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NASA NTRSDate not supplied

Modal Correlation of Complex Aerospace Joints Using Automated Variable Substitution

A critical task involved with being able to predict flight loads accurately in aerospace finite element models (FEMs) is the prior verification of the FEMs by conducting modal survey testing (MST). Experience comparing dynamic response of initial FEMs to MST data tends to demonstrate that FEMs can have unacceptable accuracy even when best modeling practices are followed. One inherent source of inaccuracy in linear dynamic FEMs is the modeling of nonlinear joints with mechanisms such as spherical bearings. These joints are usually designed to freely translate or rotate under the high levels of loading experienced in flight. Engineers who create linear FEMs conventionally model these joints without any stiffness in the mechanism degrees of freedom to meet this design intent. However, inaccuracy is observed during test validation of these FEMs, which usually relies on low-level force excitation orders of magnitude below flight load levels. This low-level modal test rarely overcomes the joint friction that is present, and thus the mechanism joints are able to react loads. This divide between the test results and the FEM creates a significant challenge to the engineer who is performing the correlation, in that the engineer has no basis for what stiffness value should be used to make the FEM match the test results. A compounding challenge is that complicated built-up aerospace structures commonly have multiple joints through a load path where each joint will “stick” and “slip” at different levels of force input. Explicitly matching the dynamics of a system containing these nonlinear mechanisms would require a nonlinear FEM, which is prohibitively costly for dynamic simulations of most aerospace systems. The objective of this paper is to present a workflow that can efficiently cycle through many iterations of a FEM, allowing a Monte Carlo style examination of the design space to identify candidate stiffness values for nonlinear mechanism joints. The outlined approach is specific to MSC Nastran and utilizes MSC Nastran’s symbolic substitution capabilities, coupled with the IMAT™ and Attune™ software packages developed by ATA Engineering, Inc. (ATA). The workflow is demonstrated with a case study from the correlation effort for The Boeing Company’s Crew Space Transportation (CST)-100 Starliner FEM. Keywords: Correlation, MSC Nastran, IMAT™, Attune™, Finite Element Model, Modal Testing

Correlation↗

NASA NTRS2011

TAMU: a new space mission operations paradigm

The Transferable, Adaptable, Modular and Upgradeable (TAMU) Flight Production Process (FPP) is a model-centric System of System (SoS) framework which cuts across multiple organizations and their associated facilities, that are, in the most general case, in geographically diverse locations, to develop the architecture and associated workflow processes for a broad range of mission operations. Further, TAMU FPP envisions the simulation, automatic execution and re-planning of orchestrated workflow processes as they become operational. This paper provides the vision for the TAMU FPP paradigm. This includes a complete, coherent technique, process and tool set that result in an infrastructure that can be used for full lifecycle design and decision making during any flight production process. A flight production process is the process of developing all products that are necessary for flight.

Meshkat, Leila↗

NASA NTRSDate not supplied

Analytical Needs in a Sample Receiving Facility: Input from the MSR Operation Definition Team

