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Engineering the Interface: Advanced Surface Technologies for Lunar Dust Management and Equipment Longevity

Through the Artemis program, NASA intends to develop a sustainable human foothold on the Moon, ultimately paving the way for crewed exploration of Mars. The Moon's hostile environment poses numerous obstacles, including exposure to radiation, temperature extremes, micrometeoroid threats, and particularly the persistent problem of lunar dust. Lunar dust impacts nearly every aspect of surface operations through adhesion and abrasion mechanisms, with contamination from anthropogenic activities (landing, rovers) far outweighing natural phenomena. Multiple adhesion pathways contribute to surface contamination in the lunar environment, including van der Waals forces, electrostatic forces, chemical reaction, and magnetic forces from elemental iron deposits. Sharp asperities from micrometeoroid bombardment and atmospheric absence increase interaction potential and enable mechanical interlocking. Low cohesion between dust particles exacerbates these challenges, as minimal interaction potential between dust and nearby surfaces overcomes particle cohesion, causing contamination. Lunar dust adhesion mitigation technologies can be categorized as either active, requiring external energy, or passive, relying on intrinsic material properties. Ultrasonic and electrodynamic technologies have been developed to the highest technology readiness level for active approaches. Passive strategies primarily focus on surface chemistry and topography modifications. At NASA Langley Research Center, approaches include surface migration agents to reduce surface energy, topographical modification using laser ablation patterning, and tailored surface conductivity to reduce intrinsic adhesion force. Performance has been evaluated using custom-built ultrasonic and centrifuge instruments. Plume-surface interactions from lunar landers can propel micrometer-sized particles at velocities up to 1000 m s-1.8 These particles pose risks to landers, habitats and infrastructure, leading to erosion, degradation, and reduced component lifespan. A panel recovered from Surveyor III was determined to have been severely abraded because of lunar dust displaced from the Apollo 12 lunar module that landed 160 m away. The performance of metallic surfaces has been evaluated via high velocity single particle impact using the laser-induced project impact test (LIPIT) facility at the University of Utah. Peridynamics modeling, a form of continuum mechanics that uses a nonlocal approach enabling greater simulation capabilities of crack initiation and fracture, has also been utilized to gain greater insight into material response during impact events. Lunar dust contamination challenges extend to power generation systems and moving equipment. Cables, rotation stages, and other mechanisms may experience limited range of motion and reduced lifetime due to dust infiltration. NASA Langley Research Center has evaluated traditional aerospace alloys, softgoods, wear resistant ceramics, and several polymer and polymer composite materials. Test methods have included traditional techniques like Taber abrasion testing, as well as designed test configurations developed in the DUSTE (dust, ultraviolet radiation, and space thermal environmental) chamber that reproduce mechanism functions in operational environment. Beyond laboratory experiments, several flight experiments have been conducted. Materials were exposed to the low Earth orbit environment on the Materials International Space Station Experiment (MISSE) and to the lunar surface environment through the Aegis Aerospace Regolith Adherence Characterization (RAC) payload and the Honeybee Robotics PlanetVac payload. Determining lunar dust's impact on surface exploration and habitation requires comprehensive experimental and computational capabilities combined with lessons learned from initial lunar activities. Identifying the greatest environmental challenges and developing mitigation technologies provides the clearest path toward successfully, expeditiously, and efficaciously completing NASA's mission. This presentation will discuss ongoing efforts at NASA Langley Research Center and collaborator contributions to these critical objectives.

Surface Engineering↗

NASA NTRS2016

ESTA Exit Report

The Energy Test System's Area (ESTA) provides test capabilities and facilities to develop, evaluate or certify hardware in support of human spaceflight. The branch has a few different technical areas including pyrotechnics, batteries, electrical systems, power systems, propulsion and fluids. I will be mainly worked in the propulsion and fluids area. The tests/activities include testing the fluid and energy conversion systems that are required for the exploration and development of space. This group includes function and vibration tests, as well as thermal and vacuum tests. I was trained and certified as an ESTA test director in order to work on tests and sub tests with my mentor as well as the rest of the ESTA team. As a test director, I had the responsibility and authority for planning, developing, safety, execution and reporting on assigned test programs.

