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Electrostatic Discharges from Conductive Thermal Coatings

Selecting the correct thermal control coating for a spacecraft can be a significant challenge. From the start, the process includes balancing conflicting needs. Thermal control paints must have the ability to either absorb or emit heat as desired and this property cannot change beyond a set point over the life of the mission. When the mission involves operating in a heavy charging environment, the control coating must be static dissipative enough to bleed away absorbed energetic electrons to minimize induced electric fields and the risk of electrostatic discharges. Finding the right balance of thermal performance and electrical performance can be difficult for spacecraft designers. In an effort to aid in spacecraft design, a number of white and black thermal control coatings were tested at the Jet Propulsion Laboratory using a two-part test campaign. These tests involved an initial screening test to determine the bulk resistivity of the material using a traditional parallel plate test, but placed in a vacuum chamber immersed in a bath of liquid nitrogen to obtain data over a range of temperatures. The most promising materials were then exposed to a stream of energetic electrons and monitored for the production of electrostatic discharges. Results from these tests indicated that only a few of the common thermal control coatings have a resistivity below 109 ohm-cm as suggested in NASA-HDBK-4002A. Of those that meet this criterion, most will still produce electrostatic discharges when exposed to electrons with energies from 20keV to 60keV while held at cryogenic temperatures. Additional testing is required to characterize additional coatings to create a database that designers may use when selecting an appropriate coating for their application.

Chinn, James↗

Three-Dimensional Printing GRCop-42

GRCop-42 (Cu-4 at.% Cr-2 at.% Nb) is a copper (Cu)-chromium (Cr)-niobium (Nb) alloy that NASA developed for use in rocket propulsion components that required high thermal conductivity, excellent creep resistance, low-cycle fatigue life, and strength at elevated temperatures, such as combustion chamber liners and fuel injector face plates. Using powder bed fusion (PBF) 3D printing, NASA Marshall Space Flight Center (MSFC) and NASA Glenn Research Center (GRC) successfully printed near-fully-dense GRCop-42 components that may equal to or exceed their traditionally manufactured predecessors. This Technical Memorandum serves to summarize the process that was developed to achieve 3D printable near-fully-dense and functional GRCop-42.

Cooper, K. G.↗

Fabrication of GRCop-84 Rocket Thrust Chambers

GRCop-84, a copper alloy, Cu-8 at% Cr-4 at% Nb developed at NASA Glenn Research Center for regeneratively cooled rocket engine liners has excellent combinations of elevated temperature strength, creep resistance, thermal conductivity and low cycle fatigue. GRCop-84 is produced from prealloyed atomized powder and has been fabricated into plate, sheet and tube forms as well as near net shapes. Fabrication processes to produce demonstration rocket combustion chambers will be presented and includes powder production, extruding, rolling, forming, friction stir welding, and metal spinning. GRCop-84 has excellent workability and can be readily fabricated into complex components using conventional powder and wrought metallurgy processes. Rolling was examined in detail for process sensitivity at various levels of total reduction, rolling speed and rolling temperature representing extremes of commercial processing conditions. Results indicate that process conditions can range over reasonable levels without any negative impact to properties.

Loewenthal, William S.↗

Fabrication of GRCop-84 Rocket Thrust Chambers

GRCop-84, a copper alloy, Cu-8 at% Cr-4 at% Nb developed at NASA Glenn Research Center for regenerative1y cooled rocket engine liners has excellent combinations of elevated temperature strength, creep resistance, thermal conductivity and low cycle fatigue. GRCop-84 is produced from pre-alloyed atomized powder and has been fabricated into plate, sheet and tube forms as well as near net shapes. Fabrication processes to produce demonstration rocket combustion chambers will be presented and includes powder production, extruding, rolling, forming, friction stir welding, and metal spinning. GRCop-84 has excellent workability and can be readily fabricated into complex components using conventional powder and wrought metallurgy processes. Rolling was examined in detail for process sensitivity at various levels of total reduction, rolling speed and rolling temperature representing extremes of commercial processing conditions. Results indicate that process conditions can range over reasonable levels without any negative impact to properties.

