Refractory materials in thermionic converters for space applications.
Refractory materials in thermionic converters for spacecraft use, noting manufacturing problems and performance characteristiss
SPACECRAFT INSTRUMENTATION↗
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Thermal Cycle and Capacitance Testing of Mezzo Industries Phase Changer Material Heat Capacitor
Effective Thermal management is essential for the safety and performance of human spacecraft, especially during long-duration missions with fluctuating heat loads. Phase Change Material (PCM) heat exchangers offer a compact, efficient solution by storing and releasing thermal energy through latent heat during phase transitions. This allows PCM systems to buffer transient thermal loads without immediate heat rejection, reducing the need for oversized radiators – particularly critical during ascent and re-entry when radiators are stowed. By maintaining stable temperatures in crew cabins and equipment bays, PCM technology enhances crew comfort, protects sensitive systems, and supports long-term mission sustainability with minimal mass and volume impact. A phase change material heat capacitor prototype, designed and built under a NASA Small Business Innovation Research grant by Mezzo Technologies, utilizes a laser welding microtube manufacturing process that promises increased reliability and performance over current manufacturing methods like brazing. This heat exchanger was tested through coolant thermal cycling within the expected flow rates and temperature range of the Orion spacecraft, the crewed spacecraft taking NASA astronauts to the moon under the Artemis Program. The useful heat storage capacitance was measured and compared to Orion spacecraft requirements.
Active Thermal Control Systems↗
The effects of 1 kW class arcjet thruster plumes on spacecraft charging and spacecraft thermal control materials
Arcjet thrusters are soon to be used for north/south stationkeeping on commercial communications satellites. A series of tests was performed to evaluate the possible effects of these thrusters on spacecraft charging and the degradation of thermal control material. During the tests the interaction between arcjet plumes and both charged and uncharged surfaces did not cause any significant material degradation. In addition, firing an arcjet thruster benignly reduced the potential of charged surfaces to near zero.
Bogorad, A.↗
Thermal and Mechanical Performance of a Carbon/Carbon Composite Spacecraft Radiator
Carbon-carbon composite materials offer greater thermal efficiency, stiffness to weight ratio, tailorability, and dimensional stability than aluminum. These lightweight thermal materials could significantly reduce the overall costs associated with satellite thermal control and weight. However, the high cost and long lead-time for carbon-carbon manufacture have limited their widespread usage. Consequently, an informal partnership between government and industrial personnel called the Carbon-Carbon Spacecraft Radiator Partnership (CSRP) was created to foster carbon-carbon composite use for thermally and structurally demanding space radiator applications. The first CSRP flight opportunity is on the New Millennium Program (NMP) Earth Orbiter-1 (EO-1) spacecraft, scheduled for launch in late 1999. For EO-1, the CSRP designed and fabricated a Carbon-Carbon Radiator (CCR) with carbon-carbon facesheets and aluminum honeycomb core, which will also serve as a structural shear panel. While carbon-carbon is an ideal thermal candidate for spacecraft radiators, in practice there are technical challenges that may compromise performance. In this work, the thermal and mechanical performance of the EO-1 CCR is assessed by analysis and testing. Both then-nal and mechanical analyses were conducted to predict the radiator response to anticipated launch and on-orbit loads. The thermal model developed was based on thermal balance test conditions. The thermal analysis was performed using SINDA version 4.0. Structural finite element modeling and analysis were performed using SDRC/1-DEAS and UAI/NASTRAN, respectively. In addition, the CCR was subjected to flight qualification thermal/vacuum and vibration tests. The panel meets or exceeds the requirements for space flight and demonstrates promise for future satellite missions.
Kuhn, Jonathan↗
Testing Protocol Proposal to Identify and Evaluate Candidate Materials to Substitute for Silverized Teflon in Thermal Control Applications
Electrostatic discharge (ESD) has been shown to be the primary cause of several glitches in spacecraft operations. It appears that charged particles encountered in the natural environment in certain orbits can collect on the outer surfaces of a spacecraft, building up a charge of several thousand volts. If the potential exceeds the breakdown voltage of the charged material, then an ESD will occur. ESD events involving relatively low voltages, on the order of 100 V, have been shown to damage electronic components. When ESD occurs, electronic and electrical components can be damaged, computer instructions can be garbled, and ablation of material from the spacecraft may occur; degrading both the performance of the thermal control blankets, and the cleanliness of any surfaces on which the detritus becomes deposited. There appear to be six ways to prevent or mitigate the effects of ESD: (1) Choose an orbit where charging is not a problem; (2) Carry extra electromagnetic shielding; (3) Provide redundancy in components and programming; (4) Provide for active dissipation of the charge, by generating a plasma with which to bathe susceptible surfaces; (5) Provide for passive dissipation from a plasma contactors on the susceptible surfaces; and (6) Provide thermal control blankets that do not hold a charge, i.e., that are conductive enough to bleed a charge off harmlessly. These six options are discussed in detail in Losure (1996). Of these six options, number 1 is not always practical, given other requirements of the mission; 2, 3, 4 and 5 will require that extra mass in the form of shielding, etc., be carried by the spacecraft. The most attractive option from a mass and energy point of view seems to be that of finding a material which matches the other performance characteristics of the current thermal control blankets without their tendency to build up an electrostatic charge. The goal of this paper is to describe and justify a testing program which will lead to the approval of materials of this kind.
