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NASA NTRS2018

The Importance of Contamination Knowledge - Insights into Mars Sample Return

The Astromaterials Acquisition and Curation Office at NASA Johnson Space Center (JSC), in Houston, TX (henceforth Curation Office) manages the curation of all past, present, and future extraterrestrial samples returned by NASA missions and shared collections from international partners, preserving their integrity for future scientific study while providing the samples to the international community in a fair and unbiased way. The Curation Office also curates all reference and witness materials for each mission (e.g., flight and non-flight hardware coupons; lubricants; non-flight, flight-like, and flown witness plates). These reference and witness materials provide the scientific community with the fundamental ability to reconstruct the contamination/alteration history of the sample collection through the course of the mission, with the overall goal of strengthening the scientific conclusions drawn from the study of returned materials. The information gained from characterizing the physical, biological, inorganic, and organic chemical properties of reference and witness materials is defined as the Contamination Knowledge (CK) of the sample collection. Unlike the data collected for Contamination Control (CC) and Planetary Protection (PP), CK is exclusively concerned with preserving reference and witness materials for study by future scientists upon sample return. Although CC and PP data collected for sample integrity and forward contamination purposes can be complementary to CK, they are two separate data sets with distinct objectives. A robust collection of samples for CK is necessary to allow the extraterrestrial material in a returned sample to be distinguished from terrestrial contamination. Traditionally CK is utilized by sample scientists in order to accomplish the mission’s scientific objectives, however this information can also be utilized by the Office of Planetary Protection to help evaluate the presence of any back contamination. Mars 2020, the first phase of a potential multipart Mars Sample Return (MSR) campaign, is expected to contribute to NASA’s Mars Exploration Program Science Goals by filling in knowledge gaps concerning: 1) the existence of past or present life on Mars, 2) the past and present climate of Mars, 3) the geology of Mars, and 4) hazards associated with human exploration of Mars. Although there is debate concerning which samples will best answer these questions, the necessity for proper sample blanks is well-understood. The CC and PP requirements, driven by the restricted Class V mission designation, are the most stringent of any sample return mission in recent history. The extremely low levels of allowable terrestrial contamination on the spacecraft and rover can complicate these analyses given the detection limits of current analytical instrumentation, especially in the case of biological contamination. By collecting and curating unanalyzed samples specifically for CK, future sample scientists will not be relegated to: 1) relying on data collected using possibly obsolete tools and techniques for return sample blanks, or 2) using remnants of extracted and/or cultured samples from ATLO (Assembly, Test, and Launch Operations), which could be incompatible with the desired experimental endpoints or state-of-the-art techniques available at the time of sample return.The addition of biological experimental endpoints to a sample return campaign’s objectives broadens the requisite range in preservation environments (e.g. inert ultra-pure nitrogen gaseous environment at 18 degrees Centigrade versus less than or equal to minus 80 degrees Centigrade) and types of CK samples. As a result, the Curation Office will also curate the following CK samples at less than or equal to minus 80 degrees Centigrade for the Mars 2020 mission: 1) unanalyzed swabs and wipes in sterile containers, 2) all recirculation filters from the clean rooms used for sample and caching subsystem assembly and all filters from the laminar flow benches used to assemble sample intimate hardware, and 3) witness plates collecting airborne contamination within the assembly clean rooms. It has been Curation Office policy since the Apollo missions to preserve as many pristine samples as possible for future scientific research. Although CK is required to be collected for all stages of the MSR campaign, the CK for the Mars 2020 mission is the most critical for understanding contamination in the returned samples given the intimacy between the Martian samples and the Mars 2020 flight hardware. This presentation highlights the importance of CK for sample return missions as well as the traditional and novel types of CK samples required for a successful MSR campaign.

