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Presented is a training handbook for Mix/Cast Contamination Control; a part of a series of training courses to qualify access to Mix/Cast facilities. Contents: List Contamination Control Requirements; Identify foreign objects debris (FOD), Control Areas and their guidelines; Describe environmental monitoring; List Contamination Control Initiatives; Describe concern for Controlled Materials; Identify FOD Controlled Areas in Mix/Cast.
Contaminated air, whether in a crewed spacecraft cabin or terrestrial work and living spaces, is a pervasive problem affecting human health, performance, and well being. The need for highly effective, economical air quality processes spans a wide range of terrestrial and space flight applications. Typically, air quality control processes rely on absorption-based processes. Most industrial packed-bed adsorption processes use activated carbon. Once saturated, the carbon is either dumped or regenerated. In either case, the dumped carbon and concentrated waste streams constitute a hazardous waste that must be handled safely while minimizing environmental impact. Thermal catalytic oxidation processes designed to address waste handling issues are moving to the forefront of cleaner air quality control and process gas decontamination processes. Careful consideration in designing the catalyst substrate and reactor can lead to more complete contaminant destruction and poisoning resistance. Maintenance improvements leading to reduced waste handling and process downtime can also be realized. Performance of a prototype thermal catalytic reaction based on ultra-short waste channel, monolith catalyst substrate design, under a variety of process flow and contaminant loading conditions, is discussed.
Under a NASA-sponsored technology development project, a multi-disciplinary team consisting of industry, academia, and government organizations lead by Hamilton Sundstrand is developing an amine-based humidity and CO2 removal process and prototype equipment for Vision for Space Exploration (VSE) applications. Originally this project sought to research enhanced amine formulations and incorporate a trace contaminant control capability into the sorbent. In October 2005, NASA re-directed the project team to accelerate the delivery of hardware by approximately one year and emphasize deployment on board the Crew Exploration Vehicle (CEV) as the near-term developmental goal. Preliminary performance requirements were defined based on nominal and off-nominal conditions and the design effort was initiated using the baseline amine sorbent, SA9T. As part of the original project effort, basic sorbent development was continued with the University of Connecticut and dynamic equilibrium trace contaminant adsorption characteristics were evaluated by NASA. This paper summarizes the University sorbent research effort, the basic trace contaminant loading characteristics of the SA9T sorbent, design support testing, and the status of the full-scale system hardware design and manufacturing effort.
Bi-directional reflectance distribution function (BRDF) measurements of optical surfaces both before and after molecular contamination were done using UV, VUV and visible light. Molecular contamination of optical surfaces from outgassed material has been shown in many cases to proceed from acclimation centers, and to produce many roughly hemispherical "islands" of contamination on the surface. Vacuum Ultraviolet (VW) wavelengths are used here to measure angularly scattered light from optical surfaces.
Recent quartz crystal microbalance measurements made in the Marshall Space Flight Center, Photo-Deposition Facility, for several materials, recorded a significant loss of deposited contaminants when the deposition surface of the microbalance was illuminated by a deuterium lamp. These measurements differ from observations made by other investigators in which the rate of deposition increased significantly when the deposition surface was illuminated with vacuum ultraviolet radiation. These observations suggest that the accelerated deposition of molecular contaminants on optically sensitive surfaces is dependant upon the contaminant being deposited and must be addressed during the materials selection process by common material screening techniques.
Sublimators have been used for heat rejection for a variety of space applications including the Apollo Lunar Module and the Extravehicular Mobility Unit (EMU). Some of the attractive features of sublimators are that they are compact, lightweight, and self-regulating. One of the drawbacks of previous designs has been sensitivity to non-volatile contamination in the feedwater, which can clog relatively small pores (approx.3-6 microns) in the porous plates where ice forms and sublimates. A new design that is less sensitive to contaminants is being developed at the Johnson Space Center. This paper describes the design, fabrication, and testing of the Contaminant Insensitive Sublimator (CIS) Engineering Development Unit (EDU).
Sublimators have been used for heat rejection for a variety of space applications including the Apollo Lunar Module and the Extravehicular Mobility Unit (EMU). Some of the attractive features of sublimators are that they are compact, lightweight, and self-regulating. One of the drawbacks of previous designs has been sensitivity to non-volatile contamination in the feedwater, which can clog relatively small pores (approx. 3-6 micrometers) in the porous plates where ice forms and sublimates. A new design that is less sensitive to contaminants is being developed at the Johnson Space Center (JSC). This paper describes the design, fabrication, and testing of the Contaminant Insensitive Sublimator (CIS) Engineering Development Unit (EDU).