Losure, Nancy S.↗
Polyimide adhesives for titanium and composite bonding
Approach results in synthesis of addition polyimide adhesives with exceptional high temperature capabilities that show excellent potential for bonding titanium metal, polyimide/graphite composites, and combinations of these materials. Adhesives compatible with materials used in high performance aircraft and spacecraft structures also prove highly desirable in many other applications involving similar adherents.
St. Clair, A. K.↗
Analysis of Spacecraft Materials Discrimination Using Color Indices for Remote Sensing for Space Situational Awareness
The increasing number of space missions have resulted in an augmented density of artificial objects positioned in orbital domains near Earth. Knowing the material composition of the resident space object can be of value in object identification and risk assessment using remote sensing techniques. To perform this task, it is increasingly imperative to optically characterize spacecraft materials to identify unique material-specific spectroscopic markers. In this work, a variety of materials frequently utilized by the aerospace industry in spacecraft design and construction were analyzed using reflectance spectroscopy. The collected data provide a spectral characterization baseline for modern-day and historical spacecraft materials. The color index was computed for standard astronomical and suggested theoretical filter passbands and compared to each other in their capability to discriminate materials belonging to different classes. The color index was calculated from reflectance spectra of common spacecraft materials in their pristine, as-received conditions that fell under different family groupings. Different color-index combinations were studied using color-color diagrams. Visual and quantitative analysis of the color-color diagrams were used to evaluate the possibility of discriminating materials from one another by means of optical measurements. Results of the analysis show that polyimide and photovoltaic materials are most easy to discriminate from all other materials via color indices using different filter passbands evaluated in this study.
spectral reflectance↗
Development of contamination requirements for spaceborne optical instrumentation
High performance satellites and critical surfaces aboard advanced long-life spacecraft require effective contamination control measures to maintain performance stability and to ensure data accuracy. Contamination is said to exist and be of concern if a spacecraft or launch vehicle produced material interferes with the intended performance of a surface or sensor. This paper will discuss the development of contamination requirements for spaceborne optical instrumentation. In addition, a comparison of instrument contamination requirements to measured instrument degradation levels for mission activities will be presented. If maintained, these requirements ensure against undesirable instrument degradation due to the contamination environment created by fabrication, launch, mission activities, ambient atmosphere and the instruments themselves.
Hansen, Patricia A.↗
Advanced composites for large Navy spacecraft
An overview is given of work conducted on contract for the Naval Sea Systems Command. The objective of this contract was to provide direction for the development of high modulus graphite reinforced metal matrix composites. These advanced materials can have a significant effect on the performance of a spacecraft before, during and after an evasive maneuver. The work conducted on this program was organized into seven technical tasks. Task 1 was development of a generic Navy spacecraft model. Finite element models of candidate structural designs were developed. In Task 2, the finite-element model(s) of the structure were used to conduct analytical assessments involving conventional materials, resin matrix composites and metal matrix composites (MMC). In Task 3 and 4, MMC material design, fabrication and evaluation was conducted. This consisted of generating material designs and developing a data base for a broad range of graphite reinforced MMC materials. All material was procured according to specifications which set material quality and material property standards. In Task 5, a set of evasive maneuvering requirements were derived and used in Task 6 to conduct analytical simulations. These analytical simulations used current SOA material properties and projected material properties to provide an indication of key payoffs for material development. In Task 7, a set of material development recommendations was generated.
Davis, William E.↗
Particle Morphology and Elemental Composition of Smoke Generated by Overheating Common Spacecraft Materials
Fire safety in the indoor spacecraft environment is concerned with a unique set of fuels which are designed to not combust. Unlike terrestrial flaming fires, which often can consume an abundance of wood, paper and cloth, spacecraft fires are expected to be generated from overheating electronics consisting of flame resistant materials. Therefore, NASA prioritizes fire characterization research for these fuels undergoing oxidative pyrolysis in order to improve spacecraft fire detector design. A thermal precipitator designed and built for spacecraft fire safety test campaigns at the NASA White Sands Test Facility (WSTF) successfully collected an abundance of smoke particles from oxidative pyrolysis. A thorough microscopic characterization has been performed for ten types of smoke from common spacecraft materials or mixed materials heated at multiple temperatures using the following techniques: SEM, TEM, high resolution TEM, high resolution STEM and EDS. Resulting smoke particle morphologies and elemental compositions have been observed which are consistent with known thermal decomposition mechanisms in the literature and chemical make-up of the spacecraft fuels. Some conclusions about particle formation mechanisms are explored based on images of the microstructure of Teflon smoke particles and tar ball-like particles from Nomex fabric smoke.