Harrington, A. D.↗

NASA NTRSDate not supplied

Metallic Environmentally Resistant Coating Rapid Innovation Initiative Under Extreme Space Environments

Mission concepts such as JPL’s Endurance-A campaign will utilize rovers such as Astrolab’s FLEX concept to explore the lunar surface. For these types of systems, lightweight alloys such as aluminum (Al) and titanium (Ti) are often specified to minimize mass while maintaining structural integrity [1,2,3]. Such alloys, however, exhibit poor tribological response in the form of high friction and wear, especially in extreme space environments and with the additional presence of lunar regolith. This shortens the lifetimes of these systems which have a requirement to traverse 1,00km/year [2,3]. The MERCRII project is ad-dressing the technology need of this and future rover missions by developing advanced wear- and radiation-resistant coatings for lightweight parts to extend the lifetime and sustainability of both lunar and Martian assets. The MERCRII project focuses on the technology taxonomies of exploration destination systems, mission infrastructure, and sustainability and supportability to explore both new and existing coating technologies, including material formulations and application methods. Several material formulations were considered for their wear resistance and fracture toughness and the following were chosen for Phase I testing: Nickle Titani-um (NiTi), Aluminum Oxide (AlO), and Ti64 with hBN at two and ten vol percent (Ti-2vol%hBN and Ti-10vol%hBN).

S. Rengifo↗

NASA NTRS2001

High Temperature Polyimide Materials in Extreme Temperature Environments

At the end of the NASA High Speed Research (HSR) Program, NASA Langley Research Center (LaRC) began a program to screen the high-temperature Polymeric Composite Materials (PMCs) characterized by the HSR Durability Program for possible use in Reusable Launch Vehicles (RLVs) operating under extreme temperature conditions. The HSR Program focused on developing material-related technologies to enable a High Speed Civil Transport (HSCT) capable of operating temperatures ranging from 54 C (-65 F) to 177 C (350 F). A high-temperature polymeric resin, PETI-5 was used in the HSR Program to satisfy the requirements for performance and durability for a PMC. For RLVs, it was anticipated that this high temperature material would contribute to reducing the overall weight of a vehicle by eliminating or reducing the thermal protection required to protect the internal structural elements of the vehicle and increasing the structural strain limits. The tests were performed to determine temperature-dependent mechanical and physical proper-ties of IM7/PETI-5 composite over a temperature range from cryogenic temperature -253 C (-423F) to the material's maximum use temperature of 230 C (450 F). This paper presents results from the test program for the temperature-dependent mechanical and physical properties of IM7/PETI-5 composite in the temperature range from -253 C (-423 F) to 27 C (80 F).

Johnson, Theodore F.↗

NASA NTRS2018

Chapter 12: Materials for Liquid Propulsion Systems

Earth to orbit launch vehicles are propelled by rocket engines and motors, both liquid and solid. This chapter will discuss liquid engines. The heart of a launch vehicle is its engine. The remainder of the vehicle (with the notable exceptions of the payload and guidance system) is an aero structure to support the propellant tanks which provide the fuel and oxidizer to feed the engine or engines. The basic principle behind a rocket engine is straightforward. The engine is a means to convert potential thermochemical energy of one or more propellants into exhaust jet kinetic energy. Fuel and oxidizer are burned in a combustion chamber where they create hot gases under high pressure. These hot gases are allowed to expand through a nozzle. The molecules of hot gas are first constricted by the throat of the nozzle (de-Laval nozzle) which forces them to accelerate; then as the nozzle flares outwards, they expand and further accelerate. It is the mass of the combustion gases times their velocity, reacting against the walls of the combustion chamber and nozzle, which produce thrust according to Newton's third law: for every action there is an equal and opposite reaction. Solid rocket motors are cheaper to manufacture and offer good values for their cost. Liquid propellant engines offer higher performance, that is, they deliver greater thrust per unit weight of propellant burned. They also have a considerably higher thrust to weigh ratio. Since liquid rocket engines can be tested several times before flight, they have the capability to be more reliable, and their ability to shut down once started provides an extra margin of safety. Liquid propellant engines also can be designed with restart capability to provide orbital maneuvering capability. In some instances, liquid engines also can be designed to be reusable. On the solid side, hybrid solid motors also have been developed with the capability to stop and restart. Solid motors are covered in detail in chapter 11. Liquid rocket engine operational factors can be described in terms of extremes: temperatures ranging from that of liquid hydrogen (-423 F) to 6000 F hot gases; enormous thermal shock (7000 F/sec); large temperature differentials between contiguous components; reactive propellants; extreme acoustic environments; high rotational speeds for turbo machinery and extreme power densities. These factors place great demands on materials selection and each must be dealt with while maintaining an engine of the lightest possible weight. This chapter will describe the design considerations for the materials used in the various components of liquid rocket engines and provide examples of usage and experiences in each.