The majority of surface particles were found to be < 5 microns in diameter with increasing numbers close to the optical resolution limit of 0.3 microns. Acceleration grid EDS results show that the majority of materials appear to be from the SRC shell and SLA materials which include carbon-carbon fibers and Si-rich microspheres in a possible silicone binder. Other major debris material from the SRC included white paint, kapton, collector array fragments, and Al. Image analysis also revealed that SRC materials were also found mixed with the Utah mud and salt deposits. The EDS analysis of the acceleration grid showed that particles < 1 m where generally carbon based particles. Chemical cleaning techniques with Xylene and HF in an ultrasonic bath are currently being investigated for removal of small particles by the Genesis science team as well as ultra-pure water megasonic cleaning by the JSC team [4]. Removal of organic contamination from target materials is also being investigated by the science team with the use of UV-ozone cleaning devices at JSC and Open University [5]. In preparation for solar wind oxygen analyses at UCLA and Open University [1, 2], surface particle contamination on three Genesis concentrator targets was closely examined to evaluate cleaning strategies. Two silicon carbide (Genesis sample # 60001 and 60003) and one chemical vapor deposited (CVD) 13C concentrator target (60002) were imaged and mosaic mapped with optical microscopes. The resulting full target mosaic images and particle feature maps were subsequently compared with non-flight, but flight-like, concentrator targets and sample return capsule (SRC) materials. Contamination found on the flown concentrator acceleration grid was further examined using a scanning electron microscope (SEM). Energy dispersive X-ray spectroscopy (EDS) for particle identification was subsequently compared with the optical images from the flown targets. Figure 1 show that all three targets imaged in this report are fully intact and do not show any signs of material fractures. However, previous ellipsometry results and overview imaging of both flown SiC targets show a solar wind irradiation gradient from the center focal point to the outer edge [3]. In addition, due to the hard landing, each target has experienced varying degrees of impacts, scratches, and particle debris from the spacecraft and Utah impact site.
Molecular contamination of optical surfaces from outgassed material has been shown in many cases to proceed from acclimation centers and to produce many roughly hemispherical "islands" of contamination on the surface. The mathematics of the hemispherical scattering is simplified by introducing a Virtual source below the plane of the optic, in this case a mirror, allowing the use of Mie theory to produce a solution for the resulting sphere .in transmission. Experimentally, a fixed wavelength in the vacuum ultraviolet was used as the illumination source and scattered light from the polished and coated glass mirrors was detected at a fixed angle as the contamination islands grew in time.
The hard landing experienced by the Genesis sample return capsule breached the science canister containing the solar wind collectors. This impact into the damp lakebed contaminated collector surfaces with pulverized collector and spacecraft materials and Utah sediment and brine residue. The gold foil, polished aluminum, and bulk metallic glass remained intact, but the solar wind bulk and regime-specific array collectors were jarred loose from their frames and fractured into greater than 10,000 specimens. After a year of investigation and cleaning experimentation, the Genesis Science Team determined that array collectors had 4 classes of contaminants: particles, molecular film, submicron inorganic particulate ("aerosol"), and pre-launch surface contamination. We discuss here use of megasonically energized ultrapure water (UPW) for removing particulate debris from array collector fragments.
Dimethylamine and nitrite, which are non-combustion reaction products of unsymmetrical dimethylhydrazine (UDMH) and nitrogen tetroxide (NTO) propellants, can contaminate spacesuits during extra-vehicular activity (EVA) operations. They can react with water in the International Space Station (ISS) airlock to form N-nitrosodimethylamine (NDMA), a carcinogen. Detection methods for assessing nitrite and dimethylamine contamination were investigated. The methods are based on color-forming reactions in which intensity of color is proportional to concentration. A concept color detection kit using a commercially available presumptive field test for methamphetamine coupled with nitrite test strips was developed and used to detect dimethylamine and nitrite. Contamination mitigation strategies were also developed.
As the United States plans to return astronauts to the moon, designing the most effective and efficient life support systems is of extreme importance. The trace contaminant control system (TCCS) will be located within the Portable Life Support System (PLSS) of the Constellation Space Suit Element (CSSE), and is responsible for removing contaminants, which at increased levels can be hazardous to a crewmember s health. These contaminants come from several sources including metabolic production of the crewmember (breathing, sweating, etc.) and offgassing of the space suit material layers. This paper summarizes the results of a trade study that investigated TCC technologies used in NASA space suits and vehicles as well as commercial and academic applications, to identify the best technology options for the CSSE PLSS. The trade study also looked at the feasibility of regeneration of TCC technologies, specifically to determine the viability of vacuum regeneration for on-back, realtime EVA.
