SEARCH · Search NASA

Results for “cleanroom assembly”

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

SourceResearch connectionFrom yearThrough year

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 73 records · Page 4

All sources NASA NTRS DOE OSTI

NASA NTRS1994

Using a temperature-controlled quartz crystal microbalance in a space equipment cleanroom to monitor molecular contamination

There is a need for continuous monitoring for molecular contamination in clean rooms where spaceflight equipment is assembled, integrated, and tested to insure that contamination budgets are met. The TQCM (temperature-controlled quartz crystal microbalance) can be used to provide both a real time warning and a cumulative measurement of molecular contamination. It has advantages over the other measurement methods such as witness mirrors, NVR (non-volatile residue) plates, and gas analyzers. A comparison of the TQCM sensitivity and ease of operations is made with the other methods. The surface acoustic wave microbalance (SAW), a newly developed instrument similar to TQCM, is considered in the comparison. An example is provided of TQCM use at Goddard Space Flight Center when the Wide Field Planetary Camera 2(WFPC-2) and the Corrective Optics Space Telescope Axial Replacement (COSTAR) were undergoing integrated testing prior to their installation in the Hubble Space Telescope on its first servicing mission. Areas for further investigation are presented.

Mitchell, William J.↗

NASA NTRS2008

Special ISO Class 6 Cleanroom for the Lunar Reconnaissance Orbiter (LRO) Project

The parameters and restrictions for a horizontal flow ISO Class 6 Clean room to support the assembly of the new LRO (Lunar Reconnaissance Orbiter) were unusual. The project time line was critical. A novel Clean room design was developed and built within the time restraints. This paper describes the design criteria, timing, successful performance, and future benefits of this unique Clean room project.

Matthews, Richard A.↗

DOE OSTI2024

Successful cleanroom installation of PIP-II SSR2 coupler using robotic arm

To minimize the contamination of SRF cavities, remote installation techniques are needed during the installation of components. Recent work at Fermilab has been performed to begin the process of developing techniques for assembling cavities using robotics. Multiple alignment methods were prototyped including alignment and computer vision methods. Using a remotely controlled robotic arm, the alignment and installation of couplers have been successfully performed on prototype PIP-II SSR2 cavities in a cleanroom. The installation process will be shown to show to demonstrate the potential of future installations on other cavities and cavity ancillaries.

43 PARTICLE ACCELERATORS↗

NASA NTRS2006

Genesis Spacecraft Science Canister Preliminary Inspection and Cleaning

The Genesis science canister is an aluminum cylinder (75 cm diameter and 35 cm tall) hinged at the mid-line for opening. This canister was cleaned and assembled in an ISO level 4 (Class 10) clean room at Johnson Space Center (JSC) prior to launch. The clean solar collectors were installed and the canister closed in the cleanroom to preserve collector cleanliness. The canister remained closed until opened on station at Earth-Sun L1 for solar wind collection. At the conclusion of collection, the canister was again closed to preserve collector cleanliness during Earth return and re-entry. Upon impacting the dry Utah lakebed at 300 kph the science canister integrity was breached. The canister was returned to JSC. The canister shell was briefly examined, imaged, gently cleaned of dust and packaged for storage in anticipation of future detailed examination. The condition of the science canister shell noted during this brief examination is presented here. The canister interior components were packaged and stored without imaging due to time constraints.

Hittle, J. D.↗

NASA NTRS2018

The Opera Instrument: An Advanced Curation Development for Mars Sample Return Organic Contamination Monitoring

Mars Sample Return (MSR) requires strict organic contamination control (CC) and contamination knowledge (CK) as outlined by the Mars 2020 Organic Contamination Panel (OCP). This includes a need to monitor surficial organic contamination to a ng/sq. cm sensitivity level. Archiving and maintaining this degree of surface cleanliness may be difficult but has been achieved. MSR's CK effort will be very important because all returned samples will be studied thoroughly and in minute detail. Consequently, accurate CK must be collected and characterized to best interpret scientific results from the returned samples. The CK data are not only required to make accurate measurements and interpretations for carbon-depleted martian samples, but also to strengthen the validity of science investigations performed on the samples. The Opera instrument prototype is intended to fulfill a CC/CK role in the assembly, cleaning, and overall contamination history of hardware used in the MSR effort, from initial hardware assembly through post-flight sample curation. Opera is intended to monitor particulate and organic contamination using quartz crystal microbalances (QCMs), in a self-contained portable package that is cleanroom-compliant. The Opera prototype is in initial development capable of approximately 100 ng/sq. cm organic contamination sensitivity, with additional development planned to achieve 1 ng/sq. cm. The Opera prototype was funded by the 2017 NASA Johnson Space Center Innovation Charge Account (ICA), which provides funding for small, short-term projects.