Loewenthal, William↗

High-Speed Automated Tester for Vacuum Chamber Feedthrough Connectors and Cables

The Goddard Space Flight Center's thermal vacuum laboratory has developed a high-speed automated system for testing the integrity of 37-pin MIL-C-5015 cylindrical electrical feedthrough connectors used on penetration plates of thermal vacuum chambers. The system consists of a desktop PC driving a data acquisition front end. The latter measures the resistance through each pin of the connector and the resistance from each pin to all other pins and the connector shell. In addition to identifying unacceptable feedthroughs, the system is also used for testing cables. In the special case of Type T thermocouples (used almost exclusively at the lab), the difference in resistance between the copper and constantan wires provides positive proof of accidentally reversed connector wiring. Data acquisition time to completely test a cable or feedthrough connector is less than thirty seconds. The system provides a hardcopy printout of the resistance readings. Connectors or cables with fewer wires are tested using simple adapter cables. Initial tests indicate that the performance of a given feedthrough connector can be predicted on the basis of measured resistance readings, reducing ongoing cost of connector replacement. The opportunity to positively certify the integrity of cables, cable connectors and feedthroughs before the start of a thermal vacuum test minimizes the likelihood of a circuit problem that would require returning the chamber to ambient conditions for repair. This system has two principal advantages for the Goddard thermal vacuum laboratory. Its only significant cost was the labor to fabricate the test cable and shorting cable -- about 40 man-hours total. The system was built around a computer and data acquisition unit that were already on hand. The second advantage is that it very quickly tests both of the parameters that are essential.

Swope, Robert H.↗

Acoustic Panel Liner for an Engine Nacelle

An acoustic panel liner includes a face sheet, back plate, and liner core positioned there-between, which may be used in an engine nacelle. Elongated chambers contain variable amounts of septa at a calibrated depth or depths. The septa may have varying DC flow resistance. The chambers may have a hexagonal or other polygonal cross sections. The septa, such as mesh caps, may be bonded to an inner wall of a corresponding chamber. The insertion depths may be the same or different. If different, the pattern of distribution of the depths may be randomized.

Jones, Michael G.↗

Daytime Solar Heating of Photovoltaic Arrays in Low Density Plasmas

The purpose of the current work is to determine the out-gassing rate of H2O molecules for a solar array placed under daytime solar heating (full sunlight) conditions typically encountered in a Low Earth Orbital (LEO) environment. Arc rates are established for individual arrays held at 14 C and are used as a baseline for future comparisons. Radiated thermal solar flux incident to the array is simulated by mounting a stainless steel panel equipped with resistive heating elements several centimeters behind the array. A thermal plot of the heater plate temperature and the array temperature as a function of heating time is then obtained. A mass spectrometer is used to record the levels of partial pressure of water vapor in the test chamber after each of the 5 heating/cooling cycles. Each of the heating cycles was set to time duration of 40 minutes to simulate the daytime solar heat flux to the array over a single orbit. Finally the array is cooled back to ambient temperature after 5 complete cycles and the arc rates of the solar arrays is retested. A comparison of the various data is presented with rather some unexpected results.

Galofaro, J.↗

Temperature Knowledge and Model Correlation for the Soil Moisture Active and Passive (SMAP) Reflector Mesh

NASA's Earth observing Soil Moisture Active & Passive (SMAP) Mission is scheduled to launch in November 2014 into a 685 km near-polar, sun synchronous orbit. SMAP will provide comprehensive global mapping measurements of soil moisture and freeze/thaw state in order to enhance understanding of the processes that link the water, energy, and carbon cycles. The primary objectives of SMAP are to improve worldwide weather and flood forecasting, enhance climate prediction, and refine drought and agriculture monitoring during its 3 year mission. The SMAP instrument architecture incorporates an L-band radar and an L-band radiometer which share a common feed horn and parabolic mesh reflector. The instrument rotates about the nadir axis at approximately 15 rpm, thereby providing a conically scanning wide swath antenna beam that is capable of achieving global coverage within 3 days. In order to make the necessary precise surface emission measurements from space, a temperature knowledge of 60 deg C for the mesh reflector is required. In order to show compliance, a thermal vacuum test was conducted using a portable solar simulator to illuminate a non flight, but flight-like test article through the quartz window of the vacuum chamber. The molybdenum wire of the antenna mesh is too fine to accommodate thermal sensors for direct temperature measurements. Instead, the mesh temperature was inferred from resistance measurements made during the test. The test article was rotated to five separate angles between 10 deg and 90 deg via chamber breaks to simulate the maximum expected on-orbit solar loading during the mission. The resistance measurements were converted to temperature via a resistance versus temperature calibration plot that was constructed from data collected in a separate calibration test. A simple thermal model of two different representations of the mesh (plate and torus) was created to correlate the mesh temperature predictions to within 60 deg C. The on-orbit mesh temperature will be predicted using the correlated analytical thermal model since direct measurements from in-situ flight thermal sensors are not possible.

