NASA Goddard Thermal Technology Overview 2022 - May 24-26, 2022 Sergey Semenov, Vivek Dwivedi, NASA Goddard

NASA Goddard Thermal
Technology Overview 2022

 Sergey Semenov, Vivek Dwivedi, NASA Goddard

 Spacecraft Thermal Control Workshop
 Aerospace Corporation (Virtual Event)
 May 24-26, 2022

 Background Image: JWST Alignment Evaluation Image, Credits: NASA/STScI
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NASA Status FY 22 (Oct 21 to Oct 22)

NASA's FY 2022 Budget
• NASA's budget is $24.04 billion for fiscal year (FY) 2022, $800 million less than the President's Budget Request of $24.8 billion.
• Though the fiscal year began in October of 2021, the final congressional legislation was not passed until March of 2022, six months late.
• Increases in Defense spending and prioritization of other social programs ultimately limited the amount of funding available to NASA
 and many other science programs in the U.S. government. The final amount still represents an increase of 3.3% over the previous year.

The President's Budget Request for NASA was released on May 28th, 2021.
Highlights of the proposal included:
• "The Earth Systems Observatory...a new set of Earth-focused missions to provide key information to guide efforts related to
 climate change, disaster mitigation, fighting forest fires, and improving real-time agricultural processes"
• Full funding to support a Mars Sample Return mission
• $143.2 million for the NEO Surveyor mission to enable a mid-2020s launch
• Continues the Roman Space Telescope, the follow-on mission from JWST
• Modest increases for Artemis human landing system (HLS) and Gateway lunar station. Supports a single award for development
 of the HLS program.

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NASA On-orbit Missions Update

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New Horizon
• New Horizons itself remains healthy while continuing its
 exploration of the Kuiper Belt and outer heliosphere. The
 spacecraft is about 4.9 billion miles (7.8 billion kilometers) from
 home – more than 52 times farther from the Sun than Earth – in a
 region where a radio signal from New Horizons, even traveling at
 the speed of light, needs more than seven hours to reach Earth.

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Solar Probe
The Parker Solar Probe is a NASA space probe
launched in 2018 with the mission of making
observations of the outer corona of the Sun. It will
approach to within 9.86 solar radii from the center of
the Sun, and by 2025 will travel, at closest
approach, as fast as 690,000 km/h, or 0.064% the
speed of light.

The view from Earth: The red line indicates path of
NASA’s Parker Solar Probe across the face of the Sun, as
seen from Earth, from Feb. 24–27, 2022. The red dots
indicate an hour along the trajectory, and the appearance
of the path heading into the Sun at right accounts for
Earth’s own movement around our star. The image of the
Sun was captured by NASA’s Solar Dynamics
Observatory. Credit: NASA/Johns Hopkins APL/Steve
Gribben/SDO

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Osiris-Rex

• OSIRIS-REx is a NASA asteroid-study and sample-return mission. The
 mission's primary goal is to obtain a sample of at least 60 g from 101955 Bennu,
 a carbonaceous near-Earth asteroid, and return the sample to Earth for a
 detailed analysis. The material returned is expected to enable scientists to learn
 more about the formation and evolution of the Solar System, its initial stages of
 planet formation, and the source of organic compounds that led to the formation
 of life on Earth.
• The Origins, Spectral Interpretation, Resource Identification, Security, Regolith
 Explorer (OSIRIS-REx) Visible and Infrared Spectrometer (OVIRS) is a
 cryogenic instrument.

 OVIRS with a Two-Stage Radiator, Flexures and MLI Blankets.

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ICESAT-2 / ATLAS
• The ICESat-2 mission is designed to provide elevation data needed to
 determine ice sheet mass balance as well as vegetation canopy
 information. It provides topography measurements of cities, lakes and
 reservoirs, oceans and land surfaces around the globe, in addition to
 the polar-specific coverage. ICESat-2 also has the ability to detect
 seafloor topography up to 100 feet (30m) below the surface in clear
 watered coastal areas.
• ATLAS (Advanced Topographic Laser Altimeter System) instrument,
 sole for the mission, carries two lasers onboard.

 • Redundant lasers are cooled via a
 single Laser Thermal Control
 System (LTCS) consisting of a
 constant conductance heat pipe
 (CCHP), a loop heat pipe (LHP), and
 a radiator.