A habitable atmosphere is a fundamental requirement for human spaceflight. To meet such a requirement, the cabin atmosphere must be constantly scrubbed to maintain human life and system functionality. The primary system for atmospheric scrubbing of the US on-orbit segment (USOS) of the International Space Station (ISS) is the Trace Contaminant Control System (TCCS). As part of the Environmental Control and Life Support Systems (ECLSS) atmosphere revitalization rack in the US Lab, the TCCS operates continuously, scrubbing trace contaminants generated primarily by two sources: the metabolic offgassing of crew members and the offgassing of equipment in the ISS. It has been online for approximately 95% since activated in February 2001. The TCCS is comprised of a charcoal bed, a catalytic oxidizer, and a lithium hydroxide post-sorbent bed, all of which are designed to be replaced onorbit when necessary. In 2006, all three beds were replaced following an observed increase in the system resistance that occurred over a period several months. The beds were returned to ground and subjected to a test, teardown and evaluation to investigate the root cause(s) of the decrease in flow rate through the system. In addition, various chemical and physical analyses of the bed materials were performed to determine contaminant loading and any changes in performance. This paper will mainly focus on the results of these analyses and how this correlates with what has been observed from archival sampling and onorbit events. This may provide insight into the future performance of the TCCS and rate of change for orbital replacement units in the TCCS.
Metallic contaminant was found in the liquid oxygen (LOX) pre-valve screen of the shuttle main engine propulsion system on two orbiter vehicles. To investigate the potential for an ignition, NASA Johnson Space Center White Sands Test Facility performed (modified) rotating friction ignition testing in LOX. This testing simulated a contaminant particle in the low-pressure oxygen turbo pump (LPOTP) and the high-pressure oxygen turbo pump (HPOTP) of the shuttle main propulsion system. Monel(R) K-500 and Inconel(R) 718 samples represented the LPOTP and HPOTP materials. Aluminum foil tape and titanium foil represented the contaminant particles. In both the Monel(R) and Inconel(R) material configurations, the aluminum foil tape samples did not ignite after 30 s of rubbing. In contrast, all of the titanium foil samples ignited regardless of the rubbing duration or material configuration. However, the titanium foil ignitions did not propagate to the Monel and Inconel materials.
As the United States plans to return astronauts to the moon, designing the most effective and efficient life support systems is of extreme importance. The trace contaminant control system (TCCS) will be located within the Portable Life Support System (PLSS) of the Constellation Space Suit Element (CSSE), and is responsible for removing contaminants, which at increased levels can be hazardous to a crewmember's health. These contaminants come from several sources including metabolic production of the crewmember (breathing, sweating, etc.) and offgassing of the space suit material layers. This paper summarizes the results of a trade study that investigated TCC technologies used in NASA space suits and vehicles as well as commercial and academic applications, to identify the best technology options for the CSSE PLSS. The trade study also looked at the feasibility of regeneration of TCC technologies, specifically to determine the viability of vacuum regeneration for on-back, real-time EVA.
During redesign of the Space Shuttle reusable solid rocket motor (RSRM), NASA amended the contract with ATK Launch Systems (then Morton Thiokol Inc.) with Change Order 966 to implement a contamination control and cleanliness verification method. The change order required: (1) A quantitative inspection method (2) A written record of actual contamination levels versus a known reject level (3) A method that is more sensitive than existing methods of visual and black light inspection. Black light inspection is only useful for inspection of contaminants that fluoresce near the 365 nm spectral line and is not useful for inspection of most silicones that will not produce strong fluorescence. Black light inspection conducted by a qualified inspector under controlled light is capable of detecting Conoco HD-2 grease in gross amounts and is very subjective due to operator sensitivity. Optically stimulated electron emission (OSEE), developed at the Materials and Process Laboratory at Marshall Space Flight Center (MSFC), was selected to satisfy Change Order 966. OSEE offers several important advantages over existing laboratory methods with similar sensitivity, e.g., spectroscopy and nonvolatile residue sampling, which provide turn around time, real time capability, and full coverage inspection capability. Laboratory methods require sample gathering and in-lab analysis, which sometimes takes several days to get results. This is not practical in a production environment. In addition, these methods do not offer full coverage inspection of the large components
As the United States plans to return astronauts to the moon and eventually to Mars, designing the most effective, efficient, and robust space suit life support system that will operate successfully in these dusty environments is vital. There is some knowledge of the contaminants and level of infiltration expected from the Lunar and Mars dust, however risk mitigation strategies and filtration designs to prevent contamination within the space suit life support system are still undefined. A trade study was initiated to identify and address these concerns, and to develop new requirements for the Constellation Space Suit Element (CSSE) Portable Life Support System (PLSS). This trade study investigates historical methods of particulate contamination control in space suits and vehicles, and evaluated the possibility of using commercial technologies for this application. In addition, the trade study examined potential filtration designs. This paper summarizes the results of this trade study.
Successful trace chemical contamination control is one of the components necessary for achieving good cabin atmospheric quality. While employing seemingly simple process technologies, sizing the active contamination control equipment must employ a reliable design basis for the trace chemical load in the cabin atmosphere. A simplified design basis that draws on experience gained from the International Space Station program is presented. The trace chemical contamination control design load refines generation source magnitudes and includes key chemical functional groups representing both engineering and toxicology challenges.