Halchak, John A.↗

NASA NTRS2018

Qualifying Bulk Metallic Glass Gear Materials for Spacecraft Applications

NASA is evaluating bulk metallic glass (BMG) gears for extreme environment (cryogenic) applications; e.g., Europa Lander. The main purpose of this report is to recommend a quality assurance (QA) protocol for the production of consistent and reliable gear castings. Currently, there are two, separate manufacturers involved; Materion Corporation produces re-melt stock and Visser Precision Cast, Inc. produces BMG castings. Division of the existing alloy specifications document into material supplier-specific documents is proposed. Until a composition-based specification is established, processability- and performance-based methodologies may be an option during manufacturing development. It is recommended that each of the documents has a distinct focus; the processing behavior of crystalline feedstock, and the mechanical behavior of amorphous castings. The report addresses the “gray area” in QA testing between these materials suppliers by outlining an equitable division of responsibilities. The use of a number of dedicated reference dies to produce witness materials for physical and mechanical property evaluation is strongly recommended. Allocation of QA tests between screen testing of gear castings, and formal testing of witness materials, including cryogenic properties, is also proposed. The most effective suite of tests for both physical and mechanical property determination are down-selected from available national and international standards. The contents of this report create a solid basis for selection of QA tests, thereby setting the stage for negotiations between the materials suppliers and the customer.This technical paper:a) provides recommendations to advance materials specifications document JPL D-56223,Rev. A from “draft” to “preliminary” status;b) proposes division of the current document into two supplier-specific documents;c) separates testing methods by “ingots/castings” and “witness materials”;d) classifies test methodology based on “processability” and “performance”;e) assembles candidate ASTM specifications for “screen testing” and “formal testing”;f) identifies standard tests compatible with evaluation of BMG flexspline gears;g) suggests division of responsibilities for processability and performance testing; andh) addresses the QA “gray area” between production of ingots and castings.The report recommends that:a) processability- and performance-based QA methods might be used in lieu ofcompositional specifications during manufacturing development only;b) reference dies be designed for “acceptance” and “qualification” castings;c) witness materials provide physical and mechanical property data;d) formal testing be conducted at ambient and cryogenic temperatures; ande) processing/properties be correlated with compositional variations.

Hales, Stephen J.↗

NASA NTRS2012

Survival of B. Horneckiae Spores Under Ground-simulated Space Conditions

To prevent forward contamination and maintain the scientific integrity of future life detection missions, it is important to characterize and attempt to eliminate terrestrial microorganisms associated with exploratory spacecraft and landing vehicles. Among the organisms isolated from spacecraft-associated habitats, spore-forming microbes are highly resistant to various physical and chemical conditions, which include ionizing and UV radiation, desiccation and oxidative stress, and the harsh environment of outer space or planetary surfaces. Recently a radiation resistant, spore forming bacterial isolate, Bacillus horneckiae, was isolated from a clean room of the Kennedy Space Center where the Phoenix spacecraft was assembled. The exceptionally high tolerance of extreme conditions demonstrated by sporeforming bacteria highlighted the need to assess the viability of these microbes in situ (in real) space. The proposed BOSS (Biofilm Organisms Surfing Space) project aims to understand the mechanisms by which biofilm forming organisms, such as B. horneckiae, will potentially be able to withstand harsh space conditions. As previously stated, the spore producing ability of these species gives them increased survivability to harsh conditions. Some of the spores will have the protective exosporium layer artificially removed before the test to determine if the existence of this layer significantly changes the survivability during the mission. In preparation for that experiment, we analyzed spores which were exposed during a ground simulation, the EXPOSE R2 Biofilm Organisms Surfing Space (BOSS). Previous to exposure, spores were deposited onto spacecraft grade aluminum coupons in a spore suspension calculated to contain between 10(exp 7) and 10(exp 8) spores. This precursor series will be used to establish a baseline survivability function for comparison with the future flight tests during EXPOSE-R. For each coupon, a 10% polyvinyl alcohol (PVA) film was applied and peeled from the coupon to recover the spores. One hundred μl of sterile 10% PVA was applied to the surface of the coupon and allowed to dry for 1 hour at 37 C. The films were then removed using sterile scalpel and forceps and placed into a glass test tube containing 2 milliliters of sterile deionized water. The PVA film process was then repeated on each coupon one additional time to ensure recovery of the majority of spores. The second PVA film was added in the same glass tube as in the previous round. If the spores remained 100% viable, the test tubes should now contain between 5 X 10(exp 6) and 5 X 10(exp 7) spores per millimeter; however, it is expected that some loss of viability has occurred. In order to assess this loss, the number of colony forming, viable spores was counted. To count the colony forming units (CFUs), the spore containing solution was diluted in a process of 10-fold serial dilution by mixing successive solutions in a 100 microliter spore suspension to 900 microliter deionized H2O ratio. A sample dilution series revealed that 10(exp -3) and 10(exp -4) concentrations would be necessary for an accurate CFU count to be taken. For those two concentrations, a spread on a TSA plate was prepared and incubated at 32 C. For the samples exposed to UV radiation, the cell survivability was too low to establish a count from 100 microliter spread plating. Instead, no dilutions were performed and the entire 2 milliliter spore suspension was plated and incubated at 32 C. The plate's CFU counts were taken at 24 hours and 48 hours from the time of plating. At the end of the CFU counting the total surviving spores in each sample were calculated based on the number of CFUs that were observed per 100 microliters, or per 2 milliliters for the UV irradiated samples. The results of these calculations are shown in Figures 1 and 2.

