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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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At least 19 records
All sourcesNASA NTRSDOE OSTI
NASA NTRS1991

Rapid thermal cycling of solar array blanket coupons for Space Station Freedom

The NASA Lewis Research Center has been conducting rapid thermal cycling on blanket coupons for Space Station Freedom. This testing includes two designs (8 coupons total) of the solar array. Four coupons were fabricated as part of the Photovoltaic Array Environmental Protection Program (PAEP), NAS3-25079, at Lockheed Missiles and Space Company. These coupons began cycling in early 1989 and have completed 172,000 thermal cycles. Four other coupons were fabricated a year later and included several design changes; cycling of these began in early 1990 and has reached 90,000 cycles. The objective of this testing is to demonstrate the durability or operational lifetime (15 yrs.) of the welded interconnects within a low earth orbit (LEO) thermal cycling environment. The blanket coupons, design changes, test description, status to date including performance and observed anomalies, and any insights related to the testing of these coupons are described. The description of a third design is included.

Scheiman, David A.↗
NASA NTRS1993

Plasma chamber testing of APSA coupons for the SAMPIE flight experiment

Among the solar cell technologies to be tested in space as part of the Solar Array Module Plasma Interactions Experiment (SAMPIE) will be the Advanced Photovoltaic Solar Array (APSA). Several prototype twelve cell coupons were built for NASA using different blanket materials and mounting techniques. The first conforms to the baseline design for APSA which calls for the cells to be mounted on a carbon loaded Kapton blanket to control charging in GEO. When deployed, this design has a flexible blanket supported around the edges. A second coupon was built with the cells mounted on Kapton-H, which was in turn cemented to a solid aluminum substrate. A final coupon was identical to the latter but used germanium coated Kapton to control atomic oxygen attack in LEO. Ground testing of these coupons in a plasma chamber showed considerable differences in plasma current collection. The Kapton-H coupon demonstrated current collection consistent with exposed interconnects and some degree of cell snapover. The other two coupons experienced anomalously large collection currents. This behavior is believed to a consequence of enhanced plasma sheaths supported by the weakly conducting carbon and germanium used in these coupons. The results reported here are the first experimental evidence that the use of such materials can result in power losses to high voltage space power systems.

Hillard, G. Barry↗
NASA NTRS2016

Micrometeorite Impact Test of Flex Solar Array Coupon

Spacecraft with solar arrays operate throughout the near earth environment and are increasingly planned for outer planet missions. An often overlooked test condition for solar arrays that is applicable to these missions is micrometeorite impacts and possibly electrostatic discharge (ESD) events resulting from these impacts. The Marshall Space Flight Center (MSFC) is partnering with Space Systems/Loral, LLC (SSL) to examine the results of simulated micrometeorite impacts on the electrical performance of an advanced, lightweight flexible solar array design. The test is performed at NASA MSFC's Microlight Gas Gun Facility. The SSL-provided coupons consist of three strings, each string with two solar cells in series. Five impacts will be induced at various locations on a powered test coupon under different string voltage (0 volts - 150 volts) and string current (1.1 amperes - 1.65 amperes) conditions. The maximum specified test voltage and current represent margins of 1.5 times for both voltage and current. The test parameters are chosen to demonstrate new array design robustness to any ESD event caused by plasma plumes resulting from a simulated micrometeorite impact. A second unpowered coupon will undergo two impacts: one impact on the front side and one impact on the back side. Following the impact testing, the second coupon will be exposed to a thermal cycle test to determine possible damage propagation and further electrical degradation due to thermally-induced stress. The setup, checkout, and results from the impact testing are discussed. The challenges for impact testing include precise coupon alignment to control impact location; pressure management during the impact process; and measurement of the true transient electrical response during impact on the powered coupon. Results from pre- and post-test visual and electrical functional testing are also discussed.

Wright, K. H.↗
NASA NTRS1993

Determination of atomic oxygen fluence using spectrophotometric analysis of infrared transparent witness coupons for long duration exposure tests

Atomic oxygen degradation is one of several major threats to the durability of spaceborne systems in low Earth orbit. Ground-based simulations are conducted to learn how to minimize the adverse effects of atomic oxygen exposure. Assessing the fluence of atomic oxygen in test chambers such as a plasma asher over long periods of time is necessary for accurate determination of atomic oxygen exposure. Currently, an atomic oxygen susceptible organic material such as Kapton is placed next to samples as a witness coupon and its mass loss is monitored and used to determine the effective atomic oxygen fluence. However, degradation of the Kapton witness coupons occurs so rapidly in plasma ashers that for any long term test many witness coupons must be used sequentially in order to keep track of the fluence. This necessitates opening vacuum to substitute fresh coupons. A passive dosimetry technique was sought to monitor atomic oxygen exposure over longer periods without the need to open the plasma asher to the atmosphere. This paper investigates the use of spectrophotometric analysis of durable IR transparent witness coupons to measure atomic oxygen exposure for longer duration testing. The method considered would be conductive to making in situ measurements of atomic oxygen fluence.

