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Pressure pulses, shock and vibratory loading on launch vehicle connectors - heat environment, vacuum and radiation effects on connector gaskets
Microcircuits encapsulated in three plastic package styles were stored in different environments at temperatures varying from 130 C to 225 C for up to 4,000 hours in some cases. To assess the effect of oxygen, the parts were aged at high temperatures in air and in vacuum chambers. The effect of humidity was evaluated during long-term highly accelerated temperature and humidity stress testing (HAST) at temperatures of 130 C and 150 C. High temperature storage testing of decapsulated microcircuits in air, vacuum, and HAST chambers was carried out to evaluate the role of molding compounds in the environmentally-induced degradation and failure of wire bonds (WB). This paper reports on accelerating factors of environment and molding compound on WB failures. It has been shown that all environments, including oxygen, moisture, and the presence of molding compounds reduce time-to-failures compared to unencapsulated devices in vacuum conditions. The mechanism of the environmental effect on KB degradation is discussed.
Mathematical model of macroscopic elastic contact between mating members for predicting thermal contact resistance in vacuum environment
The mechanism by which atmospheric moisture affects the conductivity and dielectric constant of rock specimens was studied in time and frequency domains. It is suggested that adsorbed water molecules alter the surface conductivity in a manner similar to that observed in semiconductors and insulators. Powdered basalts show a low-frequency dispersion produced by the atmospheric moisture remaining in the pore system of the sample in a high vacuum; this effect is attributed to isolated adsorption centers. Simulated lunar permafrost at 100 K and a vacuum of 10 to the -8th power torr together with data on lunar samples contaminated with atmospheric moisture and the dielectric properties of ice at various temperatures indicate that, if permafrost exists in the moon it should present a relaxation peak at approximately 300 Hz; for temperatures up to 263 K it may go up to 20 KHz. It is concluded that in order to have electrical steady state conditions in rock samples it is necessary to have volume charge accumulations at interfaces within the sample and at the electrode sample interface. A method for measuring heterogeneous dielectrics with non-negligible ohmic and dielectric conductivities is proposed and experimentally verified.
Error sources in carbon black coating on thin foil heat flux sensors accounting for false altitude effects in vacuum calibration
Techniques used in the prediction of spacecraft contamination for the Galileo Jupiter Orbiter and in the determination of the effects of such contamination are presented. Following a quick-look assessment of the contributions of ground-based initial contaminant loading, launch vehicle interface effects, vacuum-exposed outgassing deposition and attitude control thruster impingement and venting to the spacecraft contamination burden, the evaluations centered on the effects of the attitude control thruster on the scan platform optics, including calculations of thruster flowfields and a high-fidelity computer simulation of contaminant distribution. The evaluations revealed a considerable problem with thruster contamination, which could be solved by the use of a thrust shield and the avoidance of thruster operation at certain scan platform orientations. The effects of the various possible contaminants on spacecraft thermal and optical system performances were also investigated in studies of the optical transmittance of deposited monomethyl hydrazine nitrate, vacuum optical degradation due to contaminant outgassing and re-emission outgassing, and an operational satellite contaminant monitor on the NOAA-C satellite. It is concluded that with a good evaluation and testing program, contamination control may become a necessary portion of system design procedures, and recommendations for the implementation of various practices and tests to minimize contamination effects are presented.
The effect of surface temperature on the initial transient and subsequent steady-state behavior of the vacuum-sublimation rate and the UV/visible spectral reflectance of frozen sulfur has been investigated. Surface temperature is found to be the dominant parameter controlling the rate of vacuum weathering of sulfur. The present results suggest that any freshly-frozen sulfur deposits on Io at typical Io hotspot temperatures should display major transient changes in color in a matter of hours to days. It is noted that these rapid changes in spectral reflectivity should be readily detectable by future high-resolution synotopic observations of Io spectrum in the UV/visible.
Thermal performance of Cassini MLI blankets was characterized in thermal vacuum tests. Effective emittance was derived for the standard and high-temperature layups, with or without micrometeoroid protection standoffs, and for a high-performance duo-layup with staggered seams. The all-Kapton layup wa shown to have a 19% higher effective emittance than the hybrid Kapton-Mylar layup, and the duo-layup exhibited a dramatic capability of reducing heat dissipation by 2.6 fold. Several different definitions of effective emittance are discussed, and their relations to distinct hardware-MLI configurations and corresponding modeling techniques clarified. Large temperature differences (up to 70 C) were observed between the center and seam of a blanket. Heat losses in the vicinity of seams are qualified, and a major MLI heat loss mechanism elucidated.