cleanroom↗

NASA NTRS2008

High-Pressure Oxygen Generation for Outpost EVA

Low Lunar Orbit (LLO) poses unique thermal challenges for the orbiting space craft, particularly regarding the performance of the radiators. The emitted infrared (IR) heat flux from the lunar surface varies drastically from the light side to the dark side of the moon. Due to the extremely high incident IR flux, especially at low beta angles, a radiator is oftentimes unable to reject the vehicle heat load throughout the entire lunar orbit. One solution to this problem is to implement Phase Change Material (PCM) Heat Exchangers. PCM Heat Exchangers act as a "thermal capacitor, storing thermal energy when the radiator is unable to reject the required heat load. The stored energy is then removed from the PCM heat exchanger when the environment is more benign. Because they do not use an expendable resource, such as the feed water used by sublimators and evaporators, PCM Heat Exchangers are ideal for long duration Low Lunar Orbit missions. The Advanced Thermal Control project at JSC is completing a PCM heat exchanger life test to determine whether further technology development is warranted. The life test is being conducted on four nPentadecane, carbon filament heat exchangers. Fluid loop performance, repeatability, and measurement of performance degradation over 2500 meltfreeze cycles will be performed and reported in the current document.

Jeng, Frank↗

NASA NTRS1990

Contamination control program results from three years of ground operations on the Extreme Ultraviolet Explorer instruments

A stringent contamination-control plan has been developed for the optical components of the Extreme Ultraviolet Explorer instruments, whose performance in the 80-900 A wavelength range is highly sensitive to particulate and molecular contamination. The contamination-control program has been implemented over the last three years during assembly, test and calibration phases of the instrument. These phases have now been completed and the optics cavities of the instruments have been sealed until deployment in space. Various approaches are discussed which have been used during ground operations to meet optics' contamination goals within the project schedule and budget. The measured optical properties of EUV witness mirrors are also presented which remained with the flight mirrors during ground operations. These were used to track optical degradation due to contamination from the cleanroom and high-vacuum test-chamber environments.

Ray, David C.↗

NASA NTRS2014

Microorganisms in the Stratosphere (MIST): In-flight Sterilization with UVC Leds

The stratosphere (10 km to 50 km above sea level) is a unique place on Earth for astrobiological studies of microbes in extreme environments due to the combination of harsh conditions (high ultraviolet radiation, low pressure, desiccation, and low temperatures). Microorganisms in the Stratosphere (MIST) will attempt to characterize the diversity of microbes at these altitudes using a balloon collection device on a meteorological weather balloon. A major challenge of such an aerobiology study is the potential for ground contamination that makes it difficult to distinguish between collected microbes and contaminants. One solution is to use germicidal ultraviolet light emitting diodes (UV LEDs) to sterilize the collection strip. To use this solution, an optimal spatial arrangement of the lights had to be determined to ensure the greatest chance of complete sterilization within the 30 to 60 minute time of balloon ascent. A novel, 3D-printed test stand was developed to experimentally determine viable Bacillus pumilus SAFR-032 spore reduction after exposure to ultraviolet radiation at various times, angles, and distances. Taken together, the experimental simulations suggested that the UV LEDs on the MIST flight hardware should be active for at least 15 minutes and mounted within 4 cm of the illuminated surface at any angle to achieve optimal sterilization. These findings will aid in the production of the balloon collection device to ensure pristine stratospheric microbial samples are collected. Flight hardware capable of in-flight self-sterilization will enable future life detection missions to minimize both forward contamination and false positives.