Podojil, Gregg M.↗
NASA NTRS1993

Plasma chamber testing of APSA coupons for the SAMPIE flight experiment

Different blanket materials and mounting techniques have been used to build 12 Advanced Photovoltaic Solar Array cell coupons for NASA's Solar Array Module Plasma Interactions Experiment. Ground testing of these coupons in a plasma chamber revealed significant differences among them in plasma current collection; while the Kapton-H coupon exhibited current collection consistent with the exposed interconnects, the other two coupon types tested experienced anomalously large collection currents. This may be due to enhanced plasma sheaths supported by the weakly conducting C and Ge employed in these coupons.

Hillard, G. B.↗
NASA NTRS2014

High Current ESD Test of Advanced Triple Junction Solar Array Coupon

A test was conducted on an Advanced Triple Junction (ATJ) coupon that was part of a risk reduction effort in the development of a high-powered solar array design by SSL. The ATJ coupon was a small, 4-cell, two-string configuration that has served as the basic test coupon design used in previous SSL environmental aging campaigns. The coupon has many attributes of the flight design; e.g., substrate structure with graphite face sheets, integrated by-pass diodes, cell interconnects, RTV grout, wire routing, etc. The objective of the present test was to evaluate the performance of the coupon after being subjected to induced electrostatic discharge testing at two string voltages (100 V, 150 V) and four array current (1.65 A, 2.0 A, 2.475 A, and 3.3 A). An ESD test circuit, unique to SSL solar array design, was built that simulates the effect of missing cells and strings in a full solar panel with special primary arc flashover circuitry. A total of 73 primary arcs were obtained that included 7 temporary sustained arcs (TSA) events. The durations of the TSAs ranged from 50 μs to 2.9 ms. All TSAs occurred at a string voltage of 150 V. Post-test Large Area Pulsed Solar Simulator (LAPSS), Dark I-V, and By-Pass Diode tests showed that no degradation occurred due to the TSA events. In addition, the post-test insulation resistance measured was > 50 G-ohms between cells and substrate. These test results indicate a robust design for application to a high-current, high-power mission application.

Wright, K. H.↗
NASA NTRS2014

High Current ESD Test of Advanced Triple Junction Solar Array Coupon

Testing was conducted on an Advanced Triple Junction (ATJ) coupon that was part of a risk reduction effort in the development of a high-powered solar array design by Space Systems/Loral, LLC (SSL). The ATJ coupon was a small, 4-cell, two-string configuration that has served as the basic test coupon design used in previous SSL environmental aging campaigns. The coupon has many attributes of the flight design; e.g., substrate structure with graphite face sheets, integrated by-pass diodes, cell interconnects, RTV grout, wire routing, etc. The objective of the present test was to evaluate the performance of the coupon after being subjected to induced electrostatic discharge (ESD) testing at two string voltages (100 V, 150 V) and four array currents (1.65 A, 2.0 A, 2.475 A, and 3.3 A). An ESD test circuit, unique to SSL solar array design, was built that simulates the effect of missing cells and strings in a full solar panel with special primary arc flashover circuitry. A total of 73 primary arcs were obtained that included 7 temporary sustained arcs (TSA) events. The durations of the TSAs ranged from 50 micro-seconds to 2.75 milli-seconds. All TSAs occurred at a string voltage of 150 V. Post-test Large Area Pulsed Solar Simulator (LAPSS), Dark I-V, and By-Pass Diode tests showed that no degradation occurred due to the TSA events. In addition, the post-test insulation resistance measured was > 50 G-ohms between cells and substrate. These test results indicate a robust design for application to a high-current, high-power mission.