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James Webb Space Telescope (JWST)
• The James Webb Space Telescope (JWST) is a space telescope designed
 primarily to conduct infrared astronomy. The most powerful telescope ever
 launched into space, with its greatly improved infrared resolution and sensitivity, it
 will view objects too old, distant, and faint for Hubble.
• The U.S. National Aeronautics and Space Administration (NASA) led JWSTs
 development in collaboration with the European Space Agency (ESA) and the
 Canadian Space Agency (CSA). The NASA Goddard Space Flight Center (GSFC)
 managed telescope development, the Space Telescope Science Institute in
 Baltimore operates JWST, and the prime contractor was Northrop Grumman.
• WST's primary mirror consists of 18 hexagonal mirror segments made of gold-
 plated beryllium which combine to create a 6.5-meter (21 ft)[23] diameter mirror,
 compared to Hubble's 2.4 m (7.9 ft). This gives the Webb telescope a light-
 collecting area about 6.25 times as large as Hubble's (25.37 square meters vs.
 Hubble's 4.0). Unlike Hubble, which observes in the near ultraviolet, visible, and
 near infrared (0.1–1.0 μm) spectra, JWST will observe in a lower frequency range,
 from long-wavelength visible light (red) through mid-infrared (0.6–28.3 μm).
• The telescope must be kept extremely cold, below 50 K (−223 °C; −370 °F), to
 observe faint signals in the infrared without interference from other sources of
 warmth. It is deployed in a solar orbit near the Sun–Earth L2 Lagrange point, about
 1.5 million kilometers (930,000 mi) from Earth, where its five layer kite-shaped
 sunshield protects it from warming by the Sun, Earth or Moon.
• It was launched in December 2021 on an ESA Ariane 5 rocket from Kourou,
 French Guiana.

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Lucy
The first space mission to explore a population of small
bodies known as the Trojan asteroids, which orbit the Sun
“in front of” and “behind” the gas giant Jupiter. The Trojan
Asteroids are leftovers from the early days of our solar
system, effectively the fossils of planet formation.

Launched October 16th, 2021

 L’Ralph
GSFC in-house instrument on Lucy with two detectors:
The visible wavelength multicolor imager (MVIC) and
the infrared Linear Etalon Imaging Spectral Array
(LEISA), which is passively cooled to 100K. Image below
shows temperature zones

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L’Ralph Thermal Technologies
 Strap and IMLI assembled on radiator
• Diffusion bonded Cu strap
 • In-house, developed by the Cryo-branch
 • Technique chemically bonds foils and improves
 thermal conductance
• Integrated-MLI (IMLI)
 • SBIR Phase 3 implementation on our
 cryoradiator from Quest Thermal Group
 • Achieved an order of magnitude improvement
 in the thermal radiative isolation we would’ve
 seen with a gold plating or other blanketing
 scheme (estar ~ 0.004)
• GSE Heat Switch
 • Novel design using vise grip mechanism from
 High Precision Devices
 • Used in TVAC to thermally drive the flight Strap
 hardware at faster rates
 • Benefited the project in terms of improving
 test quality (more and better thermal
 balances), savings in schedule, and cost (about
 10 days of 24/7 TVAC testing saved)

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Landsat 9 (Earth from Space)
• Science Instruments: OLI-2; TIRS-2
 • OLI-2 build: Ball Aerospace & Technology Corp.
 • TIRS-2 build: NASA Goddard Space Flight Center

• Design Life: 5 years
• Spacecraft Provider:Northrop Grumman Innovative
 Systems (NGIS)
• Image Data: > 700 scenes per day
• Launch Date: Sept. 27, 2021
• Launch Vehicle: United Launch Alliance Atlas V 401
• Orbit: near-polar, sun-synchronous at an altitude of
 438 miles (705 km)
• Orbital Inclination: 98.2˚
• Spacecraft Speed: 16,760 mi/hr (26,972 km/hr)

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Laser Communications Relay Demonstration (LCRD)