Lundebjerg, Kristen↗

NASA NTRS2013

Sasquatch Footprint Tool

The Crew Exploration Vehicle Parachute Assembly System (CPAS) is the parachute system for NASA s Orion spacecraft. The test program consists of numerous drop tests, wherein a test article rigged with parachutes is extracted or released from an aircraft. During such tests, range safety is paramount, as is the recoverability of the parachutes and test article. It is crucial to establish an aircraft release point that will ensure that the article and all items released from it will land in safe locations. A new footprint predictor tool, called Sasquatch, was created in MATLAB. This tool takes in a simulated trajectory for the test article, information about all released objects, and atmospheric wind data (simulated or actual) to calculate the trajectories of the released objects. Dispersions are applied to the landing locations of those objects, taking into account the variability of winds, aircraft release point, and object descent rate. Sasquatch establishes a payload release point (e.g., where the payload will be extracted from the carrier aircraft) that will ensure that the payload and all objects released from it will land in a specified cleared area. The landing locations (the final points in the trajectories) are plotted on a map of the test range. Sasquatch was originally designed for CPAS drop tests and includes extensive information about both the CPAS hardware and the primary test range used for CPAS testing. However, it can easily be adapted for more complex CPAS drop tests, other NASA projects, and commercial partners. CPAS has developed the Sasquatch footprint tool to ensure range safety during parachute drop tests. Sasquatch is well correlated to test data and continues to ensure the safety of test personnel as well as the safe recovery of all equipment. The tool will continue to be modified based on new test data, improving predictions and providing added capability to meet the requirements of more complex testing.

Bledsoe, Kristin↗

NASA NTRS1996

Feasibility Study of Velocity and Temperature Measurements of an Arcjet Flow using Laser Resonance Doppler Velocimetric (LRDV) Technique

Thermal Protection System (TPS) materials are used in space vehicles to shield from high heating environment encountered during their atmospheric reentry. Arcjet wind tunnels are used to simulate the flowfield encountered by the spacecrafts, and are used for testing TPS materials. How well these tests simulate the actual heating environment encountered by space vehicles depends on the characteristics of the simulated flow. The flow characterization requires the determination of temperature, concentration, and velocity of the various atomic and molecular species present in the flow. However, determining these parameters requires a complex set of both analytical and experimental procedures. The ability to properly simulate the flight environment is directly related to the accuracy with which these techniques can be used to define the arcjet Laser Resonance Doppler Velocimetric (LRDV) technique can be used to accurately determine the velocity and temperature of a gaseous species. In this technique, the medium is probed with a laser beam that is in resonance with an absorbing transition of the species. The absorption lineshape is Doppler-shifted due to the flow velocity of the species, and the frequency shift is detected as the variation in intensity of the fluorescence emitted by the species. Thus a measurement of the Doppler shift and the width of a spectral line can give both the temperature and the velocity of the flowfield. This summer, our project was to make a feasibility study to set up an experimental arrangement for the laser resonance Doppler velocimetric technique using a ring dye laser. Experiments required troubleshooting, cleaning, testing, and alignment of two lasers and several diagnostics instruments. All instruments and lasers necessary for the project worked well, but the output power of the broadband fundamental dye laser was limited to about 20 mW. This was quite low as compared to that necessary to obtain second harmonic oscillation at 327.49 nm for the LRDV studies. Further optimization of the dye laser optical elements is necessary before it can be used for the experiment, which requires narrowband (about 20 Mhz) laser operation.