An experimental investigation was initiated to establish conditioning procedures for reliable hollow cathode operation via the characterization of critical parameters in a representative cathode test facility. From vacuum pumpdown rates, it was found that approximately 1.5 hours were required to achieve pressure levels within 5 percent of the lowest attainable pressure for this facility, depending on the purge conditions. The facility atmosphere was determined by a residual gas analyzer to be composed of primarily air and water vapor. The effects of vacuum pumping and inert gas purging were evaluated. A maximum effective leakage rate of 2.0 x 10(exp -3)sccm was observed and its probable causes were examined. An extended test of a 0.64 cm diameter Mo-Re hollow cathode was successfully completed. This test ran for 504 hours at an emission current of 23.0 amperes and a xenon flow rate of 6.1 sccm. Discharge voltage rose continuously from 15 to 21 volts over the course of the test. The temperature of the cathode body during the test was relatively stable at 1160 C. Post-test examination revealed ion-bombardment texturing of the orifice plate to be the only detectable sign of wear on the hollow cathode.
An experimental investigation was initiated to establish conditioning procedures for reliable hollow cathode operation via the characterization of critical parameters in a representative cathode test facility. From vacuum pumpdown rates, it was found that approximately 1.5 hours were required to achieve pressure levels within 5 percent of the lowest attainable pressure for this facility, depending on the purge conditions. The facility atmosphere was determined by a residual gas analyzer to be composed of primarily air and water vapor. The effects of vacuum pumping and inert gas purging were evaluated. A maximum effective leakage rate of 2.0 x 10 (exp -3) sccm was observed and its probable causes were examined. An extended test of a 0.64 cm diameter Mo-Re hollow cathode was successfully completed. This test ran for 504 hours at an emission current of 23.0 amperes and a xenon flow rate of 6.1 sccm. Discharge voltage rose continuously from 15 to 21 volts over the course of the test. The temperature of the cathode body during the test was relatively stable at 1160 C. Post-test examination revealed ion-bombardment texturing of the orifice plate to be the only detectable sign of wear on the hollow cathode.
Silicon monoxide (SiO) coated silicon solar cells covered with fluorinated ethylene-propylene-A (FEP-A) were irradiated by 1-MeV electrons in vacuum. The effect of irradiation on the light transmittance of FEP-A was checked by measuring the short-circuit current of the cells while in vacuum after each dose increment, immediately after the irradiation, and again after a minimum elapsed time of 16 hr. The results indicated no apparent loss in transmission due to irradiation of FEP-A and no delamination from the SiO surface while the cells were in vacuum, but embrittlement of FEP-A occurred at the accumulated dose.
The tribology program at NASA Glenn Research Center in Cleveland, Ohio, is investigating carbon based nano-particles for their potential in advanced concept lubrication products. Service conditions range from high temperature atmospheric to low temperature vacuum. Some of the lubricants and surface coatings of tribological significance that we have evaluated include neat nano-particles, both grown in-situ and as bulk material deposited on the substrate, and nano-particles dispersed in oils which are all highly substrate interactive. We discuss results of testing these systems in a spiral orbit tribometer (SOT) and a unidirectional pin-on-disc (PoD) tribometer. A nano-onions/Krytox mixture evaluated as a lubricant for angular contact bearings in air caused a marked lowering of the coefficient of friction (CoF) (0.04 to 0.05) for the mixture with an eight-fold improvement in lifetime over that of the Krytox alone. In vacuum, no effect was observed from the nano-onions. Multi-walled nanotubes (MWNT) and graphitized MWNT were tested under sliding friction in both air and vacuum. The MWNT which were grown in-situ oriented normal to the sliding surface exhibited low CoF (0.04) and long wear lives. Bulk MWNT also generate low CoF (0.01 to 0.04, vacuum; and 0.06, air) and long wear life (>1 million orbits, vacuum; and >3.5 million, air). Dispersed graphitized MWNT were superior to MWNT and both were superior to aligned MWNT indicating that orientation is not an issue for solid lubrication. Single-walled nanotubes (SWNT) were modified by cutting into shorter segments and by fluorination. All SWNTs exhibited low CoF in air, with good wear lives. The SWNT with slight fluorination yielded an ultra-low CoF of 0.002 although the best wear life was attributed to the nascent SWNT.