Smoke↗
Reliability considerations in electronic transformers for space applications.
Quality and reliability control of spacecraft toroidal transformers noting material selection, termination techniques, performance testing, etc
Wiler, E. M.↗
Concepts for microgravity experiments utilizing gloveboxes
The need for glovebox facilities on spacecraft in which microgravity materials processing experiments are performed is discussed. At present such facilities are being designed, and some of their capabilities are briefly described. A list of experiment concepts which would require or benefit from such facilities is presented.
Kroes, Roger L.↗
Windform® XT 2.0 Use as 3U CubeSat Primary Structure
CubeSats provide a platform for small-scale space research and technology demonstration at reduced complexity, cost, and development time. These advantages drove the NASA Langley Research Center (LaRC) to develop and launch the GPX2 3U CubeSat to explore the viability of using Commercial Off-The-Shelf (COTS) differential GPS (dGPS) in low earth orbit. To reduce manufacturing costs and increase design flexibility, the project chose additive manufactured Windform® XT 2.0 as the primary bus material rather than traditional subtractive manufactured (milled) metal. The bus is a two-part, Selective Laser Sintered, 3D-print structure consisting of a single-piece, five-walled chassis and single-walled cover. The bus was specially designed to allow the project to accommodate the payload electronics stack as well as antennas, receivers, and deployable mechanisms. By using an additive manufactured solution, LaRC was able to design in features unrealizable through traditional milling, with a lead-time of roughly two weeks. In comparison, traditional subtractive manufacturing limits geometry options due to toolpath reach and bus construction would have required multiple components for each wall. This would have resulted in a more costly, longer lead-time article with more joints, fasteners, and complexity with a commensurate increase in overall mass. A number of lessons-learned were captured during the design, analysis, and testing of the GPX2 CubeSat covering thermal and structural analysis, vibration modeling, and geometric tolerancing. Additionally, a variety of material testing and verification were performed before and during spacecraft design and integration to assure the suitability of Windform® XT 2.0 for the launch and mission environments. This article provides the highlights of designing and testing the GPX2 bus.
CubeSat↗
Printable Spacecraft: Flexible Electronic Platforms for NASA Missions
Why printed electronics? Why should NASA use printed electronics to make a spacecraft? Three words provide the answer: universal, impactful, progressive. The technology is universal because the applications it can affect are broad and diverse from simple sensors to fully functional spacecraft. The impact of flexible, printed electronics range from straightforward mass, volume and cost savings all the way to enabling new mission concepts. The benefits of the technology will become progressively larger from what is achievable today so that investments will pay dividends tomorrow, next year and next decade. We started off three years ago asking the question can you build an entire spacecraft out of printed electronics? In other words, can you design and fabricate a fully integrated, electronic system that performs the same end-to-end functions of a spacecraft - take scientific measurements, perform data processing, provide data storage, transmit the data, powers itself, orients and propels itself - all out of thin flexible sheets of printed electronics? This "Printable Spacecraft" pushes the limits of printed flexible electronics performance. So the answer is yes, more or less. In our studies for the NIAC (NASA Innovative Advanced Concepts) program, we have explored this question further, to explain more completely what "more or less" means and to outline what is needed to make the answer a definitive "yes". Despite its appealing "Flat Stanley"-like (a book series by Jeff Brown) qualities, making a Printable Spacecraft is not as easy as flattening the Cassini spacecraft with a bulletin board, as was Stanley Lamchop's fate. But, if NASA invests in the design challenges, the materials challenges, the performance challenges of printed electronics, it might find itself with a spacecraft that can enable as many adventures and advantages as Flat Stanley including putting it in an envelope and mailing it to the planet of your choice. You just have to let your imagination take over. In this report we document the work of the Phase 2 Printable Spacecraft task conducted under the guidance and leadership of the NIAC program. In Phase One of the NIAC task entitled "Printable Spacecraft", we investigated the viability of printed electronics technologies for creating multi-functional spacecraft platforms. Mission concepts and architectures that could be enhanced or enabled with this technology were explored. In Phase 2 we tried to answer the more practical questions such as can you really build a multi-functional printed electronic spacecraft system? If you do, can it survive the space environment? Even if it can, what benefit does a printable system provide over a traditional implementation of a spacecraft?