Wright, Kenneth H., Jr.↗
NASA NTRS2015

High Current ESD Test of Advanced Triple Junction Solar Array Coupon

A test was conducted on an Advanced Triple Junction (ATJ) coupon that was part of a risk reduction effort in the development of a high-powered solar array design by SSL. The ATJ coupon was a small, 4-cell, two-string configuration that has served as the basic test coupon design used in previous SSL environmental aging campaigns. The coupon has many attributes of the flight design; e.g., substrate structure with graphite face sheets, integrated by-pass diodes, cell interconnects, RTV grout, wire routing, etc. The objective of the present test was to evaluate the performance of the coupon after being subjected to induced electrostatic discharge testing at two string voltages (100 V, 150 V) and four array current (1.65 A, 2.0 A, 2.475 A, and 3.3 A). An ESD test circuit, unique to SSL solar array design, was built that simulates the effect of missing cells and strings in a full solar panel with special primary arc flashover circuitry. A total of 73 primary arcs were obtained that included 7 temporary sustained arcs (TSA) events. The durations of the TSAs ranged from 50 micros to 2.9 ms. All TSAs occurred at a string voltage of 150 V. Post-test Large Area Pulsed Solar Simulator (LAPSS), Dark I-V, and By-Pass Diode tests showed that no degradation occurred due to the TSA events. In addition, the post-test insulation resistance measured was > 50 G-ohms between cells and substrate. These test results indicate a robust design for application to a high-current, high-power mission application.

Wright, Kenneth H., Jr.↗
NASA NTRS2012

Age Induced Effects on ESD Characteristics of Solar Array Coupons After Combined Space Environmental Exposures

A set of multi-junction GaAs/Ge solar array test coupons provided by Space Systems/Loral were subjected to a sequence of 5-year increments of combined space environment exposure tests. The test coupons capture an integrated design intended for use in a geosynchronous (GEO) space environment. A key component of this test campaign is performing electrostatic discharge (ESD) tests in the inverted gradient mode. The protocol of the ESD tests is based on the ISO standard for ESD testing on solar array panels [ISO-11221]. The test schematic in the ISO reference has been modified with Space System/Loral designed circuitry to better simulate the on-orbit operational conditions of its solar array design. Part of the modified circuitry is to simulate a solar array panel coverglass flashover discharge. All solar array coupons used in the test campaign consist of four cells constructed to form two strings. The ESD tests were performed at the beginning-of-life (BOL) and at each 5-year environment exposure point until end-of-life (EOL) at 15 years. The space environmental exposure sequence consisted of ultra-violet radiation, electron/proton particle radiation, thermal cycling, and Xenon ion thruster plume erosion. This paper describes the ESD test setup and the importance of the electrical test design in simulating the on-orbit operational conditions. Arc inception voltage results along with ESD test behavior from the BOL condition through the 15th year age condition are discussed. In addition, results from a Xenon plasma plume exposure test with an EOL coupon under the full ESD test condition will be discussed.

Wright, Kenneth H.↗
NASA NTRS2014

High Current ESD Test of Advanced Triple Junction Solar Array Coupon

Testing was conducted on an Advanced Triple Junction (ATJ) coupon that was part of a risk reduction effort in the development of a high-powered solar array design by Space Systems Loral, LLC (SSL). The ATJ coupon was a small, 4-cell, two-string configuration of flight-type design that has served as the basic test coupon design used in previous SSL environmental aging campaigns. The objective of the present test was to evaluate the performance of the coupon after being subjected to induced electrostatic discharge (ESD) testing at two string voltages (100 V, 150 V) and four string currents (1.65 A, 2.0 A, 2.475 A, and 3.3 A). An ESD test circuit, unique to SSL solar array design, was built that simulates the effect of missing cells and strings in a full solar panel with special primary arc flashover circuitry. A total of 73 primary arcs were obtained that included 7 temporary sustained arcs (TSA) events. The durations of the TSAs ranged from 50 micro-seconds to 2.75 milli-seconds. All TSAs occurred at a string voltage of 150 V. Post-ESD functional testing showed that no degradation occurred due to the TSA events. These test results point to a robust design for application to a high-current, high-power mission.