Rob, Mohammad A.↗

NASA NTRS2024

SMAnalytics Automated Shape Memory Test Analysis Software User's Manual: UCFTC, UPER, and DSC Test Methods, Version 1.0.2

Over the course of 60 years of shape memory alloy research and development, the properties of these alloys have been measured using various testing methods, which are often customized by the organization performing the test. However, commercial adoption of shape memory alloys in aeronautic actuator applications requires reducing property uncertainty through standardizing test methods. Historically, differential scanning calorimetry (DSC) has been used to measure transformation temperatures under stress-free conditions. This testing method is well established, and tests are run under the applicable standard, ASTM F2004-17: Standard Test Method for Transformation Temperature of Nickel-Titanium Alloys by Thermal Analysis. Two other test methods for measuring strains and transformation temperatures under constant load or free recovery after prestraining have only recently been standardized—ASTM E3097: Standard Test Method for Mechanical Uniaxial Constant Force Thermal Cycling of SMAs (UCFTC) and ASTM E3098: Standard Test Method for Mechanical Uniaxial Pre-Strain and Thermal Free Recovery of SMAs (UPFR). These standards represent a critical step forward in producing reliable material property data for the use of these alloys in aeronautics and other commercial areas. However, no standard programs or software packages were previously available for postprocessing UCFTC- and UPFR-type test data to extract property data. Each organization that performed the testing analyzed data using its own custom manual methods, such as using a plot and a straight edge, spreadsheet plotting methods, or custom code routines, to extract the required values for strains, stresses, and transformation temperatures. SMAnalytics represents the first publicly available uniform software package for processing data generated using the DSC, UCFTC, and UPFR test methods, as well as many modifications of these methods, including loading in martensite versus austenite and performing multiple thermal cycles at stress. In doing so, it provides a tool for reducing potential error or variability in the measured values due to the precision of the technique used and person-to-person variability. It is also expected that this automated data-parsing tool can accelerate the data analysis phase of the test campaign, especially for large data files. This User’s Manual describes how the SMAnalytics software works and the method for its use.

Shape Memory Alloy↗

NASA NTRS1972

Hydrogen-oxygen catalytic ignition and thruster investigation. Volume 2: High pressure thruster evaluations

A high pressure thruster effort was conducted with the major objective of demonstrating a duct cooling concept with gaseous propellant in a thruster operating at nominally 300 psia and 1500 lbf. The analytical design methods for the duct cooling were proven in a series of tests with both ambient and reduced temperature propellants. Long duration tests as well as pulse mode tests demonstrated the feasibility of the concept. All tests were conducted with a scaling of the raised post triplet injector design previously demonstrated at 900 lbf in demonstration firings. A series of environmental conditioned firings were also conducted to determine the effects of thermal soaks, atmospheric air and high humidity. This volume presents the results of the high pressure thruster evaluations.

Johnson, R. J.↗

NASA NTRS1985

Constitutive modeling for isotropic materials (HOST)

This report presents the results of the second year of work on a problem which is part of the NASA HOST Program. Its goals are: (1) to develop and validate unified constitutive models for isotropic materials, and (2) to demonstrate their usefulness for structural analyses of hot section components of gas turbine engines. The unified models selected for development and evaluation are that of Bodner-Partom and Walker. For model evaluation purposes, a large constitutive data base is generated for a B1900 + Hf alloy by performing uniaxial tensile, creep, cyclic, stress relation, and thermomechanical fatigue (TMF) tests as well as biaxial (tension/torsion) tests under proportional and nonproportional loading over a wide range of strain rates and temperatures. Systematic approaches for evaluating material constants from a small subset of the data base are developed. Correlations of the uniaxial and biaxial tests data with the theories of Bodner-Partom and Walker are performed to establish the accuracy, range of applicability, and integability of the models. Both models are implemented in the MARC finite element computer code and used for TMF analyses. Benchmark notch round experiments are conducted and the results compared with finite-element analyses using the MARC code and the Walker model.