• The LCRD payload is hosted aboard the U.S. Department of Defense’s Space Test
 Program Satellite 6 (STPSat-6). After launch Dec. 7, 2021, engineers at LCRD’s mission
 operations center in Las Cruces, New Mexico, turned the payload on and prepared it to
 start transmitting data over infrared lasers.
• Milestones
 • On Dec. 7, 2021, LCRD launched from the Cape Canaveral Space Force Station in Florida. The payload,
 hosted on the U.S. Department of Defense’s STPSat-6 spacecraft, launched aboard a United Launch
 Alliance Atlas V 551 rocket.
 • On Jan. 22, 2020, the LCRD flight payload was delivered to Northrop Grumman’s facility in Sterling,
 Virginia, for integration onto the U.S. Department of Defense Space Test Program Satellite 6 (STPSat-6).
 • On July 7, 2020, the LCRD payload was fully integrated with U.S. Department of Defense’s STPSat-6
 and the entire spacecraft entered into the final environmental testing phase.

• With LCRD relaying data for ILLUMA-T, this will be the first operational optical
 communications system for human spaceflight. ILLUMA-T will send data to LCRD at
 rates of 1.2 gigabits per second over optical links, allowing for more high-resolution
 experiment data to be transmitted back to Earth.
• LCRD will be able to downlink data over optical signals at a rate of 1.2 gigabits per
 second. This is almost double the rates of the 2013 Lunar Laser Communications
 Demonstration, which downlinked data from the Moon over an optical signal of 622
 megabits per second.
• Although optical communications systems reduce size, weight, and power requirements,
 the entire LCRD payload is actually the size of a standard king-sized mattress!

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NASA GSFC Future Missions

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Capture Containment and Return System (CCRS)

• CCRS is part of the Mars Sample Return program (MSR) with contributions from JPL, GSFC, LaRC, and ARC to
 fly on the ESA Earth Return Orbiter spacecraft (ERO).
• CCRS will ride on ESA’s Earth Return Orbiter (ERO) in a 5-year mission to Mars and back to Earth
• At Mars, CCRS will capture the samples, in orbit, and place them in the Earth Entry Vehicle (EEV)
• Anticipated Launch 2027

 CCRS Orbiting Sample EEV
 CCRS

 ERO

 Anticipated launch: 2027

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CCRS – Thermal Challenges
• Maintaining sample integrity, while meeting Back Planetary Protection requirements, is a
 considerable thermal challenge.
• Thermal challenges include:
 1. low survival power
 2. wide sink temperature range
 3. multiple phases of sample handling with varying operational powers
• All to be managed with high TRL thermal solutions.

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Plankton, Aerosol, Cloud, ocean Ecosystem (PACE)

• Plankton, Aerosol, Cloud, ocean Ecosystem (PACE)
 is a NASA Earth-observing satellite mission that
 will continue and advance observations of global
 ocean color, biogeochemistry, and ecology, as well
 as the carbon cycle, aerosols and clouds.
• PACE has two fundamental science goals:
 1. To extend key systematic ocean color, aerosol, and
 cloud data records for Earth system and
 2. climate studies, and to address new and emerging
 science questions using its advanced instruments,
 surpassing the capabilities of previous and current
 missions.
• The ocean and atmosphere are directly
 connected, moving and transferring energy, water,
 nutrients, gases, aerosols, and pollutants.
 Aerosols, clouds, and phytoplankton can also
 affect one another.
• Anticipated launch 2023.

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PACE Instruments
• Ocean Color Instrument (OCI), primary sensor, is a highly
 advanced optical spectrometer that will be used to measure
 properties of light over portions of the electromagnetic
 spectrum. It will enable continuous measurement of light at
 finer wavelength resolution than previous NASA satellite
 sensors, extending key system ocean color data records for
 climate studies. It is capable of measuring the color of the
 ocean from ultraviolet to shortwave infrared.
• Spectro-Polarimeter for Planetary Exploration (SPEXone) is
 a multi-angle polarimeter that provides continuous
 wavelengths coverage in the range 385-770 nm. It measures
 the intensity, Degree of Linear Polarization (DoLP) and Angle
 of Linear Polarization (AoLP) of sunlight reflected back from
 Earth's atmosphere, land surface, and ocean.
• Hyper-Angular Rainbow Polarimeter #2 (HARP2) is a wide
 angle imaging polarimeter designed to measure aerosol
 particles and clouds, as well as properties of land and water
 surfaces.