Wright, Kenneth H., Jr.↗
NASA NTRSDate not supplied

Challenges in Scaling Analysis from Coupons to Elements in 3D Woven Composites for a Launch Vehicle End-Ring Structure

The limitations of structural design with 3D woven composites based on homogenized material models characterized using coupon test data, representative unit cell analysis, or a combination of the two are discussed in the context of a space launch system (SLS)-scale end ring. Selected building block test configurations at the coupon, element, and subcomponent scales are described in detail. Highly instrumented tests and X-ray computed tomography inspections are used to characterize the structural behavior and associated damage progression with increasing load. It is shown that a single homogenized material constitutive relationship, applied at coupon and element scale, is not sufficient to model the structural response observed in both tests. In fact, substantially different stress-strain laws are required to predict the response of the coupon and element scale specimens, despite similar loading conditions. A model with discrete representation of the binder tows and cohesive interfaces to model matrix cracking shows much better agreement with the test data at the two length scales. Thus, evidence is provided showing that predictive structural analysis of 3D woven composites requires discrete representation of the tows, matrix cracking morphology, and their interactions in the structural configuration. With accurate knowledge of the element scale behavior, engineering approximations readily enable analysis scale-up to the subcomponent level.

Andrew C Bergan↗
NASA NTRSDate not supplied

Analysis of CDC Bioreactor Internal Thermal Measurements and Sample Coupon Temperatures

The CDC Biofilm Reactor is an integral laboratory tool for the Environmental Control and Life Support Systems (ECLSS) biofilm formation and growth research program. Critical to this research is the need to adjust and maintain various surface temperatures of the coupons housed within the CDC Biofilm Reactor. The purpose of this study was to provide quantitative temperature gradient information when the CDC Biofilm Reactor was operating according to several process scenarios. Two primary process parameters were evaluated. For the first set of test parameters, the liquid level was maintained at 350 mL, with an inlet flowrate of 0.1 mL/min, 1 mL/min, 10 mL/min. The liquid was allowed to gravity drain out of the outlet spout. For the second set of test parameters, the liquid level within the reactor was maintained at 550 mL, with an inlet flow of 0.1 mL/min, 1 mL/min, 10 mL/min and draining intermittently controlled to 0.8 mL/min to maintain the 550 mL level. Due to the placement of the thermocouple in the reactor, a difference in temperature occurred between the coupon surfaces and target biofilm reactor temperature when operated according to the first set of test parameters. When the reactor was operated according to the second set of parameters, which resulted in the thermocouple being submerged, the temperature gradient was eliminated. The results demonstrated minimal temperature gradient between the top and bottom coupon surfaces for coupons placed in a single rod within the CDC Biofilm Reactor for both sets of test parameters evaluated. The collection of this information helped to explain previous ECLSS biofilm formation test runs, along with providing guidance on best operating practices for future ECLSS experiments. The placement of the thermocouple also helps to explain the challenge of achieving and maintaining bulk liquid temperatures when biofilm is grown according to the standardized test methods.

CDC Bioreactor↗
NASA NTRSDate not supplied

Analysis of CDC Bioreactor Internal Thermal Measurements and Sample Coupon Temperatures

The Center for Disease Control and Prevention (CDC) bioreactor is an integral laboratory tool for the Environmental Control and Life Support Systems (ECLSS) biofilm formation and growth research program. Critical to this research is the need to adjust and maintain various surface temperatures of the coupons housed within the CDC Bioreactor. The purpose of this study was to provide quantitative temperature gradient information when the CDC Bioreactor was operating according to several process scenarios. Two primary process parameters were evaluated. For the first set of test parameters, the liquid level was maintained at 350 mL, with an inlet flowrate of 0.1 mL/min, 1 mL/min, 10 mL/min. The liquid was allowed to gravity drain out of the outlet spout. For the second set of test parameters, the liquid level within the reactor was maintained at 550 mL, with an inlet flow of 0.1 mL/min, 1 mL/min, 10 mL/min and draining intermittently controlled to 0.8 mL/min to maintain the 550 mL level. Due to the placement of the thermocouple in the reactor, a difference in temperature occurred between the coupon surfaces and target Bioreactor temperature when operated according to the first set of test parameters. When the reactor was operated according to the second set of parameters, which resulted in the thermocouple being submerged, the temperature gradient was eliminated. The results demonstrated minimal temperature gradient between the top and bottom coupon surfaces for coupons placed in a single rod within the CDC Bioreactor for both sets of test parameters evaluated. The collection of this information helped to explain previous ECLSS biofilm formation test runs, along with providing guidance on best operating practices for future ECLSS experiments. The placement of the thermocouple also helps to explain the challenge of achieving and maintaining bulk liquid temperatures when biofilm is grown according to the standardized test methods.

