Cleanroom Assembly and Cavity Testing
A tutorial about the cleanroom assembly and cavity testing. The presentation discusses how-tos, best practices, and lessons learned.
Wu, Genfa [Fermilab]↗
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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.
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Hardy Bacterium Isolated From Two Geographically Distinct Spacecraft Assembly Cleanroom Facilities
Earlier studies have confirmed that a tenacious hardy bacterial population manages to persist and survive throughout a spacecraft assembly process. The widespread detection of these organisms underscores the challenges in eliminating them completely. Only comprehensive and repetitive microbial diversity studies of geographically distinct cleanroom facilities will bolster the understanding of planetary protection relevant microbes. Extensive characterizations of the physiological traits demonstrated by cleanroom microbes will aid NASA in gauging the forward contamination risk that hardy bacteria (such as Tersicoccus phoenicis) pose to spacecraft. This study reports on the isolation and identification of two gram-positive, non-motile, non-spore-forming bacterial strains from the spacecraft assembly facilities at Kennedy Space Center, Florida, USA and Centre Spatial Guyanais, Kourou, French Guiana. DNA-DNA relatedness values between the novel strains indicates that these novel strains were indeed members of a same species. Phylogenetic evidence derived from a 16S ribosomal DNA analysis indicated that both the novel strains are less closely related to all other Arthrobacter species.
Vaisham-payan, Parag A.↗
Characterization of Additive Manufacturing Materials for String Assembly in Cleanroom
Beamline components, such as superconducting radio frequency cavities and focusing lenses, need to be assembled together in a string while in a cleanroom environment. The present contribution identifies and characterizes materials for additive manufacturing that can be used in a cleanroom. The well known advantages of additive manufacturing processes would highly benefit the design and development of tooling needed for the mechanical support and alignment of string components. Cleanliness, mechanical properties, and leak tightness of the chosen materials are the main focus of this contribution, which also paves the way for the integration of such materials in cryomodule assemblies. Results reported here were obtained in the framework of the PIP-II project at Fermilab.
43 PARTICLE ACCELERATORS↗
Robotic Systems integration for cleanroom SRF assembly at Fermilab
Superconducting Radio Frequency (SRF) cryomodule assembly is a critical process that demands the highest levels of contamination control in a cleanroom to ensure product quality and reliability. Within the cleanroom environment, human-driven activities remain the major source of uncontrolled particulate. Moreover, the precise manual alignment of components often exceeds expected timeframes, increasing the risk of particulate migration into the critical inner space of the SRF resonant cavity, and causing extended discomfort for workers. Automation comes as a natural solution to address these challenges. The goal of this activity is to set up and integrate a robotic system to support cavity coupler installation in the cleanroom environment. Initially, remote control of a 6-axis collaborative robot arm will be implemented as an introductory step towards automation in the cleanroom. Subsequently, the system will be further enhanced by integrating manipulation capabilities through an appropriate end-effector, and computer vision technology to enable accurate pose estimation. This comprehensive approach aims to achieve a fully automated and adaptable assembly process in the partially structured cleanroom environment, thereby enhancing efficiency and mitigating existing challenges for better product quality and workers safety.