The return of scientifically selected samples from Mars would provide a rare opportunity forinvestigation with the full range of the latest technology available, but to take full advantageof this opportunity, it is important to plan ahead to ensure the pristine nature of the samplesupon arrival within the Earth environment until scientific investigations can begin.The NASA/ESA science community-driven MSR Science Planning Group – Phase 2 (MSPG2)delivered recommendations and guidance regarding curation (1) and science (2, 3) activities tobe performed on the samples under containment. High-level requirements for the infrastruc-ture were also developed by MSPG2 (4). In order to prepare infrastructure-targeted input forthe ESA and NASA facility studies planned in the 2022-2023 timeframe, the agency-led MSROperational Scenarios Definition Team (MOSDT) was assembled to conceptualize the sampleoperations that will inform future architecture teams. Emphasis was placed on the respon-sibility of MOSDT to use community-defined requirements and to represent the view of the international scientific community.All necessary and sufficient instruments and analytical needs described in MSPG2 were inte-grated in MOSDT main deliverable, the operational workflow (see Hays et al, this conference).In MSPG2, notional instruments were split between curation analytical needs, and objective-driven (time-sensitive and sterilization-sensitive) science analytical needs. In MOSDT, whilethe first phases of curation, “pre-Basic Characterization” and “Basic Characterization” wererather streamlined and separate from other analytical needs, “Preliminary Examination” and“Science” instruments were not always physically segregated. In addition to the necessary andsufficient instruments described by MSPG2, the MOSDT recommended additional supportequipment for sterilization, cleanliness and contamination monitoring.It was sometimes necessary for the MOSDT to rely on assumptions to integrate instruments inthe activity workflow. In general, the assumptions were very conservative to limit contaminationand cross-contamination risks. It is expected that future work to refine limits of contaminationwill enable optimization of instrumentation.The community was consulted during the course of the MOSDT work. This abstract’s aimis two-fold: on one hand, inform the scientific community and overall MSR stakeholders, tobring their attention on the analytical needs currently considered as necessary and sufficient;on the other hand, to solicit feedback from a larger community audience to optimize and refineanalytical needs during the next phases of MSR ground-segment preparation.Disclaimer: The decision to implement Mars Sample Return will not be finalized until NASA’scompletion of the program’s National Environmental Policy Act (NEPA) process. This docu-ment is being made available for informational purposes only.[1] Tait et al. (2021) Preliminary planning for Mars Sample Return (MSR) curation activities ina Sample Receiving Facility (SRF). Astrobiology in press, doi:10.1089/ast.2021.0105. [2] Toscaet al. (2021) Time-sensitive aspects of Mars Sample Return (MSR) science. Astrobiologyin press, doi:10.1089/ast.2021.0115. [3] Velbel et al. (2021) Planning implications relatedto sterilization-sensitive science investigations associated with Mars Sample Return (MSR).Astrobiology in press, doi:10.1089/ast.2021.0113. [4] Carrier et al. (2021) Science and curationconsiderations for the design of a Mars Sample Return (MSR) Sample Receiving Facility (SRF).Astrobiology in press, doi:10.1089/ast.2021.0110.

Mars Sample Return↗

NASA NTRSDate not supplied

Machine-Learning for Safety Critical Airborne Applications Part II: Case Study

The exceptional progress in the field of Artificial Intelligence (AI) systems, enabled by Machine Learning (ML) technology in recent years provides historic opportunities for the aviation industry. Current certification standards for avionics were developed prior to the ML renaissance and have several fundamental incompatibilities with the ML technology. WG-114 is working hard to release a new standard as soon as possible but for now there is no recognized means of compliance for ML based systems even of low criticality. In this talk, we present the custom ML workflow that can be used comply with all objectives of the current certification standards for a low-criticality (DAL D and C) ML-based system. To illustrate the practical application of the custom ML workflow we present a case study of a system based on a Deep Neural Network (DNN) intended to detect and identify airport runway signs. We present the system design, data generation, training, and verification in detail and describe how the design assurance objectives can be met for a DAL D and DAL C systems.

Johann Schumann↗

NASA NTRS2021

Three-dimensional estimation of deciduous forest canopy structure and leaf area using multi-directional, leaf-on and leaf-off airborne lidar data