Lindholm, U. S.↗

NASA NTRS1988

Berthing mechanism final test report and program assessment

The purpose is to document the testing performed on both hardware and software developed under the Space Station Berthing Mechanisms Program. Testing of the mechanism occurred at three locations. Several system components, e.g., actuators and computer systems, were functionally tested before assembly. A series of post assembly tests were performed. The post assembly tests, as well as the dynamic testing of the mechanism, are presented.

Source record↗

NASA NTRS1994

Space simulation techniques and facilities for SAX STM test campaign

SAX is a satellite for X-Ray astronomy. It is a major element of the overall basic Science Program of the Italian Space Agency (ASI) and is being developed with the contribution of the Netherlands Agency for Aerospace Programs (NIVR). The scientific objectives of SAX are to carry out systematic and comprehensive observations of celestial X-Ray sources over the 0.1 - 300 KeV energy range with special emphasis on spectral and timing measurements. The satellite will also monitor the X-Ray sky to investigate long-term source variability and to permit localization and study of X-Ray transients. Alenia Spazio is developing the satellite that is intended for launch in the second half of 1995 in a low, near-equatorial Earth orbit. At system level a Structural Thermal Model (STM) has been conceived to verify the environmental requirements by validating the mechanical and thermal analytical models and qualifying satellite structure and thermal control. In particular, the following tests have been carried out in Alenia Spazio, CEA/CESTA and ESTEC facilities: Modal Survey, Centrifuge, Acoustic, Sinusoidal/Random Vibration and Thermal Balance. The paper, after a short introduction of the SAX satellite, summarizes the environmental qualification program performed on the SAX STM. It presents test objectives, methodologies and relevant test configurations. Peculiar aspects of the test campaign are highlighted. Problems encountered and solutions adopted in performing the tests are described as well. Furthermore, test results are presented and assessed.

Giordano, Pietro↗

NASA NTRS1998

Hyper-X Engine Design and Ground Test Program

The Hyper-X Program, NASA's focused hypersonic technology program jointly run by NASA Langley and Dryden, is designed to move hypersonic, air-breathing vehicle technology from the laboratory environment to the flight environment, the last stage preceding prototype development. The Hyper-X research vehicle will provide the first ever opportunity to obtain data on an airframe integrated supersonic combustion ramjet propulsion system in flight, providing the first flight validation of wind tunnel, numerical and analytical methods used for design of these vehicles. A substantial portion of the integrated vehicle/engine flowpath development, engine systems verification and validation and flight test risk reduction efforts are experimentally based, including vehicle aeropropulsive force and moment database generation for flight control law development, and integrated vehicle/engine performance validation. The Mach 7 engine flowpath development tests have been completed, and effort is now shifting to engine controls, systems and performance verification and validation tests, as well as, additional flight test risk reduction tests. The engine wind tunnel tests required for these efforts range from tests of partial width engines in both small and large scramjet test facilities, to tests of the full flight engine on a vehicle simulator and tests of a complete flight vehicle in the Langley 8-Ft. High Temperature Tunnel. These tests will begin in the summer of 1998 and continue through 1999. The first flight test is planned for early 2000.

Voland, R. T.↗

NASA NTRS2005

Modal Survey of ETM-3, A 5-Segment Derivative of the Space Shuttle Solid Rocket Booster

The complex interactions between internal motor generated pressure oscillations and motor structural vibration modes associated with the static test configuration of a Reusable Solid Rocket Motor have potential to generate significant dynamic thrust loads in the 5-segment configuration (Engineering Test Motor 3). Finite element model load predictions for worst-case conditions were generated based on extrapolation of a previously correlated 4-segment motor model. A modal survey was performed on the largest rocket motor to date, Engineering Test Motor #3 (ETM-3), to provide data for finite element model correlation and validation of model generated design loads. The modal survey preparation included pretest analyses to determine an efficient analysis set selection using the Effective Independence Method and test simulations to assure critical test stand component loads did not exceed design limits. Historical Reusable Solid Rocket Motor modal testing, ETM-3 test analysis model development and pre-test loads analyses, as well as test execution, and a comparison of results to pre-test predictions are discussed.