Fries, M. D.↗

NASA NTRSDate not supplied

Transforming any Facility for Meeting Strict Cleanliness Requirements

Over the life of the James Webb Space Telescope (JWST), Integration & Test (I&T) has taken place in areas that needed considerable work to make the facility itself and/or the protocols used while working in the rooms suitable to meet JWST percent area coverage (PAC) and molecular accumulation requirements. In addition to normal particulate matter, JWST had a uniquely significant challenge: fibers! Fibers not only cause much higher PAC levels, but they also risk damaging the angstrom sized Near Infrared Spectrometer (NIRSpec) microshutter array (MSA), which is critical to NIRSpec instrument performance. The primary emphasis of this paper is to address particulate and fiber contamination. The success of the JWST mission required effective cleanrooms, protocols, and mitigations in non-cleanroom areas that were pressed into service to house contamination-sensitive optics and scientific instruments. Some presented profound challenges. These included: NASA’s 60-year-old Johnson Space Center (JSC) Chamber A, which had never been used for anything contamination-sensitive, and the European tropical launch facilities, which were designed to meet International Standard Organization (ISO) Class 8 processing for communication satellites. The final challenge for JWST, as if to stare us in the face and say, “I dare you to try and make me clean enough,” was preparing the 4 areas in the Centre Spatial Guyanais (CSG) Final Assembly Building (BAF) located in French Guiana, a building in which one entire side opens for Ariane 5 rocket ingress and egress. This paper will describe our initial evaluation processes and the actual work undertaken to transform even the most challenging areas into first class cleanrooms that met JWST particulate and fiber requirements.

James Webb Space Telescope↗

NASA NTRS2006

Quantification of Spore-forming Bacteria Carried by Dust Particles

In order to establish a biological contamination transport model for predicting the cross contamination risk during spacecraft assembly and upon landing on Mars, it is important to understand the relationship between spore-forming bacteria and their carrier particles. We conducted air and surface sampling in indoor, outdoor, and cleanroom environments to determine the ratio of spore forming bacteria to their dust particle carriers of different sizes. The number of spore forming bacteria was determined from various size groups of particles in a given environment. Our data also confirms the existence of multiple spores on a single particle and spore clumps. This study will help in developing a better bio-contamination transport model, which in turn will help in determining forward contamination risks for future missions.

particles↗

NASA NTRS2022

Precious Cargo: Transporting Contamination-Sensitive Instruments & Optics

The James Webb Space Telescope (JWST) is a multi-national program with instruments and hardware supplied by companies all over the world and numerous states in the United States. In order to transport larger assemblies, like the Optical Telescope Element / Integrated Science Instrument Module (OTIS), and ultimately JWST, the Space Telescope Transporter for Air, Road and Sea (STTARS) was designed and constructed. STTARS is a massive mobile cleanroom (longer than 2 semi-trailers) that provides an ISO class 7 payload environment while being transported by road, airborne and marine vehicles. Temperature, humidity, and particle counts are controlled and continuously tracked, with fallout and NVR witness samples placed in strategic locations for confirmation. Instruments or sensitive hardware were purged continuously during transport. STTARS has 5 main components: the upper tent frame, lower tent frame, pallet, strong back and lid. After transporting OTIS to Northrup Grumman (NG), STTARS was modified to increase its height to house the JWST Observatory on its voyage to French Guiana. This new configuration was designated Observatory STTARS (OSTTARS). OSTTARS was too tall to travel by C5 aircraft, so the trip to the launch site was made by ship. Through JWST’s land, air, and sea transports, STTARS and OSTTARS kept JWST hardware exceptionally clean and safe.

James Webb Space Telescope↗

NASA NTRSDate not supplied

Precious Cargo: Transporting contamination-sensitive instruments & optics

James Webb Space Telescope↗

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 NTRS2011

Cryogenic-Compatible Winchester Connector Mount and Retaining System for Composite Tubes

A connector retainer and mounting system has been designed to replace screw-mounting of Winchester connectors. Countersunk screws are normally used to secure connectors to structures, and to keep them from coming apart. These screws are normally put into threaded or through-holes in metallic structures. This unique retainer is designed such that integral posts keep the connector halves retained, and a groove permits a cable tie to be fastened around the retainer and composite tube, thus securing the connector to the structure. The system is compatible for use on cryogenic (and conventional) bonded composite tube assemblies. Screws and tapped/through-holes needed to retain and mount Winchester connectors cannot be used on blind-access composite tubes. This system allows for rapid installation, removal, low-molecular-outgassing materials, and particulate-free installation and removal. Installation and/or changes late in the integration, and test flow with limited access in a cleanroom environment are possible. No sanding or bonding is needed.