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PACE OCI Thermal Control System
• The OCI thermal control system employs two propylene Loop Heat Pipes (LHP). These
 LHPs transfer heat from the Focal Plane Array (FPA) sensors and electronic boxes of the VISNIR
 OCI instrument to the radiator panels. The radiators reject heat into space. LHP

• The TVAC testing of the flight and spare LHPs completed at GSFC.

 UVVIS LHP

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COSI – the Compton Spectrometer and Imager

Target Launch Date: 2025
Operation: 2 year prime mission: all-sky, imaging and spectroscopic survey
Instrument: compact and powerful MeV Compton telescope w shields
Concept matured via: COSI APRA balloon 2016–2021; IRADs (PI: Brandt)
2017–2019; GRIPS balloon 2015–2021
Launch vehicle: NASA HQ provided

COSI (Compton Spectrometer and Imager) is a soft gamma-ray survey
telescope (0.2-5 MeV) designed to probe the origins of Galactic positrons,
uncover the sites of nucleosynthesis in the Galaxy, perform pioneering studies
of gamma-ray polarization, and find counterparts to multi-messenger sources.
This Small Explorer (SMEX) mission is led by the University of California,
Berkeley, Space Sciences Laboratory.

COSI SMEX will transform MeV γ-ray astrophysics.
It will revolutionize our understanding of the cycle of creation and destruction of
matter in our Galaxy by
1. resolving the glow of antimatter annihilation in the Galactic center
2. revealing sites of element formation
3. pioneering γ-ray polarization studies of extreme environments, including
 black holes.

Point of Contact: Howard Tseng
 howard.c.tseng@nasa.gov
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COSI – Cryostat Heat Removal Subsystem (CHRS)
The major components of the COSI SMEX TD Model of COSI
Cryostat Heat Removal Subsystem (CHRS) are: System
 1. Cryocooler
 2.Cryocooler Heat Pipe (CHP) interface
 3.Three cryocooler Heat Pipes (HP)
 4.Three identical radiators with HPs

 COSI - Cryostat Heat Removal Subsystem

 Radiators

 Currently a detailed design
 and analysis is being
 conducted by GSFC.

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DraMS (Dragonfly Mass Spectrometer)
• Will launch in 2027, reaching Titan in 2035 • DraMS Instrument consists of a
• Dragonfly will fly around Titan looking for origins and signs of fife mass spectrometer, Gas
• Titan’s atmosphere is 94K and 1.5 bars pressure Chromatograph, and Laser to
 analyze high molecular-weight
 materials and samples of
 prebiotic interest.
 • Sample is kept cold (

CubeSats
• General Information
 o All cubesats are 6U (30cm x 20cm x 10cm).
 o The thermal control for all of the cubesats is passive
 except for a heater on the batteries. Thermal control is
 done with coatings. None of the cubesats have any MLI*.
 ▪ *petitSat does have some MLI as a closeout but it's
 not for thermal control per se.
 o All are in various stages of I&T. All have passed mission
 CDR.
 o Most are going to LEO except for GTOSat which is going
 into a geostationary transfer orbit.
 o All are being deployed from the ISS except for GTOSat (as
 mentioned above) and Dione (will be in a LEO polar
 orbit).
• GTOSat
 o Completed TVAC Q3 2021
 o Lead thermal engineer is Mike Madden
• petitSat
 o Completed TVAC Q3 2021
 o Lead thermal engineer is Omar Quinones
• SNOOPI
 o TVAC in Q2 2022
 o Lead thermal engineer is Seth Abramczyk
• BurstCube
 o TVAC in Q2/Q3 2022
 o Lead thermal engineer is Omar Quinones
• Dione
 o TVAC in Q4 2022 or Q1 2023
 o Lead thermal engineer is Seth Abramczyk