Nielsen, D.↗

NASA NTRS2004

23rd Space Simulation Conference Proceedings

The proceedings of this conference address space environment simulation for full-scale ground tests of spacecraft, as well as testing of spacecraft components and instruments. Some of the testing and simulation techniques addressed in the conference papers include: thermal vacuum tests, cryogenic tests, thermal cycling tests, structural dynamics tests, vibration tests, magnetic tests, weightlessness simulation, solar simulation, and Mars environment simulation. The papers also address space environment test facilities, including their control systems.

Source record↗

NASA NTRS1934

Preliminary Wind-Tunnel and Flight Tests of a Balanced Split Flap, Special Report

One disadvantage that has been apparent in the operation of split flaps as used to date is the time and effort required to operate them. In this communication an investigation is being made of possible means for balancing them aerodynamically to make their operation easier. Several arrangements have been tested in the 7 by 210 foot wind tunnel, and the results of the wind-tunnel tests as well as preliminary flight tests on one of the more promising forms are given in this paper.

Weick, Fred E.↗

NASA NTRS2010

Challenges and Lessons Learned From Resurrecting a Legacy Research Flight Controller

Resurrecting the legacy Inner Loop Thrust Vectoring research flight controller to investigate the tail shock region brought unique challenges. This report documents these challenges and lessons learned from a stability and controls perspective. The flight test approach for flight envelope expansion and probing tests, as well as limited flight test results, are presented. Recent advances in sonic boom reduction technology have contributed to a resurgent interest in civilian supersonic cruise flight. These advances have focused only on fore body shaping, however, and little, if any, experimental flight data are available to develop and validate design tools for the tail shock region. In January of 2009, the NASA Dryden Flight Research Center completed research flights to investigate the tail shock region of a highly modified F-15 aircraft by probing the shock waves around it, using another F-15 aircraft. To adjust the lift distribution and plume shape, a decade-old research flight controller from the Inner Loop Thrust Vectoring project was required. To investigate the tail shock region, the lift distribution was changed by adjusting the canard position, and the plume shape was changed by adjusting the nozzle area and thrust vectoring.

Dees, Ray A.↗

NASA NTRS2011

Burst Pressure Failure of Titanium Tanks Damaged by Secondary Plumes from Hypervelocity Impacts on Aluminum Shields

Metallic pressure tanks used in space missions are inherently vulnerable to hypervelocity impacts from micrometeoroids and orbital debris; thereby knowledge of impact damage and its effect on the tank integrity is crucial to a spacecraft risk assessment. This paper describes tests that have been performed to assess the effects of hypervelocity impact (HVI) damage on Titanium alloy (Ti-6Al-4V) pressure vessels burst pressure and characteristics. The tests consisted of a pair of HVI impact tests on water-filled Ti-6Al-4V tanks (water being used as a surrogate to the actual propellant) and subsequent burst tests as well as a burst test on an undamaged control tank. The tanks were placed behind Aluminum (Al) shields and then each was impacted with a 7 km/s projectile. The resulting impact debris plumes partially penetrated the Ti-6Al-4V tank surfaces resulting in a distribution of craters. During the burst tests, the tank that failed at a lower burst pressure did appear to have the failure initiating at a crater site with observed spall cracks. A fracture mechanics analysis showed that the tanks failure at the impact location may have been due to a spall crack that formed upon impact of a fragmentation on the Titanium surface. This result was corroborated with a finite element analysis from calculated Von-Mises and hoop stresses.