Exobiology↗

NASA NTRS2023

Passive Rocket Diffuser Testing: Reacting Flow Performance of Advanced Configurations

Upper stage rocket engines are optimized for operation at the edge of space. Ground testing often requires simulation of high-altitude environments to prevent damage from off-design operation. Passive supersonic diffusers are an effective means of establishing the partial vacuum needed around the nozzle exit. The low cost of diffusers relative to active vacuum sources (ejectors, pumps, etc.) provides a perpetual incentive to improve their performance and expand the envelope of passively testable engines. Second-throat diffusers have been the de facto standard for rocket testing since the 1950s, and numerous studies have focused on parametric optimization of the topology. Yet, even the best second-throat designs may require more driving pressure than an upper stage engine can provide. To overcome conventional limits, engineers at NASA’s Stennis Space Center (SSC) adapted an obscure cold-flow diffuser topology to the extremes of immersion in supersonic combustion products. Aerodynamic experimentation was conducted at SSC’s E-3 test stand to quantify the performance of prototypical hot-fire spike diffuser hardware and enable direct comparison to prior states of the art. A LO X /GH 2 thruster was contoured to approximate the regeneratively-cooled nozzle of an upper-stage engine and fired into 28 downstream diffuser configurations: 16 second-throat, 2 centerbody, and 10 spike. Temperature and pressure were recorded along the test article walls for a range of chamber pressures spanning 3.5 - 5.0 MPa. The second-throat configurations with the lowest start and unstart pressure ratios were shown to outperform equivalent systems in literature and taken as baselines for evaluation of advanced diffuser performance. Compared to these exemplars, centerbody diffusers decreased start pressure ratio by 11% but increased unstart pressure ratio by 15%. Spike diffusers reduced start and unstart pressure ratios by 24% and 9%, respectively.

Rocket↗

NASA NTRS2023

Compliant Robotic Behaviors for Satellite Servicing

The demands of traditional industrial robotics differ significantly from those of space robotics. While industry requires robots that can perform repetitive tasks with precision and speed, the space environment needs robots to cope with uncertainties, dynamics, and communication delays or interruptions, similar to human astronauts. These demands make a well-suited application for compliant robotics and behavior-based programming. Pose Target Wrench Limiting (PTWL) is a compliant behavior paradigm developed specifically to meet these demands. PTWL controls a robot by moving a virtual attractor to a target pose. The attractor applies virtual forces, based on stiffness and damping presets, to an underlying admittance controller. Guided by virtual forces, the robot will follow the attractor until safety conditions are violated or success criteria are met. We tested PTWL on a variety of quasi-static tasks that may be useful for future space operations. Our results demonstrate that PTWL is an extremely powerful tool. It makes teleoperation easy and safe for a wide range of quasi-static tasks. It also facilitates the creation of semi-autonomous state machines that can reliably complete complex tasks with minimal human intervention.

Compliance↗

NASA NTRSDate not supplied

Thermochemical/Thermomechanical Synergies in High Temperature Solid Particle Erosion of CMAS-Exposed EBCs

Environmental barrier coatings (EBCs) are an enabling technology for the use of SiC-based ceramic matrix composites in next generation gas turbine engines. In the extreme engine environment, EBCs must be able to withstand a variety of individual damage mechanisms and their interactions with each other. Ingested particulates/debris can cause both thermochemical and thermomechanical degradation of EBCs. Siliceous debris primarily based on calcium magnesium aluminosilicates (CMAS) can melt and infiltrate and/or react with EBCs above >1200°C. Similarly, ingested debris can lead to mechanical damage and recession of coatings due to particulate erosion. Both modes of degradation can occur simultaneously during engine operation, and it is crucial to comprehensively understand the mechanisms of coating failure due to high-temperature particulate interactions. This study assesses the erosion durability of Yb2Si2O7-based EBCs exposed to CMAS of various loads in NASA Glenn’s Erosion Burner Rig Facility. CMAS exposures and erosion testing were carried out at 1316°C. The effects of CMAS loading and exposure time on EBC erosion durability were evaluated using Al2O3 as an erodent material.