Pontius, James↗

NASA NTRSDate not supplied

25 Years of Contamination Control on the James Webb Space Telescope

The James Webb Space Telescope (JWST) has actively been in process since 1996, and at last, on Christmas Day 2021, it launched. This launch was the fulfillment of an astounding level of work performed by thousands of people across the globe in dozens of disciplines. From the start, effective contamination control was considered essential for the JWST mission due to the large, exposed optics and tight sensitivity required to measure first light and faint signals at the dawn of the universe. This paper will present the JWST mission and requirements overview, including mission requirements that led to optimizing performance for collecting light in the Near Infrared (NIR, 0.6μm) – Mid Infrared (MIR, 29μm) range. Molecular films absorb in the IR bands and can alter thermal emissivity, resulting in increased noise at the longer wavelengths (MIRI). Particles increase light scatter and background noise levels at the shorter wavelengths (NIRSpec, NIRCam and FGS). The passively cooled design of JWST led to an open architecture for the optical telescope element (OTE), presenting the challenge of maintaining cleanliness throughout assembly, integration, and test in a multitude of environments. The paper will describe the mission and will introduce the specific areas of contamination control developed and advanced to keep JWST clean at an unsurpassed level of cleanliness.

Contamination Control↗

NASA NTRSDate not supplied

Evaluating the performance of portable air filter walls for the James Webb Space Telescope launch campaign

The James Webb Space Telescope (JWST) launched from the Centre Spatial Guyanais (CSG) in December 2021. JWST’s requirements permitted processing in International Organization for Standardization (ISO) Class 7 or better facilities, but CSG was only equipped with ISO Class 8 facilities. To temporarily upgrade the air cleanliness in the Payload Processing Facility, Fueling Hall, and Final Assembly Building Encapsulation Hall, NASA provided two portable High Efficiency Particulate Air (HEPA) and carbon filter walls that were used in each location. The walls were comprised of stacks of two modules high and arranged in push-push configurations as shown to be most effective via Computational Fluid Dynamics simulations of expected floor layouts in each facility. After delivery to NASA’s Goddard Space Flight Center in 2020, the walls underwent initial verification measurements inside a cleanroom and validation testing in an uncontrolled area to quantify their improvement of air cleanliness and particle and molecular fallout. Validation testing showed improvements of 83-99% for airborne particle counts, 79-91% for particle fallout, and 50-90% for molecular fallout. The particle improvements were applied to the contamination budget analysis that tracked current and predicted future cleanliness against End-of-Life requirements for JWST’s critical surfaces. At CSG, the walls successfully maintained an ISO Class 7 environment or better within their envelope in each location, despite their presence in ISO Class 8 facilities with dense integration operations.

HEPA, Contamination Control, Filtration↗

NASA NTRS2022

Evaluating the Performance of Portable Air Filter Walls for the James Webb Space Telescope Launch Campaign

HEPA, Contamination Control, Filtration↗

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.↗

DOE OSTI2024

Sampling Size Optimization for Bioburden Density Estimation in Planetary Protection