42 ENGINEERING↗
Vision based robotic assembly in cleanroom environment
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Vivai, Andrea [Fermilab]↗
Robotic Systems Integration for Cleanroom SRF Assembly at Fermilab
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Ciaramella, Alessandro↗
Machine Learning for Automated Alignment of Cleanroom Robotic Assembly
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Vivai, Andrea [Pisa U.]↗
Cleaning Genesis Sample Return Canister for Flight: Lessons for Planetary Sample Return
Sample return missions require chemical contamination to be minimized and potential sources of contamination to be documented and preserved for future use. Genesis focused on and successfully accomplished the following: - Early involvement provided input to mission design: a) cleanable materials and cleanable design; b) mission operation parameters to minimize contamination during flight. - Established contamination control authority at a high level and developed knowledge and respect for contamination control across all institutions at the working level. - Provided state-of-the-art spacecraft assembly cleanroom facilities for science canister assembly and function testing. Both particulate and airborne molecular contamination was minimized. - Using ultrapure water, cleaned spacecraft components to a very high level. Stainless steel components were cleaned to carbon monolayer levels (10 (sup 15) carbon atoms per square centimeter). - Established long-term curation facility Lessons learned and areas for improvement, include: - Bare aluminum is not a cleanable surface and should not be used for components requiring extreme levels of cleanliness. The problem is formation of oxides during rigorous cleaning. - Representative coupons of relevant spacecraft components (cut from the same block at the same time with identical surface finish and cleaning history) should be acquired, documented and preserved. Genesis experience suggests that creation of these coupons would be facilitated by specification on the engineering component drawings. - Component handling history is critical for interpretation of analytical results on returned samples. This set of relevant documents is not the same as typical documentation for one-way missions and does include data from several institutions, which need to be unified. Dedicated resources need to be provided for acquiring and archiving appropriate documents in one location with easy access for decades. - Dedicated, knowledgeable contamination control oversight should be provided at sites of fabrication and integration. Numerous excellent Genesis chemists and analytical facilities participated in the contamination oversight; however, additional oversight at fabrication sites would have been helpful.
Allton, J. H.↗
Microbial Bioburden on NASA Cleanroom Surfaces: Cell Counting and Fluorescence in situ Hybridization
Spacecraft assembly cleanrooms can harbor a low number of microbial cells that could contaminate hardware designed for life detection missions (known as “bioburden”). We are evaluating epifluorescence microscopy and fluorescence in situ hybridization (FISH) as rapid, accurate, and cost-effective methods to complement other contamination detection techniques. This study is part of a larger effort to characterize background organic contamination and the efficacy of cleaning procedures in Johnson Space Center (JSC) Astromaterials Curation Laboratories and Goddard Space Flight Center (GSFC) spacecraft assembly rooms. The low level of biomass required careful use of blanks during each stage of sample collection and preparation. FISH was performed using general archaeal and bacterial probes, as well as some group-specific probes. While some active bacteria were identified, a large majority of them were dead or inactive, and thus were difficult to identify by standard FISH. Our results are consistent with other studies that show that the bioburden present in clean rooms includes active, dormant, and dead cells.
C J Huff↗
Establishing and Monitoring an Aseptic Workspace for Building the MOMA Mass Spectrometer
Mars Organic Molecule Analyzer (MOMA) is an instrument suite on the ESA ExoMars 2018 Rover, and the Mass Spectrometer (MOMA-MS) is being built at Goddard Space Flight Center (GSFC). As MOMA-MS is a life-detection instrument and it thus falls in the most stringent category of Planetary Protection (PP) biological cleanliness requirements. Less than 0.03 sporem2 is allowed in the instrument sample path. In order to meet these PP requirements, MOMA-MS must be built and maintained in a low bioburden environment. The MOMA-MS project at GSFC maintains three cleanrooms with varying levels of bioburden control. The Aseptic Assembly Cleanroom has the highest level of control, applying three different bioburden reducing methods: 70 IPA, 7.5 Hydrogen Peroxide, and Ultra-Violet C light. The three methods are used in rotation and each kills microbes by a different mechanism, reducing the likelihood of microorganisms developing resistance to all three. The Integration and Mars Chamber Cleanrooms use less biocidal cleaning, with the option to deploy extra techniques as necessary. To support the monitoring of cleanrooms and verification that MOMA-MS hardware meets PP requirements, a new Planetary Protection lab was established that currently has the capabilities of standard growth assays for spore or vegetative bacteria, rapid bioburden analysis that detects Adenosine Triphosphate (ATP), plus autoclave and DHMR verification. The cleanrooms are monitored both for vegetative microorganisms and by rapid ATP assay, and a clear difference in bioburden is observed between the aseptic the other cleanroom.