Mikhaylov, Rebecca↗

Fuel Manifold Resists Embrittlement by Hydrogen

Completely-cast hydrogen-compatible alloy preferable to protective plating. Complexity of plating, welding, and brazing unnecessary if hydrogen-compatible alloy used for entire casting instead of protective overlay. Parts exposed to high-pressure hydrogen made immune to hydrogen embrittlement if fabricated from new alloy, Incoly 903 (or equivalent). Material strong and compatible with hydrogen at all temperatures and adapted for outlet manifold of Space Shuttle main combustion chamber.

Adams, T.↗

GRCop-84: A High Temperature Copper-based Alloy For High Heat Flux Applications

While designed for rocket engine main combustion chamber liners, GRCop-84 (Cu-8 at.% Cr-4 at.% Nb) offers potential for high heat flux applications in industrial applications requiring a temperature capability up to approximately 700 C (1292 F). GRCop-84 is a copper-based alloy with excellent elevated temperature strength, good creep resistance, long LCF lives and enhanced oxidation resistance. It also has a lower thermal expansion than copper and many other low alloy copper-based alloys. GRCop-84 can be manufactured into a variety of shapes such as tubing, bar, plate and sheet using standard production techniques and requires no special production techniques. GRCop-84 forms well, so conventional fabrication methods including stamping and bending can be used. GRCop-84 has demonstrated an ability to be friction stir welded, brazed, inertia welded, diffusion bonded and electron beam welded for joining to itself and other materials. Potential applications include plastic injection molds, resistance welding electrodes and holders, permanent metal casting molds, vacuum plasma spray nozzles and high temperature heat exchanger applications.

Ellis, David L.↗

High performance alloy electroforming

Electroformed copper and nickel are used in structural applications for advanced propellant combustion chambers. An improved process has been developed by Bell Aerospace Textron, Inc. wherein electroformed nickel-manganese alloy has demonstrated superior mechanical and thermal stability when compared to previously reported deposits from known nickel plating processes. Solution chemistry and parametric operating procedures are now established and material property data is established for deposition of thick, large complex shapes such as the Space Shuttle Main Engine. The critical operating variables are those governing the ratio of codeposited nickel and manganese. The deposition uniformity which in turn affects the manganese concentration distribution is affected by solution resistance and geometric effects as well as solution agitation. The manganese concentration in the deposit must be between 2000 and 3000 ppm for optimum physical properties to be realized. The study also includes data regarding deposition procedures for achieving excellent bond strength at an interface with copper, nickel-manganese or INCONEL 718. Applications for this electroformed material include fabrication of complex or re-entry shapes which would be difficult or impossible to form from high strength alloys such as INCONEL 718.

Malone, G. A.↗

Qualifications of Bonding Process of Temperature Sensors to Deep-Space Missions

A process has been examined for bonding a platinum resistance thermometer (PRT) onto potential aerospace materials such as flat aluminum surfaces and a flexible copper tube to simulate coaxial cables for flight applications. Primarily, PRTs were inserted into a silver-plated copper braid to avoid stresses on the sensor while the sensor was attached with the braid to the base material for long-duration, deep-space missions. A1-1145/graphite composite (planar substrate) and copper tube have been used in this study to assess the reliability of PRT bonding materials. A flexible copper tube was chosen to simulate the coaxial cable to attach PRTs. The substrate materials were cleaned with acetone wipes to remove oils and contaminants. Later, the surface was also cleaned with ethyl alcohol and was air-dried. The materials were gently abraded and then were cleaned again the same way as previously mentioned. Initially, shielded (silver plated copper braid) PRT (type X) test articles were fabricated and cleaned. The base antenna material was pretreated and shielded, and CV-2566 NuSil silicone was used to attach the shielded PRT to the base material. The test articles were cured at room temperature and humidity for seven days. The resistance of the PRTs was continuously monitored during the thermal cycling, and the test articles were inspected prior to, at various intermediate steps during, and at the end of the thermal cycling as well. All of the PRTs survived three times the expected mission life for the JUNO project. No adhesion problems were observed in the PRT sensor area, or under the shielded PRT. Furthermore, the PRT resistance accurately tracked the thermal cycling of the chamber.