Planetary protection (PP) is a discipline that focuses on minimizing the biological contamination of spacecraft to ensure compliance with international policy. Precise estimation of bioburden - the total number of microbes in or on spacecraft hardware – and the bioburden density are of utmost importance for PP. Such estimation is the way concordance with requirements is demonstrated, and it is critical for quantifying the potential risk of inadvertently contaminating other planetary bodies. Although a suite of molecular techniques have been used to thoroughly characterize and profile the microbiome of various cleanroom environments and spacecraft, the gold standard remains the physical enumeration of microbes via culturing of samples directly taken from spacecraft and associated surfaces. However, due to technical, budgetary, and programmatic constraints, only a manageable portion (around 10%) of the entire spacecraft surface is directly sampled with cotton swabs or wipes. To generate the bioburden current best estimate (CBE) for components not directly verifiable, the accepted approach is to apply a NASA-defined bioburden estimate based on the components’ manufacturing or assembly environment. This approach utilizes a prespecified bioburden density estimation that applies a maximum value across the total surface area of the specified component. For hardware components that underwent similar assembly processes, an implied bioburden is adopted for all components, based on a direct verification of a representative component within the same lot. Once all components have a CBE, the bioburden estimates are generated. In previous publication [ 1], we have shown that statistical risks quantifying the accuracy of the estimates for sampled, prespecified, and implied components can be derived and ranked. For mean squared error (MSE) function, the risks are available analytically and hence a cost function can be obtained to optimize the risks with respect to the sampling area and sampling cost. Since the sampling area and sampling cost are two complimentary variables, their sum will have a well-defined minimum. This paper presents the multivariate optimization of the integrated risk of an empirical Bayes estimator to determine the optimal sampling schedule for a given number of components. It is assumed that given a number of components, N, the bioburden density for each component can either be sampled, implied, or prespecified. The multivariate optimization searches through different options to sample, imply or prespecify the bioburden density for a component, and account for the component’s surface area and cost of sampling. The idea of the optimization is based on the observation that the statistical risk of using an estimator is a monotonically decreasing function of the sampled area. The larger the sampled area, the lower the risk of using the estimator as the estimator becomes more and more accurate as the sampling area increases. On the other hand, the cost of sampling is monotonically increasing as the sampled surface grows. This makes the risk and total cost of sampling complimentary variables which can be counterbalanced to achieve an optimal overall value with respect to the sampled surface. In this paper, the integrated risk has been used to quantify the accuracy of the estimator. This risk has been selected because it depends on neither the true value of the parameter nor on the collected data. The cost of each sample was also available to obtain the total cost of sampling of N components. The paper will present the results based on computer-simulated data as well as the data collected during the InSight mission. The computer-simulated data have N components with randomly generated total areas and each component assigned to one of the three categories according to the method of estimating of bioburden density: sampled, implied, or prespecified. The cost of sampling is also available. The cost of sampling is estimated based on a cost model provided by the planetary protection group at JPL. For this paper, the overall cost was assumed to be a linear function of exposure. The optimization process finds the allocation of the components to the three categories that minimizes the tradeoff between integrated risk and total cost. For the InSight data, a set of components is selected representing all three categories, and optimization is performed to determine if the performed allocation was optimal or if a better allocation could have been obtained. To the best of our knowledge, this work is the first attempt not only perform an accurate estimation of bioburden density but also do it in an optimal way.

97 - MATHEMATICS AND COMPUTING↗

NASA NTRS2019

Analysis of WFPC-2 Core Samples for MMOD Discrimination

An examination of the Hubble Space Telescope Wide Field Planetary Camera 2 (WFPC-2) radiator assembly was conducted at NASA Goddard Space Flight Center during the summer of 2009. Immediately apparent was the predominance of impact features, identified as simple or complex craters, resident only in the thermal paint layer; similar features were observed during a prior survey of the WFPC-1 radiator. Larger impact features displayed spallation zones, darkened areas, and other features not observed in impacts onto bare surfaces. Craters were extracted by coring the radiator in the NASA Johnson Space Center’s Space Exposed Hardware cleanroom and were subsequently examined using scanning electron microscopy/energy dispersive X-ray spectroscopy to determine the likely origin, e.g., micrometeoritic or orbital debris, of the impacting projectile. Recently, a selection of large cores was re-examined using a new technique developed to overcome some limitations of traditional crater imaging and analysis. This technique, motivated by thin section analysis, examines a polished, lateral surface area revealed by cross-sectioning the core sample. This paper reviews the technique, the classification rubric as extended by this technique, and results to date.

Anz-Meador, P.↗

NASA NTRS2014

Ambient Optomechanical Alignment and Pupil Metrology for the Flight Instruments Aboard the James Webb Space Telescope

The James Webb Space Telescope science instruments are in the final stages of being integrated into the Integrated Science Instrument Module (ISIM) element. Each instrument is tied into a common coordinate system through mechanical references that are used for optical alignment and metrology within ISIM after element-level assembly. In addition, a set of ground support equipment (GSE) consisting of large, precisely calibrated, ambient, and cryogenic structures are used as alignment references and gauges during various phases of integration and test (I&T). This GSE, the flight instruments, and ISIM structure feature different types of complimentary metrology targeting. These GSE targets are used to establish and track six degrees of freedom instrument alignment during I&T in the vehicle coordinate system (VCS). This paper describes the optomechanical metrology conducted during science instrument integration and alignment in the Spacecraft Systems Development and Integration Facility (SSDIF) cleanroom at NASA Goddard Space Flight Center (GSFC). The measurement of each instrument's ambient entrance pupil location in the telescope coordinate system is discussed. The construction of the database of target locations and the development of metrology uncertainties is also discussed.

Optomechanical Alignment↗