Airborne laser scanning (ALS) has been widely used to map gap probability and leaf area index (LAI) distribution at plot and landscape scales. As an indirect measurement, most ALS methods to estimate LAI combine waveform or point density information with supporting field measurements such as the leaf angle distribution, gap probability, or direct LAI measures. The development of a more independent estimation approach would facilitate more widespread use of existing ALS data to investigate patterns of forest structure and build realistic 3-D vegetation scenes to simulate remote sensing imagery and energy balance. Here, we develop a data processing workflow (named PVlad) using ALS point cloud apparent reflectance to estimate LAI and voxel-based leaf area density (LAD), aiming to reduce the need for associated field measurements such as the gap probability. The adaptation of the path volume (PV) concept derived from apparent reflectance integrates information from multi-directional ALS pulses, and quantifies the percentage exploration of each voxel for classification and occlusion correction, such that rigorous volumetric sampling approaches can be developed to derive LAI and LAD. The PVlad workflow was applied to discrete-return lidar data (Riegl VQ480i) acquired by NASA Goddard's LiDAR, Hyperspectral and Thermal Imager (G-LiHT) Airborne Imager during leaf-on (summer) and leaf-off (spring) conditions at the Smithsonian Environmental Research Center (SERC). The estimates of LAI and LAD captured structural differences between mature, logged, and intermediate-aged stands over eight deciduous forest plots. The derived LAI values were compared to field litter collection measurements, and the derived LAD vertical distribution was compared to the output of the VoxLAD model using terrestrial laser scan (TLS) field survey data. Using voxel sizes ranging from 0.5 m to 5 m, overall LAI estimation showed linear fitting coefficient bias and for 1 and 2 m voxel sizes, and vertical LAD distribution showed strong correlation with and for 0.5 and 1m voxel sizes. For every forest stand, upper-canopy LAD had a low variance for voxel sizes of ≤ . Application of PVlad to the G-LiHT and other similar ALS data archives enables the development of fine-resolution LAI map products, including voxelization of LAD for ecosystem science and radiative transfer simulations of remote sensing imagery or surface energy balance.

Tiangang Yin↗

NASA NTRS2021

PIXLISE-C: Exploring The Data Analysis Needs of NASA Scientists for Mineral Identification

NASA JPL scientists working on the micro x-ray fluorescence (microXRF) spectroscopy data collected from Mars surface perform data analysis to look for signs of past microbial life on Mars. Their data analysis workflow mainly involves identifying mineral com- pounds through the element abundance in spatially distributed data points. Working with the NASA JPL team, we identified pain points and needs to further develop their existing data visualization and analysis tool. Specifically, the team desired improvements for the process of creating and interpreting mineral composition groups. To address this problem, we developed an interactive tool that enables scientists to (1) cluster the data using either manual lasso-tool selection or through various machine learning clustering algorithms, and (2) compare the clusters and individual data points to make informed decisions about mineral compositions. Our preliminary tool supports a hybrid data analysis workflow where the user can manually refine the machine-generated clusters.

Davidoff, Scott↗

NASA NTRSDate not supplied

Rapid Hypersonic Simulations using US3D and Pointwise

For hypersonic simulations, unstructured flow solvers typically have problems predicting surface heat fluxes when strong shocks are present. To address these issues, this paper outlines a workflow that applies best practices developed for structured grids to unstructured meshes. In addition, unstructured grid generation can significantly reduce the time required to create quality grids for complex geometries. Several examples are computed using DPLR, a structured grid flow solver, and US3D flow, an unstructured mesh solver. Results from the two codes are compared, and they show excellent agreement. Overall, the unstructured grid workflow offers a viable and attractive alternative for hypersonic simulations.

C. Tang↗

NASA NTRSDate not supplied

Rapid Hypersonic Simulations using US3D and Pointwise

Chun Tang↗

NASA NTRSDate not supplied

Material Property Estimation in Thin Battery Components Using Guided Wave Measurement, Experimental Dispersion Curve Extraction and Finite Element Modeling