Contamination Control Engineering↗
Enumeration and Fluorescence In Situ Hybridization of Microbial Bioburden on Cleanroom Surfaces
Introduction: Microorganisms are everywhere on Earth, even in the cleanest of places. Spacecraft assembly cleanrooms can harbor low levels of living and dead microbial cells (e.g., [1,2]), and cleanroom bioburden can also include organic molecules from industrial sources and in situ biomass. Life detection missions require careful attention to avoid contaminants that can be easily convoluted with analytical targets. We are evaluating epifluorescent microscopy and fluorescence in situ hybridization (FISH) as methods to complement organic contamination detection techniques. Epifluorescent cell counting offers an accurate and cost-effective way to quantify low levels of surface biomass. FISH could allow for the identification of residual organisms, and can be targeted to detect active populations of specific organisms such as bacteria known to resist cleaning procedures. This effort is part of a larger study that is concentrated on characterizing the surface and airborne molecular organic contamination background in Johnson Space Center (JSC) Astromaterials curation laboratories and Goddard Space Flight Center (GSFC) spacecraft assembly rooms, and understanding contaminants in the context of cleaning procedures and residual bioburden. Methods: Samples were collected by swabbing surfaces in ISO 5 and ISO 7 equivalent cleanrooms at JSC. Swabs for FISH were fixed in 4% paraformaldehyde (PFA) for 3 hours and then stored in 1:1 ethanol:PBS, while swabs for cell counting were stored in 4% PFA until analysis to avoid any cell loss during centrifugation that could impact quantification of very low biomass samples. Cell counting was performed with SYBR Gold as in [3], but adapted for very low biomass. FISH was performed as in [4], using DAPI as a counterstain for all DNA-containing cells. Negative controls included wells with no probe applied, to test for natural fluorescence, as well as the nonsense probe NONEUB (reverse complement of EUB338) to evaluate non-specific probe binding. Results and Discussion: Cleanroom surfaces had 102-103 cells cm-2. The extremely low biomass of these samples was challenging for enumeration, and required careful and routine use of “field” and laboratory blanks. FISH was performed with the general archaeal and bacterial probes ARCH915 and EUB338 (EUBMIX, [4]), probe GAMBET ([4]), and PSE227, which targets the genus Pseudomonas [5]). The latter two probes were selected because Pseudomonas spp. and other Gammaproteobacteria have not been isolated from cleanroom surfaces but do appear frequently in rRNA gene libraries from these surfaces. While some active bacteria were identified (Fig. 1c), most cells detectable by DAPI did not have a strong or any fluorescent signal (e.g., Fig. 1d), indicating that the vast majority of cells are dead or inactive. This suggests that cleaning protocols are effective at inactivating microbial contaminants, but that dead or inactive cells can remain on surfaces. Cells were often clumped in a weakly autofluorescent matrix, possibly biofilm material (Fig. 1c,d). We also observed other particulate material that was collected by the swabs, including apparent textile fibers (Fig. 1b). Our results are consistent with other studies that show that the bioburden present in clean rooms includes active, dormant, and dead cells. We will discuss how FISH and epifluorescent cell counting could be applied in planetary protection protocols, including the advantages and disadvantages of FISH and cell counting for routine use, as well as different possible applications for more specialized FISH procedures. References: [1] Moissl-Eichinger et al. (2015) Sci Rep, 5, 9156 [2] Hendrickson et al. (2021) Microbiome, 9, 238 [3] Jones et al. (2017) Appl Environ Microbiol, 83, e00909-17 [4] Jones et al. (2015) Appl Environ Microbiol, 81, 1242-1250. [5] Watt et al. (2006) Environ Microbiol, 8, 871-884
