Analysis of Spacecraft Failures During Thermal-Vacuum Testing
Environmental testing - analysis of spacecraft failures during thermal vacuum testing - quality assurance and spacecraft reliability
SPACECRAFT RELIABILITY↗
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Environmental Test Effectiveness
Environmental testing of spacecraft is described, with charts and examples from Voyager and Galileo testing at JPL. Types of environmental tests used include vacuum, vibration, and dynamic.
environmental testing spacecraft testing vacuum te↗
Description and applications of a computer program for the interpretation of RGA mass spectra
Computer program for interpretation of residual gas analyzer mass spectra, considering vacuum environmental testing of spacecraft
Babst, R. W.↗
Development of a ferromagnetic rotary vacuum sealed spacecraft spin fixture
A number of successful spacecraft tests were conducted on an environmental spin fixture which utilizes a ferrofluidic rotary vacuum seal. The 27 cm (10.5 inch) diameter fixture drive shaft supports and spins communications satellites during flight acceptance testing in a thermal vacuum chamber. The drive shaft rotary seal serves to maintain the canned drive system electro-mechanical components at ambient pressure within the space simulator. The ferromagnetic fluid seal was chosen over conventional mechanical sealing devices for its zero-leakage, zero-wear, and minimum friction drag characteristics, as well as its high reliability potential.
Levine, M. B.↗
Vacuum Door For Testing A Spacecraft X-Ray Camera
Report describes vacuum door to provide environmental protection of x-ray camera aboard spacecraft, and to provide access to camera for pre-launch testing. Door seals one side of chamber and encloses vacuous or dry gas environment needed to protect camera.
Mcqueen, Donald H., Jr.↗
26th Space Simulation Conference Proceedings. Environmental Testing: The Path Forward
Topics covered include: A Multifunctional Space Environment Simulation Facility for Accelerated Spacecraft Materials Testing; Exposure of Spacecraft Surface Coatings in a Simulated GEO Radiation Environment; Gravity-Offloading System for Large-Displacement Ground Testing of Spacecraft Mechanisms; Microscopic Shutters Controlled by cRIO in Sounding Rocket; Application of a Physics-Based Stabilization Criterion to Flight System Thermal Testing; Upgrade of a Thermal Vacuum Chamber for 20 Kelvin Operations; A New Approach to Improve the Uniformity of Solar Simulator; A Perfect Space Simulation Storm; A Planetary Environmental Simulator/Test Facility; Collimation Mirror Segment Refurbishment inside ESA s Large Space; Space Simulation of the CBERS 3 and 4 Satellite Thermal Model in the New Brazilian 6x8m Thermal Vacuum Chamber; The Certification of Environmental Chambers for Testing Flight Hardware; Space Systems Environmental Test Facility Database (SSETFD), Website Development Status; Wallops Flight Facility: Current and Future Test Capabilities for Suborbital and Orbital Projects; Force Limited Vibration Testing of JWST NIRSpec Instrument Using Strain Gages; Investigation of Acoustic Field Uniformity in Direct Field Acoustic Testing; Recent Developments in Direct Field Acoustic Testing; Assembly, Integration and Test Centre in Malaysia: Integration between Building Construction Works and Equipment Installation; Complex Ground Support Equipment for Satellite Thermal Vacuum Test; Effect of Charging Electron Exposure on 1064nm Transmission through Bare Sapphire Optics and SiO2 over HfO2 AR-Coated Sapphire Optics; Environmental Testing Activities and Capabilities for Turkish Space Industry; Integrated Circuit Reliability Simulation in Space Environments; Micrometeoroid Impacts and Optical Scatter in Space Environment; Overcoming Unintended Consequences of Ambient Pressure Thermal Cycling Environmental Tests; Performance and Functionality Improvements to Next Generation Thermal Vacuum Control System; Robotic Lunar Lander Development Project: Three-Dimensional Dynamic Stability Testing and Analysis; Thermal Physical Properties of Thermal Coatings for Spacecraft in Wide Range of Environmental Conditions: Experimental and Theoretical Study; Molecular Contamination Generated in Thermal Vacuum Chambers; Preventing Cross Contamination of Hardware in Thermal Vacuum Chambers; Towards Validation of Particulate Transport Code; Updated Trends in Materials' Outgassing Technology; Electrical Power and Data Acquisition Setup for the CBER 3 and 4 Satellite TBT; Method of Obtaining High Resolution Intrinsic Wire Boom Damping Parameters for Multi-Body Dynamics Simulations; and Thermal Vacuum Testing with Scalable Software Developed In-House.