At NASA, we are investigating nondestructive evaluation (NDE) and structural health monitoring (SHM) techniques to detect precursors of thermal runaway failure in lithium metal based lithium ion batteries (LIB). The approach is centered on computational simulation models to guide inspection and aid in interpretation of results. Since lithium metal LIBs have combinations of solid and fluid-filled porous materials, obtaining accurate material properties is both challenging and critical for successful simulation of battery inspection. To this end, we investigated a multi-verification approach for material characterization of thin battery components. First, a laser Doppler vibrometer (LDV) was used to measure guided wave fields in thin (microns-thick) battery components subject to broadband excitation. The time-space wavefield data was converted to frequency-wave number data to extract guided wave dispersion curves. A data visualization and post processing graphics user interface (GUI) was developed at NASA to aid the data exploration and analysis. Due to the thinness of the samples, low frequency-thickness-product plate wave approximations allowed for the calculation of closed-form solutions for material elastic property estimation. These approximations were then verified by calculating the Lamb wave solutions using the previously obtained material properties. Finally, the estimated elastic material properties were implemented in a COMSOL simulation model, and dispersion curves were extracted from simulation results. The dispersion curves and derived material properties were then compared to the analysis results from the experimental data. These comparisons informed on the accuracy of the measured material properties and helped demonstrate the accuracy of the finite element analysis (FEA) computational models. This assessment will prove vital when we start simulating more complex multi-layer components and poroelastic media. This paper gives a brief background of the problem space, outlines the workflow for data analysis and verification, shows results from the workflow, and gives an overview of future plans for simulation of lithium metal LIB inspection.

Peter Juarez↗

NASA NTRS2022

Hypersonic Simulations with US3D using Unstructured Grids from Fidelity Pointwise

For hypersonic simulations, unstructured flow solvers typically have problems predicting surface heat fluxes when strong shocks are present. This article outlines a workflow that applies best practices for structured and unstructured grids. In addition, unstructured grid generation can significantly reduce the time required to create quality grids for complex geometries. Several examples are computed using DPLR, a structured grid flow solver, and US3D flow, an unstructured flow solver. Results from the two codes are compared and they show excellent agreement. The unstructured grid workflow offers a viable and attractive alternative for hypersonic simulations.

C. Tang↗

NASA NTRSDate not supplied

The Future of NASA Earth Science in the Commercial Cloud: Challenges and Opportunities

NASA produces a large volume and variety of data products that are used every day to support research, decision making, and education. The widespread use of NASA’s Earth Science data is enabled by NASA’s Earth Science Data System (ESDS) program, which oversees the archiving and distribution of these data and invests in the development of new data systems and tools. However, NASA’s current approach to Earth Science data distribution — based on distributed institutional archives with individual on-premises high-performance computing capabilities — faces some significant challenges, including massive increases in data volume from upcoming missions, a greater need for transdisciplinary science that synthesizes many different kinds of observations, and a push to make science more open, inclusive, and accessible. To address these challenges, NASA is aggressively migrating its Earth Science data and related tools and services into the commercial cloud. Migration of data into the commercial cloud can significantly improve NASA’s existing data system capabilities by (1) providing more flexible options for storage and compute (including rapid, as-needed access to state-of-the-art capabilities); (2) by centralizing and standardizing data access, which gives all of NASA’s institutional data centers access to all of each other’s datasets; and (3) by facilitating “analysis-in-place”, whereby users can bring their own computational workflows and tools to the data rather than having to maintain their own copies of NASA datasets. However, migration to the commercial cloud also poses some significant challenges, including (1) managing costs under a “pay-as-you-go” model; (2) incompatibility with existing tools and data formats with object-based storage and network access; (3) vendor lock-in; (4) challenges with data access for workflows that mix on-premise and cloud computing; and (5) standardization for highly diverse data as is present in NASA’s data archive. I conclude with two examples of recent NASA activities showcasing capabilities enabled by the commercial cloud: An interactive analysis and development platform for analyzing airborne imaging spectroscopy data, and a new collection of tools and services for data discovery, analysis, publication, and data-driven storytelling (Visualization, Exploration, and Data Analysis, VEDA).