Nahra, Henry↗

NASA NTRS2013

Lessons Learned from the AIRS Pre-Flight Radiometric Calibration

The Atmospheric Infrared Sounder (AIRS) instrument flies on the NASA Aqua satellite and measures the upwelling hyperspectral earth radiance in the spectral range of 3.7-15.4 micron with a nominal ground resolution at nadir of 13.5 km. The AIRS spectra are achieved using a temperature controlled grating spectrometer and HgCdTe infrared linear arrays providing 2378 channels with a nominal spectral resolution of approximately 1200. The AIRS pre-flight tests that impact the radiometric calibration include a full system radiometric response (linearity), polarization response, and response vs scan angle (RVS). We re-derive the AIRS instrument radiometric calibration coefficients from the pre-flight polarization measurements, the response vs scan (RVS) angle tests as well as the linearity tests, and a recent lunar roll test that allowed the AIRS to view the moon. The data and method for deriving the coefficients is discussed in detail and the resulting values compared amongst the different tests. Finally, we examine the residual errors in the reconstruction of the external calibrator blackbody radiances and the efficacy of a new radiometric uncertainty model. Results show the radiometric calibration of AIRS to be excellent and the radiometric uncertainty model does a reasonable job of characterizing the errors.

Sounder↗

NASA NTRS2015

Evaluation of Start Transient Oscillations with the J-2X Engine Gas Generator Assembly

During development of the gas generator for the liquid oxygen/liquid hydrogen propellant J-2X rocket engine, distinctive and oftentimes high-amplitude pressure oscillations and hardware vibrations occurred during the start transient of nearly every workhorse gas generator assembly test, as well as during many tests of engine system hardware. These oscillations appeared whether the steady-state conditions exhibited stable behavior or not. They occurred similarly with three different injector types, and with every combustion chamber configuration tested, including chamber lengths ranging over a 5:1 range, several different nozzle types, and with or without a side branch line simulating a turbine spin start gas supply line. Generally, two sets of oscillations occurred, one earlier in the start transient and at higher frequencies, and the other almost immediately following and at lower frequencies. Multiple dynamic pressure measurements in the workhorse combustion chambers indicated that the oscillations were associated with longitudinal acoustic modes of the combustion chambers, with the earlier and higher frequency oscillation usually related to the second longitudinal acoustic mode and the later and lower frequency oscillation usually related to the first longitudinal acoustic mode. Given that several early development gas generator assemblies exhibited unstable behavior at frequencies near the first longitudinal acoustic modes of longer combustion chambers, the start transient oscillations are presumed to provide additional insight into the nature of the combustion instability mechanisms. Aspects of the steadystate oscillations and combustion instabilities from development and engine system test programs have been reported extensively in the three previous JANNAF Liquid Propulsion Subcommittee meetings (see references below). This paper describes the hardware configurations, start transient sequence operations, and transient and dynamic test data during the start transient. The implications of these results on previous analyses and understanding of the combustion instability observed during steady-state conditions, especially the effects of injector influences, is discussed.

Hulka, J. R.↗

NASA NTRS2021

Random vibration, exported vibration, and passive isolation testing of the Ricor K508N cryocooler

The Ricor K508N is a rotary Stirling Cryocooler whose predecessor, the K508, has extensive flight heritage. The K508N has significant potential as a low-cost option for CubeSat infrared electro-optical payload applications. This paper will explore the work done by the ATA project on the exported vibration characterization of a set of standard K508N cryocoolers (35 atm) and the implementation and performance comparison of several passive vibration isolation and damping technologies to help mitigate the jitter effect of COTS cryocoolers. Kistler Force dynamometers and accelerometers were used to measure the K508N’s body and cold tip Multicomponent Exported Forces and Torques (EFT). Wire rope and Pyrolytic Graphite Sheet thermal straps are used as vibration isolation technologies. The K508N also underwent sine sweep resonant and peak profile testing as well as random vibration testing to GEVS launch loads in a NanoRacks soft stow configuration.

Mok, M↗