Packard, Edward A.↗
Lessons Learned from the Flight Unit Testing of the Near Earth Asteroid Scout Flight System
The Near Earth Asteroid Scout flight mission is set to launch on the maiden voyage of the Space Launch System as a secondary payload. The spacecraft will be jettisoned in cis-lunar space and embark on an ambitious 2.5 year mission to image an asteroid. The spacecraft is uniquely equipped with an 85m2 solar sail as the main propulsion system. The monolithic sail system is designed to package within a 6U volume for launch and then deploy during flight. The NEA Scout team has presented in the past to the International Symposium on Solar Sailing topics related to the engineering development unit and design efforts to achieve flight hardware build. This paper will focus on the lessons learned from building and testing the NEA Scout flight system. Focus will be on the mechanical, software, and electrical interfaces as well as preparation for subsystem environmental tests, including thermal vacuum. Due to the unique design of the spacecraft, the solar sail subsystem was required to be located in the center of the spacecraft. This requirement lead to design challenges such as designing and accommodating critical cable harnesses to run through the center of the sail subsystem, packaging and deployment design of the sail subsystem, and integrated testing efforts through an avionics test bed to verify and validate a complete system architecture.
Lockett, Tiffany Russell↗
SWAS Spacecraft T/V Test, Unique In Chamber Tests Systems Actuation
The Sub-Millimeter Wave Astronomy Satellite (SWAS) is the third mission of the Small Explorer (SMEX) Project at Goddard Space Flight Center (GSFC). It is a path finding mission to study the chemical composition of interstellar galactic clouds to help determine the process of star formation. The spacecraft recently completed a month-long then-nal vacuum/thermal balance test in the Solar Environmental Simulator, the largest thermal vacuum facility at Goddard. Rather extensive fixturing was required for the test, considering the small size of the spacecraft, and two unusual deployments were completed in order to accomplish the goals of the test. This paper discusses the space simulation testing of the fully integrated SWAS spacecraft and the unique fixturing required.
Dunn, Jamie L.↗
MMS Observatory Thermal Vacuum Results Contamination Summary
The MMS mission is a constellation of 4 observatories designed to investigate the fundamental plasma physics of reconnection in the Earths magnetosphere. Each spacecraft has undergone extensive environmental testing to prepare it for its minimum 2 year mission. The various instrument suites measure electric and magnetic fields, energetic particles, and plasma composition. Thermal vacuum testing was conducted at the Naval Research Laboratory (NRL) in their Big Blue vacuum chamber. The individual spacecraft were tested and enclosed in a cryopanel enclosure called a Hamster cage. Specific contamination control validations were actively monitored by several QCMs, a facility RGA, and at times, with 16 Ion Gauges. Each spacecraft underwent a bakeout phase, followed by 4 thermal cycles. Unique aspects of the TV environment included slow pump downs with represses, thruster firings, Helium identification, and monitoring pressure spikes with Ion gauges. Various data from these TV tests will be shown along with lessons learned.
TV↗
Environmental Verification Experiment for the Explorer Platform (EVEEP)
Satellites and long-life spacecraft require effective contamination control measures to ensure data accuracy and maintain overall system performance margins. Satellite and spacecraft contamination can occur from either molecular or particulate matter. Some of the sources of the molecular species are as follows: mass loss from nonmetallic materials; venting of confined spacecraft or experiment volumes; exhaust effluents from attitude control systems; integration and test activities; and improper cleaning of surfaces. Some of the sources of particulates are as follows: leaks or purges which condense upon vacuum exposure; abrasion of movable surfaces; and micrometeoroid impacts. The Environmental Verification Experiment for the Explorer Platform (EVEEP) was designed to investigate the following aspects of spacecraft contamination control: materials selection; contamination modeling of existing designs; and thermal vacuum testing of a spacecraft with contamination monitors.