C J Huff↗
Robotic Assembly of SRF Cavity Pair
Superconducting Radio Frequency (SRF) cavities for particle accelerators require tight tolerances, ultrahigh vacuum, and strict cleanliness during assembly. As in the semiconductor industry, defects such as particles and residues are deleterious to performance, possibly rendering a cavity unfit for use. This problem is addressed primarily through cleanroom assembly during sensitive steps and rigorous chemical processing to prevent and remove such defects. Human workers are often the largest source of contamination, even with proper gowning and practices. The semiconductor industry has long integrated robots in cleanroom operation, but this has not occurred for SRF cavity production; SRF cavities, unlike wafers, are complex shapes, require more hands-on mechanical assembly, and are low-volume production items. At Jefferson Laboratory, a co-operative robot (cobot) has been setup to overcome these problems. Cobots are safe for use alongside human workers and can integrate new tools such as a 3D camera part detection and gripper for item manipulation. Therefore, cobots represent a promising avenue for reducing particulate generated during a variety of assembly tasks. A mockup of a cavity pair and coupler was setup and the cobot programmed to automatically pick up the coupler and place on the mating cavity flange. Particle counting methods were setup to measure human vs cobot assembly particulate generation inside a cavity mockup. Other potential uses will be discussed for further improving SRF cavity assembly steps, where a cobot can replace or assist a human operator, and what potential gains are expected.
Duzik, Adam [Thomas Jefferson National Accelerator↗
Application of Whole Genome Sequencing and MALDI-TOF to the Identifcation of Bacillus Species Isolated from Cleanrooms at NASA Johnson Space Center
Astromaterial cleanrooms at NASA Johnson Space Center are built environments that hold samples, such as lunar rocks, from different space exploration missions. Bacillus sp. are frequently detected in routine microbial monitoring of these facilities. Since this, and related genera, can form endospores that can withstand harsh conditions, they could contaminate astromaterials. This could confound searches for extraterrestrial life. Whole genome sequencing (WGS) is widely used for identifying bacterial strains and tracking their source; however, WGS is expensive and time consuming. Matrix-assisted laser desorption ionization– time of flight mass spectrometry (MALDI-TOF) shows promise as a low-cost, rapid method of identifying strains of bacteria, but few studies have compared this proteomics method to WGS. To evaluate a high throughput method of tracking the source of contamination of this built environment, WGS and MALDI-TOF was conducted on 18 bacterial strains isolated from surfaces in astromaterials cleanrooms. WGS identified 14 Bacillus, 2 Paenibacillus, 1 Solibacillus and 1 Alcaligenes strains. These isolates showed similarity to strains commonly observed in spacecraft assembly cleanrooms at other facilities. Cluster analysis of mass spectra generated by MALDI-TOF grouped strains together that were greater than 94% similar to each other in terms of amino acid sequences of single copy core genes, as assessed by WGS. This suggests that MALDI-TOF and WGS results are consistent with each other and MALDI-TOF can rapidly identify strains of Bacillus sp. isolated from cleanroom environments with a resolution comparable to WGS. Based on phylogenomic analysis, these results also suggest the presence of a cosmopolitan class of Bacillus sp. that are more likely to be found in cleanrooms and similar built environments than in natural systems.