CDC Bioreactor↗
DOE OSTI2026

Evaluation of corrosion coupons exposed to molten-chloride electrorefiner salts long term

Corrosion mitigation has long been considered a challenge in long-term service of both pyrochemical reprocessing and molten salt reactor applications. Corrosion coupons consisting of 2.25Cr 1Mo ASME SA387 Grade 22 Class 2 steel, were installed in a uranium electrorefiner containing molten chloride salt at 500°C. This electrorefiner went into service at Idaho National Laboratory in 1994. Seven of these coupons were removed in 2019 (i.e., submerged in molten salt for 25 years) for analysis and characterization including neutron imaging, optical microscopy, scanning electron microscopy, and wave/energy dispersive x-ray spectroscopy. The results showed that all seven coupons experienced between 30 to 175 µm of surface degradation without evidence of brittle fracture. Meaning there was no evidence of accelerated corrosion or fractures, and the average steel surface loss was of less than 5 µm per year. All indications were that the environmental conditions inside the electrorefiner were favorable for the steel alloy.

36 - MATERIALS SCIENCE↗
DOE OSTI2025

The development and application of the stirred‐reactor coupon analysis (SRCA) test method

A new technique, termed the stirred‐reactor coupon analysis (SRCA) method, has been developed to measure the rate of glass dissolution in forward‐rate conditions. Monolithic glass coupons are partially masked with an inert material before placement in a large volume of well‐mixed solution with known chemistry and temperature for a predetermined duration. After the test, the mask is removed, and the difference in step height between the protected area and the exposed corroded portions of the sample coupon is measured to determine the extent of glass dissolution. The step height is converted to a rate measurement using the test duration and glass density. Test parameters such as sample surface preparation and test duration were evaluated to determine their effects on the measured rates. Additionally, results from an interlaboratory study (ILS) consisting of 12 laboratories from 11 different institutions are presented, where each laboratory performed 12 independent tests. When removing experimental outlier data, the 95% reproducibility limits for the SRCA method has no statistical difference with previously published standardized test methods used to determine the forward rate of glass dissolution. Overall, this paper describes steps necessary to perform the test method and provides the statistical calculations to evaluate test accuracy.

chemical durability↗
NASA NTRS1991

Thermal cycle testing of Space Station Freedom solar array blanket coupons

Lewis Research Center is presently conducting thermal cycle testing of solar array blanket coupons that represent the baseline design for Space Station Freedom. Four coupons were fabricated as part of the Photovoltaic Array Environment Protection (PAEP) Program, NAS 3-25079, at Lockheed Missile and Space Company. The objective of the testing is to demonstrate the durability or operational lifetime of the solar array welded interconnect design within the durability or operational lifetime of the solar array welded interconnect design within a low earth orbit (LEO) thermal cycling environment. Secondary objectives include the observation and identification of potential failure modes and effects that may occur within the solar array blanket coupons as a result of thermal cycling. The objectives, test articles, test chamber, performance evaluation, test requirements, and test results are presented for the successful completion of 60,000 thermal cycles.

Scheiman, David A.↗
NASA NTRS1990

Rapid thermal cycling of new technology solar array blanket coupons

NASA Lewis Research Center is conducting thermal cycle testing of a new solar array blanket technologies. These technologies include test coupons for Space Station Freedom (SSF) and the advanced photovoltaic solar array (APSA). The objective of this testing is to demonstrate the durability or operational lifetime of the solar array interconnect design and blanket technology within a low earth orbit (LEO) or geosynchronous earth orbit (GEO) thermal cycling environment. Both the SSF and the APSA array survived all rapid thermal cycling with little or no degradation in peak performance. This testing includes an equivalent of 15 years in LEO for SSF test coupons and 30 years of GEO plus ten years of LEO for the APSA test coupon. It is concluded that both the parallel gap welding of the SSF interconnects and the soldering of the APSA interconnects are adequately designed to handle the thermal stresses of space environment temperature extremes.

Scheiman, David A.↗
NASA NTRS1995

Apparatus Measures Permeation Of Gases Through Coupons

Apparatus measures permeation of any variety of commercially available pure or mixed gases through polymeric or other material coupons of various thicknesses. Permeability measured at wide range of temperatures and pressures. Includes residual-gas-analyzer (RGA) sensor head and associated circuitry, and vacuum system. Also includes manifold with valves, through which gas of interest allowed to permeate through test coupon before traveling downstream to evacuated RGA sensor head. Temperature of test coupon monitored by thermocouple and maintained at specified value above ambient by use of electrical heating mantle or below ambient by use of bath of ethylene glycol, water, and dry ice.

Adam, Steven J.↗