Norris, Bonnie↗
25th Space Simulation Conference. Environmental Testing: The Earth-Space Connection
Topics covered include: Methods of Helium Injection and Removal for Heat Transfer Augmentation; The ESA Large Space Simulator Mechanical Ground Support Equipment for Spacecraft Testing; Temperature Stability and Control Requirements for Thermal Vacuum/Thermal Balance Testing of the Aquarius Radiometer; The Liquid Nitrogen System for Chamber A: A Change from Original Forced Flow Design to a Natural Flow (Thermo Siphon) System; Return to Mercury: A Comparison of Solar Simulation and Flight Data for the MESSENGER Spacecraft; Floating Pressure Conversion and Equipment Upgrades of Two 3.5kw, 20k, Helium Refrigerators; Affect of Air Leakage into a Thermal-Vacuum Chamber on Helium Refrigeration Heat Load; Special ISO Class 6 Cleanroom for the Lunar Reconnaissance Orbiter (LRO) Project; A State-of-the-Art Contamination Effects Research and Test Facility Martian Dust Simulator; Cleanroom Design Practices and Their Influence on Particle Counts; Extra Terrestrial Environmental Chamber Design; Contamination Sources Effects Analysis (CSEA) - A Tool to Balance Cost/Schedule While Managing Facility Availability; SES and Acoustics at GSFC; HST Super Lightweight Interchangeable Carrier (SLIC) Static Test; Virtual Shaker Testing: Simulation Technology Improves Vibration Test Performance; Estimating Shock Spectra: Extensions beyond GEVS; Structural Dynamic Analysis of a Spacecraft Multi-DOF Shaker Table; Direct Field Acoustic Testing; Manufacture of Cryoshroud Surfaces for Space Simulation Chambers; The New LOTIS Test Facility; Thermal Vacuum Control Systems Options for Test Facilities; Extremely High Vacuum Chamber for Low Outgassing Processing at NASA Goddard; Precision Cleaning - Path to Premier; The New Anechoic Shielded Chambers Designed for Space and Commercial Applications at LIT; Extraction of Thermal Performance Values from Samples in the Lunar Dust Adhesion Bell Jar; Thermal (Silicon Diode) Data Acquisition System; Aquarius's Instrument Science Data System (ISDS) Automated to Acquire, Process, Trend Data and Produce Radiometric System Assessment Reports; Exhaustive Thresholds and Resistance Checkpoints; Reconfigurable HIL Testing of Earth Satellites; FPGA Control System for the Automated Test of MicroShutters; Ongoing Capabilities and Developments of Re-Entry Plasma Ground Tests at EADS-ASTRIUM; Operationally Responsive Space Standard Bus Battery Thermal Balance Testing and Heat Dissipation Analysis; Galileo - The Serial-Production AIT Challenge; The Space Systems Environmental Test Facility Database (SSETFD), Website Development Status; Simulated Reentry Heating by Torching; Micro-Vibration Measurements on Thermally Loaded Multi-Layer Insulation Samples in Vacuum; High Temperature Life Testing of 80Ni-20Cr Wire in a Simulated Mars Atmosphere for the Sample Analysis at Mars (SAM) Instrument Suit Gas Processing System (GPS) Carbon Dioxide Scrubber; The Planning and Implementation of Test Facility Improvements; and Development of a Silicon Carbide Molecular Beam Nozzle for Simulation Planetary Flybys and Low-Earth Orbit.
Packard, Edward↗
Environmental Testing of the SMAP Spacecraft (Soil, Moisture, Active, Passive)
No abstract available
spacecraft↗
A new test method for the assessment of the arc tracking properties of wire insulation in air, oxygen enriched atmospheres and vacuum
Development of a new test method suitable for the assessment of the resistance of aerospace cables to arc tracking for different specific environmental and network conditions of spacecraft is given in view-graph format. The equipment can be easily adapted for tests at different realistic electrical network conditions incorporating circuit protection and the test system works equally well whatever the test atmosphere. Test results confirm that pure Kapton insulated wire has bad arcing characteristics and ETFE insulated wire is considerably better in air. For certain wires, arc tracking effects are increased at higher oxygen concentrations and significantly increased under vacuum. All tests on different cable insulation materials and in different environments, including enriched oxygen atmospheres, resulted in a more or less rapid extinguishing of all high temperature effects at the beginning of the post-test phase. In no case was a self-maintained fire initiated by the arc.
Koenig, Dieter↗
Plankton, Aerosol, Cloud, Ocean Ecosystem (PACE) Mission Integration and Testing
This paper describes the plans, flows, key facilities, components and equipment necessary to fully integrate, functionally test and qualify the Plankton, Aerosol, Cloud, ocean Ecosystem (PACE) Observatory. PACE is currently in the design phase of mission implementation. It is scheduled to launch in 2022, extending and improving NASA's twenty-year record of satellite observations of global ocean biology, aerosols and clouds. PACE will advance the assessment of ocean health by measuring the distribution of phytoplankton, which are small plants and algae that sustain the marine food web. It will also continue systematic records of key atmospheric variables associated with air quality and the Earth's climate. The PACE observatory is comprised of the spacecraft and three instruments, an Ocean Color Instrument (OCI) and two polarimeters, the Hyper-Angular Rainbow Polarimeter 2 (HARP2) and the Spectro-Polarimeter for Exploration (SPEXone). The spacecraft and the OCI, which is the primary instrument, are developed and integrated at the NASA Goddard Space Flight Center (GSFC). The OCI is a hyper-spectral scanning (HSS) radiometer designed to measure spectral radiances from the ultraviolet to shortwave infrared (SWIR) to enable advanced ocean color and heritage cloud and aerosol particle science. The HARP2 and SPEXone are secondary instruments on the PACE observatory, acquired outside of GSFC. The Hyper-Angular Rainbow Polarimeter instrument (HARP2) is a wide swath imaging polarimeter that is capable of characterizing atmospheric aerosols for purposes of sensor atmospheric correction as well as atmospheric science. The SPEXone provides atmospheric aerosol and cloud data at high temporal and spatial resolution. This paper will focus on the Integration and Test (I&T) activities for the PACE mission at NASA GSFC. This I&T phase consists of mechanical, electrical and thermal integration and test of all the spacecraft subsystems and the integration of the instruments with the spacecraft. The PACE observatory environmental tests include electromagnetic interference (EMI)/electromagnetic compatibility (EMC), vibration, acoustics, shock, thermal balance, thermal vacuum, mass properties and center of gravity. This paper will also discuss the observatory shipment to the launch site as well as the launch site processing.
