA NTRS2022

Environmental Testing of Contamination Sensitive Instruments and Optics in Non-Cleanliness Controlled Facilities

The James Webb Space Telescope (JWST) Optical Telescope Element + Integrated Science Instrument Module (OTIS) went through environmental testing at the Goddard Space Flight Center. The vibration and acoustic tests occurred outside of cleanrooms. These areas are typically around ISO Class 8, far out of specifications for JWST. Through collaboration between the OTIS Mechanical and Contamination Engineering teams, a portable clean enclosure was designed, built, and verified to prevent contamination of the sensitive OTIS assembly. This manuscript describes the process of designing and building this enclosure, including materials selection and High Efficiency Particle Air (HEPA) filtration. This enclosure also provided environmental control with a portable air conditioning unit to control the relative humidity level enabling personnel to work within it. The manuscript emphasizes working in a systematic order to maintain cleanliness and integrity. “Clean as you go” during construction was a top priority to ensure that this critical Ground Support Equipment (GSE) was acceptable. The process of installing the walls and then sealing their internal and external surfaces with approved films was critical to maintaining OTIS integrity. This proved important because OTIS was in the enclosure for months longer than originally planned. This manuscript concludes by reviewing the process used to verify that the OTIS clean enclosure could achieve acceptable contamination level fallout accumulation for use during the vibration and acoustic testing and then verifying that the predicted performance was achieved after testing was complete.

Contamination Control, James Webb Space Telescope,↗

NASA NTRSDate not supplied

Contamination monitoring of the OSIRIS-REx ISO5 asteroid sample cleanroom

The OSIRIS-REx mission to asteroid Bennu successfully collected hundreds of grams of asteroid regolith in October 2020 [1]. The spacecraft departed Bennu in May 2021 for Earth return and will release the sample canister to be recovered in Utah in September 2023 [2]. Samples will be transported to the curation facility at NASA Johnson Space Center, where an ISO5 equivalent cleanroom has been designed in 2017 and completed in 2021. Aspects of the design and material selection for the cleanroom and its supporting facilities (air handling system, cleanroom floors and walls, filters, paints, etc.) were optimized to minimize effects of organic and inorganic contaminants and offgassing [3]. Since its completion, the lab has been carefully monitored to understand and establish a baseline with respect to multiple environmental aspects – measurement of particle counts, deploying Si wafer witness plates for organic and inorganic contaminants, deploying aluminum foils for a focus on organics with JSC in-house expertise, gas samples, and regular microbial and fungal measurements on selected surfaces and air samples in the cleanroom. This contribution will report on nearly one year of monitoring and highlight several specific aspects that have led to a better understanding of the new cleanroom environment.

carbonaceous asteroid↗

NASA NTRSDate not supplied

Size Effects on Laser Powder Bed Fusion and Laser Powder Directed Energy Deposition GRCop-42 Alloy

Additive manufacturing (AM) plays a significant role in the fabrication of regeneratively cooled rocket engine combustion chambers, where internal channels are used to transport high pressure propellants to keep the engine from overheating. Cooling channels are designed with thin walls between the cooling and combustion sides, experiencing high thermal and mechanical stresses from large temperature gradients and internal pressures. Hence, selecting materials suited for this environment and maintaining a high-quality processing for this critical application is of utmost importance. GRCop-alloys (Cu-Cr-Nb) were developed as an ideal material for combustion chambers due to its high conductivity and high strength at temperature, being employed as a structural member for the hotwall with excellent heat transfer capabilities. GRCop-42 (Cu, 4 at% Cr, 2 at% Nb) has significantly matured using the Laser Powder Bed Fusion (L-PBF) process through microstructure, mechanical and thermophysical properties and evaluations using hot-fire testing. Additionally, Laser Powder Directed Energy Deposition (LP-DED) has demonstrated successful deposition and geometry samples using GRCop-42. While the maturation in properties has focused on bulk material properties from standard test specimens, these cannot be extrapolated to be used in thin walls, as different features (i.e., microstructure, porosity, and surface texture) have a greater effect on thin walls, especially on AM structures built using L-PBF and LP-DED. This presentation provides an overview of the effects introduced by reducing the thickness on the fabrication, microstructure, surface metrology and subsequent mechanical properties of GRCop-42 using L-PBF and LP-DED as well as future work planned for this research.

Gabriel Demeneghi↗

NASA NTRS2023

Move That Goo!