Alexey N Shiklomanov↗

NASA NTRS2023

Pypromice: A Python Package for Processing Automated Weather Station Data

The pypromice Python package is for processing and handling observation datasets from automated weather stations (AWS). It is primarily aimed at users of AWS data from the Geological Survey of Denmark and Greenland (GEUS), which collects and distributes in situ weather station observations to the cryospheric science research community. Functionality in pypromice is primarily handled using two key open-source Python packages, xarray (Hoyer & Hamman, 2017) and pandas (The pandas development team, 2020). A defined processing workflow is included in pypromice for transforming original AWS observations (Level 0, L0) to a usable, CF-convention-compliant dataset (Level 3, L3) (Figure 1). Intermediary processing levels (L1,L2) refer to key stages in the workflow, namely the conversion of variables to physical measurements and variable filtering (L1), cross-variable corrections and user-defined data flagging and fixing (L2), and derived variables (L3). Information regarding the station configuration is needed to perform the processing, such as instrument calibration coefficients and station type (one-boom tripod or two-boom mast station design, for example), which are held in a toml configuration file. Two example configuration files are provided with pypromice , which are also used in the package’s unit tests. More detailed documentation of the AWS design, instrumentation, and processing steps are described in Fausto et al. (2021).

pypromice↗

NASA NTRS2023

Easy, Scalable Subsetting of GEDI Point Clouds

The GEDI Subsetter, a Python tool developed for NASA’s Multi-mission Algorithm and Analysis Platform (MAAP), optimizes the accessibility and visualization of GEDI point clouds by enabling users to efficiently subset data in a convenient, scalable manner. Complex science data often requires users to learn new software skills and handle many large files. Handling and cleaning large data sets is tedious and error-prone. These challenges significantly impede analysis. One of the goals of NASA's MAAP is to provide a platform that lowers the barrier to conducting research and analysis at scale. When a group of MAAP users wanted to conduct above-ground biomass estimation using GEDI data, we found that their existing workflow for leveraging GEDI data suffered from the barriers mentioned above. Furthermore, their workflow did not scale easily beyond a small number of granules. We found that existing tools related to GEDI data retrieval and subsetting were too limiting, so the GEDI Subsetter was written to support MAAP users’ needs. Being able to run many subsetting jobs simultaneously in the MAAP, and parallelizing the code itself, has led to significant speed improvements in obtaining relevant data, reducing subsetting time from hours to minutes. MAAP users can now more quickly and easily obtain only the data relevant to their research, by choosing which GEDI collection they want to work with (L1A, L2A, L2B, or L4A), and how they want to subset it, by specifying an area of interest, a temporal range, and relevant attributes. This has significantly reduced the feedback loop for users, allowing them to much more quickly subset GEDI data and begin their analysis. Although the GEDI Subsetter originally targeted users of the MAAP, it is generalized such that it can also be used outside of the MAAP and includes a command-line interface for convenience. Furthermore, with minor modifications, it should be possible to use it with non-GEDI data as the general pattern should be applicable to other sparse/track-based sensors.

Charles Daniels↗

NASA NTRSDate not supplied

The Inspectability Metric: A Formalized System Of Measurement Enabling The Design For Inspection Framework