EBC↗

NASA NTRS1998

Experiment-to-Experiment Disturbance of Microgravity Environment

The STS-87 Shuttle mission carried the Fourth United States MicroGravity Payload (USMP-4) as one of the primary payloads. Four USMP-4 science experiments were installed on two carriers in the cargo bay of the Shuttle. The Confined Helium Experiment (CHeX), located on the aft carrier, was particularly susceptible to vibrations in several frequency ranges due to structural resonances of the CHeX apparatus and the extreme sensitivity of the sample to vibrations. Shortly after activation of the USMP-4 payload, a strong, vibratory disturbance within the susceptibility region of the CHeX apparatus was detected. After investigating the characteristics of the disturbance and the time at which it first appeared, it was deduced that the vibration was generated by cooling fans in the Isothermal Dendritic Growth Experiment (IDGE). This paper will summarize the development of the conflict, briefly describe the disturbance source, and the susceptibility of the CHeX apparatus, and summarize the results of post-mission tests of IDGE.

DeLombard, Richard↗

NASA NTRS2019

Technology Readiness Assessment for HEEET TPS

The HEEET project was conceived to develop a heatshield with a high performance ablative thermal protection material that can withstand the extreme entry environment produced as a result of rapid deceleration during high speed entry into Venus, Saturn, Uranus or higher speed entry into Earth's atmosphere. Successful maturation of HEEET supports future New Frontiers and Discovery AO's, as well as Flagship and directed missions in the longer term. In addition, HEEET has the potential to evolve and to support re-entry to Earth, for missions such as Mars Sample Return.The primary goal of the HEEET Project was to develop an ablative TPS heat-shield based on woven TPS technology to Technology Readiness Level (TRL) 6. Key evidence to support the TRL evaluation includes: Demonstration of reproducible manufacturing of a dual layer material over a range of thicknesses and integrated on to a heatshield engineering test unit at a scale that is applicable to near term Discovery as the highest priority and future NF missions as secondary priority set of missions. Demonstration of predictable and stable performance of the dual layer TPS over a range of entry environments that are applicable to near term Discovery and NF missions of interest to SMD.Includes completion of coupon arc jet and laser testing and development of a mid-fidelity thermal response model that correlates with test results. Demonstration of flight heatshield system design for a range of sizes and loads that are relevant to near term Discovery and NF missions of interest to SMD. Includes completion of structural testing to validate analytic thermal/structural models and development of a material property database. Includes structural testing of a ~1m Engineering Test Unit under relevant entry loads.

Gage, Peter↗

NASA NTRS1989

Low frequency electric and magnetic fields

Following preliminary investigations of the low frequency electric and magnetic fields that may exists in the Earth-ionospheric cavity, measurements were taken with state-of-the art spectrum analyzers. As a follow up to this activity, an investigation was initiated to determine sources and values for possible low frequency signal that would appear in the cavity. The lowest cavity resonance is estimated at about 8 Hz, but lower frequencies may be an important component of our electromagnetic environment. The potential field frequencies produced by the electron were investigated by a classical model that included possible cross coupling of the electric and gravitation fields. During this work, an interesting relationship was found that related the high frequency charge field with the extremely low frequency of the gravitation field. The results of numerical calculations were surprisingly accurate and this area of investigation is continuing. The work toward continued development of a standardized monitoring facility is continuing with the potential of installing the prototype at West Virginia State College early in 1990. This installation would be capable of real time monitoring of ELF signals in the Earth-ionoshpere cavity and would provide some directional information. A high gain, low noise, 1/f frequency corrected preamplifier was designed and tested for the ferrite core magnetic sensor. The potential application of a super conducting sensor for the ELF magnetic field detection is under investigation. It is hoped that a fully operational monitoring network could pinpoint the location of ELF signal sources and provide new information on where these signals originate and what causes them, assuming that they are natural in origin.