Ramesham, Rajeshuni↗

NASA welding assessment program

A program was conducted to demonstrate the cycle life capability of welded solar cell modules relative to a soldered solar cell module in a simulated low earth orbit thermal environment. A total of five 18-cell welded (parallel gap resistance welding) modules, three 18-cell soldered modules, and eighteen single cell samples were fabricated using 2 x 4 cm silicon solar cells from ASEC, fused silica cover glass from OCLI, silver plated Invar interconnectors, DC 93-500 adhesive, and Kapton-Kevlar-Kapton flexible substrate material. Zero degree pull strength ranged from 2.4 to 5.7 lbs for front welded contacts (40 samples), and 3.5 to 6.2 lbs for back welded contacts (40 samples). Solar cell cross sections show solid state welding on both front and rear contacts. The 18-cell welded modules have a specific power of 124 W/kg and an area power density of 142 W/sq m (both at 28 C). Three welded and one soldered module were thermal cycle tested in a thermal vacuum chamber simulating a low earth orbit thermal environment.

Patterson, R. E.↗

Predicting Operational Performance of xEMU Boot at Lunar South Pole Temperatures using Thermal Desktop ®

The spacesuit boots that will be used on Artemis lunar south pole surface missions will be exposed to extremely cold temperatures (down to ~50 K). To assess the performance of the government’s Exploration Extravehicular Mobility Unit (xEMU) lunar boot in these permanently shadowed regions, testing was performed at the Jet Propulsion Lab (JPL) in the Cryogenic Ice Transfer, Acquisition Development, and Excavation Laboratory (CITADEL) thermal vacuum (TVAC) chamber. This paper documents the data analysis, thermal boot model correlation, and operational predictions conducted using data from the xEMU CITADEL TVAC test. Expected thermal conductances within the boot and between the boot and environment were calculated from test data, which was then used as an initial guess for conductances within a Thermal Desktop (TD) model. Correlation of the TD model using the internal SOLVER feature was performed across 10 different test points which varied external temperature, internal boot ventilation flowrate, and contact pressure. Operational performance at the lunar south pole was then predicted using results from the correlated model. While the predictions provide evidence for acceptable performance of the boots at the 100K environment test point, there is still substantial uncertainty in performance, especially at the 48K test point. This uncertainty is due in part to testing limitations such as contacting the foot to a hard metal plate rather than granular regolith, and model limitations such as the lack of a realistic foot model. These limitations and their impacts are addressed in detail in this paper. The results of this test series and model correlation underscore the importance of additional improved testing and modeling for characterizing the expected thermal resistance between the outside of the boot and the lunar surface.

Spacesuit↗

Automating Microbial Directed Evolution For Bioengineering Applications

From a micro-biology perspective, directed evolution is a technique that uses controlled environmental pressures to select for a desired phenotype. Directed evolution has the distinct advantage over rational design of not needing extensive knowledge of the genome or pathways associated with a microorganism to induce phenotypes. However, there are currently limitations to the applicability of this technique including being time-consuming, error-prone, and dependent on existing assays that may lack selectivity for the given phenotype. The AADEC (Autonomous Adaptive Directed Evolution Chamber) system is a proof-of-concept instrument to automate and improve the technique such that directed evolution can be used more effectively as a general bioengineering tool. A series of tests using the automated system and comparable by-hand survival assay measurements have been carried out using UV-C radiation and Escherichia coli cultures in order to demonstrate the advantages of the AADEC versus traditional implementations of directed evolution such as random mutagenesis. AADEC uses UV-C exposure as both a source of environmental stress and mutagenesis, so in order to evaluate the UV-C tolerance obtained from the cultures, a manual UV-C exposure survival assay was developed alongside the device to compare the survival fractions at a fixed dosage. This survival assay involves exposing E. coli to UV-C radiation using a custom-designed exposure hood to control the flux and dose. Surviving cells are counted then transferred to the next iteration and so on for several iterations to calculate the survival fractions for each exposure iteration.This survival assay primarily serves as a baseline for the AADEC device, allowing quantification of the differences between the AADEC system over the manual approach. The primary data of comparison is survival fractions; this is obtained by optical density and plate counts in the manual assay and by optical density growth curve fits pre- and post-exposure in the automated case. This data can then be compiled to calculate trends over the iterations to characterize increasing UV-C resistance of the E.coli strains. The observed trends are statistically indistinguishable through several iterations from both sources.