Nondestructive evaluation (NDE) engineers are often confronted with structural design choices that present challenges to meeting inspection requirements. These challenges, at best, increase the resources needed to design an inspection solution and, at worst, require resource intensive redesign of the structure. If the inspectability of the structure can be determined early in the design cycle, these challenging inspection scenarios can be avoided. The emergence of additive manufacturing has further compounded this problem by enabling the creation of highly optimized structures with no regard to inspection constraints. Design for inspection (DFI) offers a framework to integrate nondestructive evaluation (NDE) into the design process to alleviate the mechanisms that produce uninspectable designs. DFI is the concept of including inspectability in a multi-objective optimization framework so that it can be considered in parallel to other metrics such as mass and manufacturability. This allows rapid evaluation of the trade-off between design metrics to find solutions that meet the inspection needs of a particular material system, structural concept, or vehicle program. To enable DFI, there must be a system by which the inspectability of a structure can be measured. This system must be agile to produce results quickly, it must be versatile to work with the type of incomplete information one would encounter early in the design process (such as lack of inspection requirements), and it must be delivered in a form that is easily understood by designers. To meet this need, this presentation introduces the novel inspectability metric as a system to measure inspectability. The inspectability metric is a standardized, automation friendly procedure that uses simulations to determine inspectability. Along with guidelines to properly process designs and integrate with existing workflows, the inspectability metric provides a suite of simulation tests to interrogate the ability to find defects and the sensitivity to variability. The testing rubric is designed to maximize the coverage of the parameter space while minimizing the number of simulations needed. The inspectability metric has been in development in collaboration with industry partners to ensure compatibility with modern simulation tools and aerospace design workflows. In this study, we will demonstrate how the inspectability metric is able to determine the inspectability of multiple types of structures, including aerospace composites and additively manufactured parts. We will then show how the inspectability score can be plugged into existing design optimization tasks, such as structural sizing algorithms or design for manufacturing (DFM) frameworks.

Design for inspection↗

NASA NTRSDate not supplied

AI-Enhanced Computational Tools for Entry Systems Modeling

To advance the understanding of complex atmospheric entry phenomena, NASA’s Entry Systems Modeling (ESM) team [1] has developed high-fidelity computational tools addressing multiscale challenges, from material microstructures to full-scale heatshield response. This abstract highlights a subset of ESM tools, focusing on AI integration to enhance workflows and predictive modeling. - PuMA [2] computes effective material properties from high-resolution micro-CT scans, supporting TPS analysis for NASA missions. - TomoSAM [3] automates 3D tomography dataset segmentation for PuMA using the Segment Anything Model, reducing manual effort and improving accuracy. - PATO [4] models porous reactive materials under extreme conditions, with advancements such as unified solvers, mechanical erosion, and TPS coatings for NASA missions. - arcjetCV [5] employs deep learning to analyze arc jet test footage, measuring recession rates, shape changes, and shock standoff distances, bridging simulations, and experiments to reveal TPS ablation behavior. - ARCHeS [6] simulates arc heater plasma flows, modeling turbulence, radiation, and electromagnetic interactions to optimize arc heater performance, validate TPS under extreme conditions, and serve as a foundation for developing digital twins of arc heater facilities. - SPARTA [7] simulates rarefied hypersonic flows and gas-surface interactions for planetary entry missions, leveraging GPU architectures for scalable and efficient aerothermal and ablation analyses. AI-driven solutions, such as deep learning segmentation, have streamlined workflows in ESM tools and still hold significant potential to further accelerate processes and enhance automation in entry systems modeling. [1] Haskins, J.B. (2023), [2] Ferguson, J.C. (2018), [3] Meurisse, J.B.E. (2018), [4] Semeraro, F. (2023), [5] Quintart, A. (2024) [6] Meurisse, J.B.E. (2022), [7] Plimpton, S.J. (2019)

Predictive Modeling↗

NASA NTRS2026

NASA Weather Balloon Demonstration of an Additively Manufactured Antenna

Additive manufacturing (AM) enables low-cost, lightweight, and geometrically flexible antennas for rapid deployment missions. This work reports a left-hand circularly polarized magneto-electric dipole printed on a Radix dielectric with inkjet silver metallization and demonstrated as a process replacement for NASA weather-balloon RF hardware. By combining substrate fabrication and metallization, AM provides value for unrecoverable or field-replaceable systems. A physics based verification workflow links AM-specific material behavior to electromagnetic performance and yields bounded total, radiation, and mismatch efficiencies. Standard surface-impedance and roughness models failed to reproduce the frequency-dependent radiation loss observed in printed inks, underscoring the need for AM-specific conductor parameterization. Mission testing confirmed TDRSS link closure from NASA’s Columbia Scientific Balloon Facility and validated a repeatable print–measure–fly workflow for bounding RF performance and qualifying AM antennas for field use.