Petro, Susanna↗
Mars Exploration Rover thermal test program overview
In January 2004, two Mars Exploration Rovers (MER) landed on the surface of Mars to begin their mission as robotic geologists. A year prior to these historic landings, both rovers and the spacecraft that delivered them to Mars, were completing a series of environmental tests in facilities at the Jet Propulsion Laboratory. This paper describes the test program undertaken to validate the thermal design and verify the workmanship integrity of both rovers and the spacecraft. The spacecraft, which contained the rover within the aeroshell, were tested in a 7.5 m diameter thermal vacuum chamber. Thermal balance was performed for the near earth (hot case) condition and for the near Mars (cold case) condition. A solar simulator was used to provide the solar boundary condition on the solar array. IR lamps were used to simulate the solar heat load on the aeroshell for the off-sun attitudes experienced by the spacecraft during its cruise to Mars. Each rover was tested separately in a 3.0 m diameter thermal vacuum chamber over conditions simulating the warmest and coldest expected Mars diurnal temperature cycles. The environmental tests were conducted in a quiescent nitrogen atmosphere at a pressure of 8 to 10 Torr. In addition to thermal balance testing, the science instruments on board the rovers were tested successfully in the extreme environmental conditions anticipated for the mission. A solar simulator was not used in these tests.
thermal vacuum test↗
Capabilities of the Environmental Effects Branch at Marshall Space Flight Cente
The Environmental Effects Branch at the Marshall Space Flight Center supports a myriad array of programs for NASA, DoD, and commercial space including human exploration, advanced space propulsion, improving life on Earth, and the study of the Sun, the Earth, and the solar system. The branch provides testing, evaluation, and qualification of materials for use on external spacecraft surfaces and in contamination-sensitive systems. Space environment capabilities include charged particle radiation, ultraviolet radiation, atomic oxygen, impact, plasma, and thermal vacuum, anchored by flight experiments and analysis of returned space hardware. These environmental components can be combined for solar wind or planetary surface environment studies or to evaluate synergistic effects. The Impact Testing Facility allows simulation of impacts ranging from sand and rain to micrometeoroids and orbital debris in order to evaluate materials and components for flight and ground-based systems. The Contamination Control Team is involved in the evaluation of environmentally-friendly replacements for HCFC-225 for use in propulsion oxygen systems, developing cleaning methods for additively manufactured hardware, and reducing risk for the Space Launch System.
Rogers, Jan↗
Thermal Testing and Analysis Techniques for Wires and Wire Bundles
Determining wire and wire bundle amperage capacity (i.e., “ampacity”) currently relies on the use of standards to derate wire ampacity when in a bundle configuration. The feasibility of developing physics-based and regression thermal models of single wires and wire bundles to determine ampacity using a customized test apparatus was investigated during a pathfinder study. A wire bundle test apparatus was developed for measuring the temperatures of single wires and wire bundles and collected wire conductor temperature data under high vacuum and atmospheric conditions and varying environmental temperatures and currents for the two most common wire types used on spacecraft.
Thermal↗
MMS Observatory TV Results Contamination Summary
The Magnetospheric Multiscale (MMS) mission is a constellation of 4 observatories designed to investigate the fundamental plasma physics of reconnection in the Earth's magnetosphere. The various instrument suites measure electric and magnetic fields, energetic particles, and plasma composition. Each spacecraft has undergone extensive environmental testing to prepare it for its minimum 2 year mission. In this paper, we report on the extensive thermal vacuum testing campaign. The testing was performed at the Naval Research Laboratory utilizing the "Big Blue" vacuum chamber. A total of ten thermal vacuum tests were performed, including two chamber certifications, three dry runs, and five tests of the individual MMS observatories. During the test, the observatories were enclosed in a thermal enclosure known as the "hamster cage". The enclosure allowed for a detailed thermal control of various observatory zone, but at the same time, imposed additional contamination and system performance requirements. The environment inside the enclosure and the vacuum chamber was actively monitored by several QCMs, RGA, and up to 18 ion gauges. Each spacecraft underwent a bakeout phase, which was followed by 4 thermal cycles. Unique aspects of the TV campaign included slow pump downs with a partial represses, thruster firings, Helium identification, and monitoring pressure spikes with ion gauges. Selected data from these TV tests is presented along with lessons learned.
Pressure↗