Bioengineering↗

Copper-Multiwall Carbon Nanotubes and Copper-Diamond Composites for Advanced Rocket Engines

This paper reports on the research effort to improve the thermal conductivity of the copper-based alloy NARloy-Z (Cu-3 wt.%Ag-0.5 wt.% Zr), the state-of-the-art alloy used to make combustion chamber liners in regeneratively-cooled liquid rocket engines, using nanotechnology. The approach was to embed high thermal conductivity multiwall carbon nanotubes (MWCNTs) and diamond (D) particles in the NARloy-Z matrix using powder metallurgy techniques. The thermal conductivity of MWCNTs and D have been reported to be 5 to 10 times that of NARloy-Z. Hence, 10 to 20 vol. % MWCNT finely dispersed in NARloy-Z matrix could nearly double the thermal conductivity, provided there is a good thermal bond between MWCNTs and copper matrix. Quantum mechanics-based modeling showed that zirconium (Zr) in NARloy-Z should form ZrC at the MWCNT-Cu interface and provide a good thermal bond. In this study, NARloy-Z powder was blended with MWCNTs in a ball mill, and the resulting mixture was consolidated under high pressure and temperature using Field Assisted Sintering Technology (FAST). Microstructural analysis showed that the MWCNTs, which were provided as tangles of MWCNTs by the manufacturer, did not detangle well during blending and formed clumps at the prior particle boundaries. The composites made form these powders showed lower thermal conductivity than the base NARloy-Z. To eliminate the observed physical agglomeration, tangled multiwall MWCNTs were separated by acid treatment and electroless plated with a thin layer of chromium to keep them separated during further processing. Separately, the thermal conductivities of MWCNTs used in this work were measured, and the results showed very low values, a major factor in the low thermal conductivity of the composite. On the other hand, D particles embedded in NARloy-Z matrix showed much improved thermal conductivity. Elemental analysis showed migration of Zr to the NARloy-Z-D interface to form ZrC, which appeared to provide a low contact thermal resistance. These results are consistent with the quantum mechanics-based model predictions. NARloy-Z-D composites have relatively high thermal conductivities and are promising for further development.

Bhat, Biliyar N.↗

Copper Multiwall Carbon Nanotubes and Copper-Diamond Composites for Advanced Rocket Engines

This paper reports on the research effort to improve the thermal conductivity of the copper-based alloy NARloy-Z (Cu-3 wt.%Ag-0.5 wt.% Zr), the state-of-the-art alloy used to make combustion chamber liners in regeneratively-cooled liquid rocket engines, using nanotechnology. The approach was to embed high thermal conductivity multiwall carbon nanotubes (MWCNTs) and diamond (D) particles in the NARloy-Z matrix using powder metallurgy techniques. The thermal conductivity of MWCNTs and D have been reported to be 5 to 10 times that of NARloy-Z. Hence, 10 to 20 vol. % MWCNT finely dispersed in NARloy-Z matrix could nearly double the thermal conductivity, provided there is a good thermal bond between MWCNTs and copper matrix. Quantum mechanics-based modeling showed that zirconium (Zr) in NARloy-Z should form ZrC at the MWCNT-Cu interface and provide a good thermal bond. In this study, NARloy-Z powder was blended with MWCNTs in a ball mill, and the resulting mixture was consolidated under high pressure and temperature using Field Assisted Sintering Technology (FAST). Microstructural analysis showed that the MWCNTs, which were provided as tangles of MWCNTs by the manufacturer, did not detangle well during blending and formed clumps at the prior particle boundaries. The composites made form these powders showed lower thermal conductivity than the base NARloy-Z. To eliminate the observed physical agglomeration, tangled multiwall MWCNTs were separated by acid treatment and electroless plated with a thin layer of chromium to keep them separated during further processing. Separately, the thermal conductivities of MWCNTs used in this work were measured, and the results showed very low values, a major factor in the low thermal conductivity of the composite. On the other hand, D particles embedded in NARloy-Z matrix showed much improved thermal conductivity. Elemental analysis showed migration of Zr to the NARloy-Z-D interface to form ZrC, which appeared to provide a low contact thermal resistance. These results are consistent with the quantum mechanics-based model predictions. NARloy-Z-D composites have relatively high thermal conductivities and are promising for further development.

Bhat, Biliyar N.↗