Materials↗
NASA's Space Environments and Effects Program: Technology for the New Millennium
Current trends in spacecraft development include the use of advanced technologies while maintaining the "faster, better, cheaper" philosophy. Spacecraft designers are continually designing with smaller and faster electronics as well as lighter and thinner materials providing better performance, lower weight, and ultimately lower costs. Given this technology trend, spacecraft will become increasingly susceptible to the harsh space environments, causing damaging or even disabling effects on space systems. NASA's Space Environments and Effects (SEE) Program defines the space environments and provides advanced technology development to support the design, development, and operation of spacecraft systems that will accommodate or mitigate effects due to the harsh space environments. This Program provides a comprehensive and focused approach to understanding the space environment, to define the best techniques for both flight and ground-based experimentation, to update the models which predict both the environments and the environmental effects on spacecraft, and finally to ensure that this multitudinous information is properly maintained and inserted into spacecraft design programs. A description of the SEE Program, its accomplishments, and future activities is provided.
Hardage, Donna M.↗
Automating Structural Analysis of Spacecraft Vehicles
A major effort within NASA's vehicle analysis discipline has been to automate structural analysis and sizing optimization during conceptual design studies of advanced spacecraft. Traditional spacecraft structural sizing has involved detailed finite element analysis (FEA) requiring large degree-of-freedom (DOF) finite element models (FEM). Creation and analysis of these models can be time consuming and limit model size during conceptual designs. The goal is to find an optimal design that meets the mission requirements but produces the lightest structure. A structural sizing tool called HyperSizer has been successfully used in the conceptual design phase of a reusable launch vehicle and planetary exploration spacecraft. The program couples with FEA to enable system level performance assessments and weight predictions including design optimization of material selections and sizing of spacecraft members. The software's analysis capabilities are based on established aerospace structural methods for strength, stability and stiffness that produce adequately sized members and reliable structural weight estimates. The software also helps to identify potential structural deficiencies early in the conceptual design so changes can be made without wasted time. HyperSizer's automated analysis and sizing optimization increases productivity and brings standardization to a systems study. These benefits will be illustrated in examining two different types of conceptual spacecraft designed using the software. A hypersonic air breathing, single stage to orbit (SSTO), reusable launch vehicle (RLV) will be highlighted as well as an aeroshell for a planetary exploration vehicle used for aerocapture at Mars. By showing the two different types of vehicles, the software's flexibility will be demonstrated with an emphasis on reducing aeroshell structural weight. Member sizes, concepts and material selections will be discussed as well as analysis methods used in optimizing the structure. Analysis based on the HyperSizer structural sizing software will be discussed. Design trades required to optimize structural weight will be presented.
Hrinda, Glenn A.↗
Nanoscale Materials Make for Large-Scale Applications
Since its dawning days, NASA has been at the forefront of developing and improving materials for aerospace applications. In particular, NASA requires dramatic advancements in material properties to enhance the performance, robustness, and reliability of its launch vehicles, spacecraft, and the International Space Station. Such advancements over the years include noise-abatement materials, fire-resistant fibers, heat-absorbing insulation, and light-but-strong moldable composites. In 1991, a new carbon fiber called a carbon nanotube was discovered and fully substantiated by a Japanese electron microscopist. Its dramatic strength and low density (20 times the tensile strength and one-sixth the density of steel) were turning the heads of materials scientists and engineers all around the world, including those who developed equipment for NASA. While NASA did not invent the carbon nanotube, it is working to advance the fibrous material for widespread, low-cost application in sending humans beyond low-Earth orbit, well into the outer reaches of the universe. Carbon nanotubes have the potential to reduce spacecraft weight by 50 percent or more, by replacing the heavier copper wires currently used, according to NASA scientists. Furthermore, NASA researchers have reported a new method for producing integrated circuits using carbon nanotubes instead of copper for interconnects. This technology has the capability to extend the life of the silicon chip industry by 10 years. Because of this growing interest in carbon nanotubes and their perpetual possibilities, NASA has funded both internal and external research in this field.
Source record↗
Performance and properties of atomic oxygen protective coatings for polymeric materials
Such large LEO spacecraft as the Space Station Freedom will encounter high atomic oxygen fluences which entail the use of protective coatings for their polymeric structural materials. Such coatings have demonstrated polymer mass losses due to oxidation that are much smaller than those of unprotected materials. Attention is here given to protective and/or electrically conductive coatings of SiO(x), Ge, and indium-tin oxide which have been exposed to atomic oxygen in order to ascertain mass loss, electrical conductivity, and optical property dependence on atomic oxygen exposure.
Banks, Bruce A.↗