On May 5, 1961, Alan B. Shepard became the first American in space (K. Mars); since then, NASA has made leaps and bounds in space exploration and continues to develop new technologies. Through their X-Hab program, NASA has teamed up with the National Space Grant Foundation to fund our student-centered project with one main goal: Move That Goo! Liquid amine absorption is a method by which CO2 is removed from an environment and is intended to be the primary method for CO2 removal for NASA’s sustained human presence on extraterrestrial bodies such as the Moon and Mars. Liquid amines can be highly viscous when absorbing CO2, thus the team needed to produce a design that could move a high viscosity fluid while staying under the power requirement of 1 kW and allowing a few square meters in a closed system. Prompted by NASA and with the support of our faculty mentors, we have been tasked with the research, development, production, and testing of a system able to move a high viscosity liquid amine which requires adequate air exposure to absorb carbon dioxide from a habitat atmosphere in low gravity. The system is split into two main groups, fluids, and materials, with two separate teams of students assigned to their half of the design. The fluids team is responsible for everything in the design that directly touches the fluid. The materials team is responsible for the test stand to which the fluids team’s design is attached to as well as additive manufacturing material selection. In the first semester, the team focused on brainstorming ideas, design selection, budget creation, and CAD modeling. Multiple concepts were generated but the team decided on a design to get the high viscosity fluid to move around a rectangular channel using a screw conveyor mechanism. The liquid must be moved by the turning screw from the thermal chamber going around a rectangular trough back to the thermal chamber. The screw and the trough geometry will be important to allow for the high viscosity fluid to flow, utilizing surface tension to maintain contact to the trough as seen in Figure 1 below.

Olivia Angst↗

NASA NTRS2023

NASCAP Surface Charging Tool Development - Nascap-2k Additional Examples

This document consists of examples of the use of Nascap-2k to analyze moderately complex interactions between spacecraft surfaces and the plasma environment. The narrative assumes familiarity with the use of Nascap-2k and the field of spacecraft-environment interactions. Specific results may be slightly different from those given here due to small differences in the geometry, material selection, and version of Nascap-2k.

Charge Plate Analyzer↗

NASA NTRS2024

Post-CDR Thermal Design and Analysis of the Starburst Instrument

The StarBurst Multimessenger Pioneer is a small satellite serving as a wide-field gamma-ray observatory designed to detect the initial emissions of short gamma ray bursts, electromagnetic indicators of neutron star mergers. This paper will detail the thermal design and analysis of the instrument, which includes both the control electronics and crystal detector units (CDUs). The CDUs are a critical component essential to mission success and have the narrowest temperature range, however the CDU thermal model is low fidelity at the time of Critical Design Review (CDR) before a final CDU design is completed. Therefore, a more detailed CDU model is created for post-CDR analysis to update the passive Thermal Control System (TCS) design and efficiently maintain the operational and survival temperature limits with minimal heater power. Including the additional detail is necessary to determine the final Multilayer Insulation (MLI) design, including material selection and coverage, coating selection, and required heater power.

thermal design↗

NASA NTRS2024

Post-CDR Thermal Design and Analysis of the Starburst Instrument

thermal design↗

NASA NTRSDate not supplied

An Evaluation of Composite Primary Structure for Habitat Modules

Boeing studied the use of composite structures in deep space habitats. Compared to metallic modules, composite structures offer increased strength and stiffness with reduced mass. The study evaluated the design considerations and the mass benefits of an all composite primary structure. The composite module design included a continuous pressure shell, composite longerons, and circumferential ring frames. The composite material selected was a high strength carbon fiber and epoxy slit tape prepreg. The manufacturing involved automated fiber placement and utilizing existing facilities and autoclaves. Analysis showed a 33% reduction in primary structure mass and an overall net reduction of nearly 1900 kg compared to metallic modules. The composite module demonstrated improved mass efficiency and opens new possibilities for mission performance in deep space exploration.

Composite↗

NASA NTRS2026

Manufacturing Process Development of a Carbon Fiber Reinforced Polymer Composite Shaft for Electric Motors

Electric aircraft applications require electric motors with increased specific power and efficiency. Composite structural components in motors are a potential solution for reducing motor mass, reducing magnetic losses, and limiting undesired conduction paths for fault, electromagnetic interference, or common-mode currents. In this report, manufacturing trials for a high-speed carbon fiber reinforced polymer composite motor shaft are presented. Four prototype shafts were produced using a hybrid biaxial/triaxial fabric that was circumferentially wrapped onto an additively manufactured high-temperature washout mandrel. An additional traditional overbraid approach was also evaluated and shows promise for high-rate, high-performance parts using automated manufacturing. This paper discusses the shaft design, manufacturing methods explored, material selection, the manufacturing trials, and the lessons learned. The results of this manufacturing investigation show feasibility for manufacturing composite shafts for electric motors.

Electric moto shaft↗

NASA NTRS2004

A Constitutive Equation for Stratospheric Balloon Materials

The selection of a suitable material for use as a reliable stratospheric balloon gas barrier and structural component is based on a variety of properties. Due to a more desirable combination of properties, the low density polyethylene that has been used for the last half century has been replaced during the last decade by linear low density polyethylene (LLDPE). This paper describes the effort to characterize the time dependent properties of a 38 micron coextrusion of LLDPE. The nonlinear viscoelastic constitutive equation presented may be used to accurately describe the creep and/or relaxation of this film when subjected to a biaxial state of stress, such as might be required for an extended balloon flight. Recent laboratory data have been used to mod@ an existing model of LLDPE to account for differences caused by the coextrusion process. The new model will facilitate structural design optimization and reliability assessment, and may be further utilized as a predictive tool to benefit in-flight operations. Current structural analysis tech&ques based on linear elastic properties have predicted stresses in excess of those which would actually exist.

Rand, J. L.↗