Peter Moschetti↗

NASA NTRS2026

Integrated Computational Materials Engineering (ICME) Capability Maturity Levels for Ecosystems Enabling Digital Transformation

Digital engineering (DE) and integrated computational materials engineering (ICME) are widely recognized as critical enablers of faster, more affordable, and more reliable aerospace systems. However, many organizations have struggled to realize the promised return on investment (ROI) from digital initiatives. A primary reason is the absence of a shared, decision-focused framework that distinguishes simple digitization of existing workflows from true digital transformation that fundamentally changes how engineering decisions are made. This paper introduces an ICME capability maturity framework that fills this gap. The framework defines six cumulative ICME capability maturity levels (CMLs), explicitly tied to decision authority, engineering integration, optimization, and uncertainty management across material, process, structure, and performance scales. It is designed to complement established readiness metrics such as technology readiness levels (TRLs), manufacturing readiness levels (MRLs), and integration readiness levels (IRLs), by addressing a missing dimension: the conditions required for model-informed decision authority across scales. A unifying figure and capability table illustrate the six-level ICME Capability Maturity Framework, showing how organizations progress from digitization—with limited or negative ROI—to true digital transformation, where ICME-enabled workflows deliver measurable improvements in decision quality, cycle time, risk reduction, and reuse. The framework is intended for both technical practitioners and executive leadership, providing a common language to assess current state, guide roadmaps, align software ecosystem investments, and set realistic expectations for digital transformation outcomes. A regulatory-relevant statement clarifying the relationship between ICME capability and existing certification frameworks is provided.

ICME↗

NASA NTRS2026

Investigation of Bipropellant Plume-Induced Contamination Effects on Coverglass Materials

Contamination and degradation of external spacecraft materials by unburned and partially combusted species from bipropellant thruster plumes has long been observed as a key component of the induced space environment. Space shuttle flight experiments and returned flight hardware from the International Space Station (ISS) have both experienced microscopic impact features induced by high-velocity thruster plume droplets. Analytical results have shown that droplet impingement angle relative to a receiving surface plays a key role in the surface damage. Although impacts with normal impingement angles contribute more severely to surface degradation than highly oblique angles, surface effects at higher impingement angles should not be dismissed. Thruster plume-induced materials degradation is a complex phenomenon that depends on a variety of parameters, including but not limited to material type, system temperature and pressure, plume composition, and thruster firing specifications such as number of pulses, pulse duration, and sample distance from the thruster. For space applications, attaining the vacuum pressure and temperature conditions necessary for flight-like plume expansion and exposure conditions is not a trivial task. The German Aerospace Center (Deutsches Zentrum für Luft- und Raumfahrt, DLR) is a facility uniquely capable of simulating such conditions. Test coupons were exposed to bipropellant thruster firings under high vacuum at the DLR facility. Percent area coverage (PAC) and droplet size distributions were evaluated for the uncoated and coated solar array coverglass materials over a range of impingement angles (0̊ to 75̊). A post-test imaging workflow was developed that aimed to quantify changes in sample surface morphology obtained from scanning electron microscopy (SEM) images using the Image Processing and Analysis in Java (ImageJ) tool; an opensource image processing software. The goal was to create a framework through which to evaluate the effect of bipropellant-induced PAC and droplet size distribution on solar array coverglass optical transmission losses. Understanding this relationship is important because optical transmission losses are known to lead to current reduction in solar power generation systems. In addition to the development of surface characterization workflows, valuable lessons learned as they pertain to future investigations and experiments will be discussed. The authors hope that sharing these lessons will facilitate more utilization of DLR’s unique capabilities as well as open the conversation for how best to address experimental characterization of flight-like plume expansion and its impacts on materials surface degradation effects.

Gateway↗