This report represents a summary of the results obtained to-date on a polymer matrix composite experiment (AO 180) located at station D-12, about 82 deg off the 'ram' direction. Different material systems comprised of graphite, boron, and aramid (Kevlar) fiber reinforcements were studied. Although previous results were presented on in-situ thermal-vacuum cycling effects, particularly dimensional changes associated with outgassing, additional comparative data will be shown from ground-based tests on control and flight samples. The system employed was fully automated for thermal-vacuum cycling using a laser interferometer for monitoring displacements. Erosion of all three classes of materials due to atomic oxygen (AO) will also be discussed, including angle of incidence effects. Data from this experiment will be compared to published results for similar materials in other LDEF experiments. Composite materials' erosion yields will be presented on an AO design nomogram useful for estimating total material loss for given exposure conditions in low Earth orbit (LEO). Optical properties of these materials will also be compared with control samples. A survey of the damage caused by micrometeoroids/debris impacts will be addressed as they relate to polymer matrix composites. Correlations between hole size and damage pattern will be given. Reference to a new nomogram for estimating the number distribution of micrometeoroid/debris impacts for a given space structure as a function of time in LEO will be addressed based on LDEF data.
Effects of vacuums, ionization, electromagnetic radiation and meteoroids on plastics, elastomers and organic coatings used in space vehicles
The interfacial shear strength of the metal-insulator system has been studied by means of the coefficient of static friction of copper, nickel, or gold contacts on sapphire in ultrahigh vacuum. The effect on contact strength of adsorbed oxygen, nitrogen, chlorine, and carbon monoxide on the metal surfaces is reported. It was found that exposures as low as 1 L of O2 on Ni produced observable increases in contact strength, whereas exposures of 3 L of Cl2 lead to a decrease in contact strength. These results imply that submonolayer concentrations of these species at the interface of a thin Ni film on Al2O3 should affect film adhesion similarly. The atomic mechanism by which these surface or interface phases affect interfacial strength is not yet understood.
Orientation effect on friction characteristics of single crystal beryllium in vacuum
This two year program will investigate Vacuum Gas Tungsten Arc Welding (VGTAW) as a method to modify or improve the weldability of normally difficult-to-weld materials. VGTAW appears to offer a significant improvement in weldability because of the clean environment and lower heat input needed. The overall objective of the program is to develop the VGTAW technology and implement it into a manufacturing environment that will result in lower cost, better quality and higher reliability aerospace components for the space shuttle and other NASA space systems. Phase 1 of this program was aimed at demonstrating the process's ability to weld normally difficult-to-weld materials. Phase 2 will focus on further evaluation, a hardware demonstration and a plan to implement VGTAW technology into a manufacturing environment. During Phase 1, the following tasks were performed: (1) Task 11000 Facility Modification - an existing vacuum chamber was modified and adapted to a GTAW power supply; (2) Task 12000 Materials Selection - four difficult-to-weld materials typically used in the construction of aerospace hardware were chosen for study; (3) Task 13000 VGTAW Experiments - welding experiments were conducted under vacuum using the hollow tungsten electrode and evaluation. As a result of this effort, two materials, NARloy Z and Incoloy 903, were downselected for further characterization in Phase 2; and (4) Task 13100 Aluminum-Lithium Weld Studies - this task was added to the original work statement to investigate the effects of vacuum welding and weld pool vibration on aluminum-lithium alloys.
Samples of a filled elastomeric ablative material were stored at 45 C and 10 to the -6th torr for 7 months. Their tensile stress-relaxation modulus at constant strain was measured throughout the 7 months. Results of the testing are discussed primarily by comparisons of the data to atmospheric-pressure moduli (determined in this work for shorter periods of time) and with moduli predicted from short-time testing. Confirmation of the strengthening effects of vacuum on this composite was obtained. The use of time-temperature superposition techniques as an approximate accelerated testing procedure for this material under these conditions was also verified.