Farnaz Mazhari↗
Contamination Impact of Station Brush Fire on Cleanroom Facilities
Brush and forest fires, both naturally occurring and anthropogenic in origin, in proximity to space flight hardware processing facilities raise concerns about the threat of contamination resulting from airborne particulate and molecular components of smoke. Perceptions of the severity of the threat are possibly heightened by the high sensitivity of the human sense of smell to some components present in the smoke of burning vegetation.On August 26th, 2009, a brushfire broke out north of Pasadena, California, two miles from the Jet Propulsion Laboratory. The Station Fire destroyed over 160,000 acres, coming within a few hundred yards of JPL. Smoke concentrations on Lab were very heavy over several days. All Lab operations were halted, and measures were taken to protect personnel, critical hardware, and facilities. Evaluation of real-time cleanroom monitoring data, visualinspection of facilities, filter systems, and analysis of surface cleanliness samples revealed facility environments andhardware were minimally effected.Outside air quality easily exceeded Class Ten Million. Prefilters captured most large ash and soot; multi-stage filtration greatly minimized the impact on the HEPA/ULPA filters. Air quality in HEPA filtered spacecraft assembly cleanrooms remained within Class 10,000 specification throughout. Surface cleanliness was inimally affected, as large particles were effectively removed from the airstream, and sub-micron particles have extremely long settling rates. Approximate particulate fallout within facilities was 0.00011% area coverage/day compared to 0.00038% area coverage/day during normal operations. Deposition of condensable airborne components, as measured in real time, peaked at approximately1.0 ng/cm2/day compared to 0.05 ng/cm2/day nominal.
airborne particulate contamination↗
Field Emission Analysis in SRF Cavities for PIP-II Using GEANT4
Field emission (FE) remains a significant hurdle for achieving optimal performance and reliability in superconducting radiofrequency (SRF) cavities used in accelerator cryomodules. A thorough understanding of the generation and propagation of FE-induced radiation is therefore essential to mitigate this problem. The absence of standardized measurement protocols further complicates the comparison of radiation data across different testing phases and facilities. This highlights the need for a precise quantitative method to diagnose and analyze FE-induced radiation. Such efforts could prove beneficial for improving cavity preparation and cleanroom assembly techniques during the prototype and production stages of Fermilab's Proton Improvement Plan-II (PIP-II) project. This study presents the initial steps of detailed Geant4 simulations aimed at analyzing FE-induced radiation in the low-beta 650 MHz 5-cell elliptical (LB650) cavity. Our goal is to combine these results with radiation diagnostics to enhance diagnostic accuracy and optimize detector positioning. This integrated approach ultimately aims to improve the preparation, assembly, and testing procedures for PIP-II SRF cavities, ensuring the delivery of FE-free cryomodules.
Wijethunga, Sajini A.K. [Fermilab] (ORCID:00000002↗
Revised planetary protection policy for solar system exploration
In order to control contamination of planets by terrestrial microorganisms and organic constituents, U.S. planetary missions have been governed by a planetary protection (or planetary quarantine) policy which has changed little since 1972. This policy has recently been reviewed in light of new information obtained from planetary exploration during the past decade and because of changes to, or uncertainties in, some parameters used in the existing quantitative approach. On the basis of this analysis, a revised planetary protection policy with the following key features is proposed: deemphasizing the use of mathematical models and quantitative analyses; establishing requirements for target planet/mission type (i.e., Orbiter, Lander, etc.) combinations; considering sample return missions a separate category; simplifying documentation; and imposing implementing procedures (i.e., trajectory biasing, cleanroom assembly, spacecraft sterilization, etc.) by exception, i.e., only if the planet/mission combination warrants such controls.
Devincenzi, D. L.↗
Science objectives lead to contamination requirements for the Cosmic Background Explorer (COBE)
The mission aims and related requirements of the Cosmic Background Explorer (COBE) are described in order to assess the measure needed for adequate control of optical system contamination. Instrument requirements are set forth so that the Diffuse IR Background Experiment (DIRBE), the Far IR Absolute Spectrophotometer (FIRAS), and the Differential Microwave Radiometers (DMRs) can achieve performance goals. The BRDF requirement for the primary mirror of the DIRBE is a maximum change of 50 percent on clean versus contaminated mirrors. The most critical components of the FIRAS and the DMR are discussed which are the sky horn and the antennae throats, respectively. The contamination-control devices include contamination covers, cleanroom assembly, and retractable cover assembly. The COBE is not found to perform unreliably due to contamination problems which suggests that the contamination program is effective.
Abrams, Eve M.↗