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Roman Space Telescope (RST)
 • The Roman Space Telescope is a NASA
 observatory designed to unravel the secrets of
 dark energy and dark matter, search for and
 image exoplanets, and explore many topics in
 infrared astrophysics.
 • The Roman Space Telescope will have two
 instruments, the Wide Field Instrument, and
 the Coronagraph Instrument.
 • The Primary Wide Field Instrument will have a field
 of view that is 100 times greater than the Hubble
 infrared instrument, capturing more of the sky with
 less observing time
 • The Coronagraph Instrument will perform high
 contrast imaging and spectroscopy of individual
 nearby exoplanets.
 • The Roman Space Telescope has a 2.4m
 telescope. the same size as Hubble’s, but with
 a view 100 times greater than Hubble’s.
 • The Roman Space Telescope is slated to launch
 in the mid-2020s.
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RST

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RST

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RST
 Integrated Payload Assembly Deployable Aperture
 12.54 m
 Cover (DAC)
 (41.2 ft.) Spacecraft

 Forward Optics
 Assembly (FOA)
 265 K
 Solar Array
Tertiary Collimator
 Sun Shield Outer Barrel
 Aft Optics Module (SASS) Assembly (OBA)
Assembly (TCA), (CGI
 (AOM), (WFI Tertiary Spacecraft Spacecraft
Tertiary Mirror)
 Mirror) 220 K
 293 K
 Wide Field
 Instrument
 (WFI)
 Instrument Coronagraph Payload
 Carrier (IC) Instrument (CGI)
 218 K Payload

 Instrument
 Mount for Carrier (IC)
 Star Trackers Bus + Avionics
 Payload
 (ST) and Wide Field Panels (x6)
 Inertial Instrument (WFI) Spacecraft
 High-Gain
 Coronagraph Reference 125 K
 Antenna System
 +X
 Instrument (CGI) Unit (IRU) +Z
 (HGAS) +Y
 293 K
 Spacecraft 26

RST Payload Status

• RST Optical Telescope Assembly:
 • Designed and built By L3Harris in Rochester NY
 • 91 Operational heater circuits to keep Telescope thermally stable
 • Primary and Secondary Mirror held at ~265K; Tertiary mirrors are held at ~293K and ~220K
 • Most components have stability requirements at mK level
 • Currently hardware being assembled and thermal cycled and structurally tested
 • Thermal Vacuum Test (Optical and Balance testing) expected in 2023
• RST Instrument Carrier:
 • Designed and analyzed by GSFC; Built by Northrup
 • Composite Tubes with titanium joints to hold instruments and telescope
 • 17 Op Heater circuits controlled to 218K
 • Expected delivery to GSFC in October of 2022; TV testing in Spring of 2023
 • TV tests will include at temperature photogrammetry to help understand deformations due to cool down
• RST Instruments:
 • Wide Field Instrument: Designed and built by Ball and GSFC
 • Coronograph Instrument: Designed and built by JPL
 • Electronics Pallet with heat pipes to dedicated radiator
 • Heated Optical Bench to 293K; Detectors with heat straps to dedicated 2 stage cryo radiator cool detectors to ~168K
• RST Payload Optical Test at temperature in 2024

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GOES-T Launched on March 1, 2022

• GOES-R launched and in orbit, 10/16, continues
 to operate one LHP.
• GOES-S launched 3/18 - ABI
 • GOES-S ABI manages to provide usable weather data
• GOES-T In-Orbit checkout period starts in late
 April 2022
 • New LHP for ABI
 • New LHP completed LHP Testing, instrument TVAC and
 SCTV.
• GOES-U launching April 2024 with a duplicate
 GOES-T LHP
• Loop Heat Pipe’s (LHP) used for thermal control
 of Advanced Baseline Imager (ABI) and
 Geostationary Lightning Mapper (GLM).

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Thermal Technology
Development through SBIR

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NASA/GSFC Thermal Subtopic Call
• From SBIR solicitations:
• Coatings for Lunar Regolith Dust Mitigation for Thermal Radiators and Extreme Environments
• Scope Description
• Thermal coatings are an integral part of a space mission and are essential to the survivability of the spacecraft and instrument. Radiator surface coatings
 with desired emissivity and absorptivity provide a passive means for instrument temperature control. The utilization of variable-emittance devices further
 enables active control of the instrument temperature when the heat output from the instrument or the thermal environment of the radiator changes. With
 NASA’s new initiative to return to the Moon, a new coating technology that will keep surfaces clean and sanitary is needed. New coating formulations utilizing
 durable, anticontamination, and self-cleaning properties that will disallow the accumulation of dust, dirt, and foreign materials are highly desirable. These
 coatings can have low absorptance and high infrared (IR) emittance properties or be transparent for use on existing thermal coating systems. The goal of this
 technology is to preserve optimal long-term performance of spacecraft and habitation components and systems. Furthermore, coatings that can survive and
 operate in extreme environments (cryogenic or high temperature) are desirable.