Spaniol, Craig↗

NASA NTRS2015

High Temperature Joining and Characterization of Joint Properties in Silicon Carbide-Based Composite Materials

Advanced silicon carbide-based ceramics and composites are being developed for a wide variety of high temperature extreme environment applications. Robust high temperature joining and integration technologies are enabling for the fabrication and manufacturing of large and complex shaped components. The development of a new joining approach called SET (Single-step Elevated Temperature) joining will be described along with the overview of previously developed joining approaches including high temperature brazing, ARCJoinT (Affordable, Robust Ceramic Joining Technology), diffusion bonding, and REABOND (Refractory Eutectic Assisted Bonding). Unlike other approaches, SET joining does not have any lower temperature phases and will therefore have a use temperature above 1315C. Optimization of the composition for full conversion to silicon carbide will be discussed. The goal is to find a composition with no remaining carbon or free silicon. Green tape interlayers were developed for joining. Microstructural analysis and preliminary mechanical tests of the joints will be presented.

Joining↗

NASA NTRSDate not supplied

Extreme Environments Solar Power Project For Use Near Jupiter

The Extreme Environment Solar Power (EESP) Project goal was to develop solar cell and solar array design concept technologies for space power applications in high radiation and low solar intensity, low temperature (LILT) environments. NASA missions focused on outer planets, such as Jupiter, are subjected to intense radiation while experiencing less than ten percent of the solar flux relative to a mission in the general vicinity of Earth. Under these conditions, present solar array technology is not as efficient in converting the sun’s energy, and the solar array performance degrades quickly due to the additional radiation exposure. The EESP Project objectives were accomplished through four competitively selected contracts. These contracts were awarded with a Base and two option periods of performance. The Base requirements included System Design and Component Test & Analysis with a duration of nine and one half (9.5) months. The Option I requirements involved the fabrication of test hardware that NASA would evaluate following its delivery, and this period of performance had a duration of thirteen (13) months. The Option II requirements involved the fabrication of a scalable system prototype that can be integrated into a system level application and be demonstrated in a relevant environment. Option II had a duration of fifteen (15) months. The Transformational Array (TA) is an array concept developed by JHU-APL with Deployable Space Systems (DSS), SolAero Technologies and NewForge Technologies that proceeded through all three contract periods. The TA combines the DSS Roll Out Solar Array (ROSA) with Flexible Array Concentrator Technology (FACT) and SolAero’s Inverted Metamorphic Multijunction (IMM) solar cells for operation in the EESP Project environment. To achieve the EESP Project goals, the JHU-APL team conducted several investigations to improve performance of the solar cells and increase their efficiency, reduce outgassing contamination of the concentrators from the solar cell assembly adhesives, and to test the robustness of a sample blanket during deployment and retraction. Additionally, the team performed vibration, thermal cycling, and performance tests at a Standard Power Module (SPM) level. At the end of Option II, the JHU-APL team achieved the following performance metrics: • 39% beginning of life (BOL) cell efficiency at 5 AU and -125 C • 29% end of life (EOL) efficiency at the blanket level at 50 W/m2, -125 C and 4x1015 1 MeV e/cm2 • Increased specific power to 8 W/kg at EOL for the entire array including structure, deployment, and pointing mechanisms • Demonstrated the ability to survive numerous deploy-retract cycles without degradation • Reached a current System-Level Technology Readiness Level, TRL5 This presentation will describe the Transformational Array and component technologies and will discuss future potential uses for the system.

Anna Maria Pal↗

NASA NTRS2022

Cold Survivable Electronics Motor Control Law Implementation

For the last seven years JPL has been developing motor control electronics for use on future missions to extreme environments such as Europa and Mars. The packaging technology developed will allow the electronics to survive the extremes seen on the surface. This packaging technology allows us to package everything to control a number of motors on a single card including the closed loop control. In order to improve the performance of the motor control we have developed FPGA code to close the position, velocity and current control loops of the motor controller. This code allowed for a significant improvement in loop rate allowing the control of the motors to be more accurate. This allows for more accurate control of descent engines, more precise control of robotic arm motors. In this paper we will present the design of the control algorithm, the performance of the sensors and the test results of the resulting system.

Cheng, Ben↗