• Heat Pumps for High-Temperature Sink Environments
• Scope Description
• Operations in extreme environments where the environment sink temperature exceeds spacecraft hardware limits will require active cooling if long-duration
 survivability is expected. Robotic science rovers operating on the lunar surface over diurnal cycles face extreme temperature environments. Landers with
 clear views of the sky can often achieve sufficient heat rejection with a zenith or, if sufficiently far from the equator, an anti-Sun-facing radiator. However,
 science rovers must accommodate random orientations with respect to the surface and Sun. Terrain features can then result in hot environment sink
 temperatures beyond operating limits, even with shielded and articulated radiator assemblies. Lunar dust degradation on radiator thermo-optical properties
 can also significantly affect effective sink temperatures. During the lunar night, heat rejection paths must be turned off to preclude excessive battery mass or
 be properly routed to reclaim nuclear-based waste heat.
• Science needs may drive rovers to extreme terrains where steady heat rejection is not otherwise possible. The paradigm of swarms or multiple smaller rovers
 enabled by commercial lander opportunities will need to leverage standard rover bus designs to permit flexibility. A heat pump provides the common
 extensibility for thermal control over the lunar diurnal. Active cooling systems or heat pumps are commonly used on spacecraft. Devices used include
 mechanical cryocoolers and thermoelectric coolers. For higher loads, vapor compression systems have been flown, and more recently, reverse turbo-Brayton-
 cycle coolers are being developed under NASA's Game Changing program for high-load, high-temperature-lift cryocoolers. However, technology gaps exist for
 midrange heat pumps that are suitable for small science rovers where internal heat dissipation may range from 20 to 100 W.
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NASA/GSFC Thermal Subtopic Call
• From SBIR solicitations:
• Advanced Manufacturing of Loop Heat Pipe Evaporator
• Scope Description
• A loop heat pipe (LHP) is a very versatile heat transport device that has been used on many spacecrafts. At the heart of the LHP is the evaporator and reservoir
 assembly. During the manufacturing, tedious processes are required to machine the porous primary wick and insert it into the evaporator, and both ends of
 the wick need to be sealed for liquid and vapor separation. One commonly used method for vapor seal is to use a bimetallic knife-edge joint, which is more
 prone to failure over long-term exposure to thermal cycles and shock and vibration. These tedious manufacturing processes add to the cost of the traditional
 LHP. A new manufacturing technique that will allow the primary wick to be welded directly to the reservoir without the use of a knife-edge seal is needed in
 order to reduce the cost and enhance the reliability.

• Approaches and Techniques for Lunar Surface Payload Survival
• Scope Description
• The lunar environment poses significant challenges to small, low-power (~100 W or less) payloads, rovers, and landers required for lunar science. The lunar
 day/night cycle is approximately one Earth month. During that time, surface temperatures on the lunar surface can reach 400 K at local solar noon or drop to
 below 100 K during the lunar night—and even colder in permanently shadowed regions. These hot and cold conditions can last several Earth days, because
 of the slow rotation of the Moon, or permanently in shadowed craters. Lunar dust deposited on heat-rejection surfaces and coatings will increase the heat
 absorbed from the Sun, thus reducing the effectiveness of radiators for heat rejection. The lunar gravity, which is 1/6th of the Earth's, will limit the ability of
 typical low-power heat transport devices, but the gravity field may provide advantages that could be utilized. Higher heat dissipation capacity should be
 addressed in Z2.01. This call seeks to solicit innovative proposals to enable lunar science in the difficult lunar environment. Example technologies may include,
 but are not limited to, active loops that may be turned off and are freeze tolerant, zero- or low-power nonconsumable/regenerative heat generation sources,
 high-thermal-capacitance thermal storage, advanced insulation, and passive switching with high turndown ratios (e.g., >400:1). Furthermore, small form factors
 are also desired. Technologies should show substantial increase over the state of the art. Technology proposals should address power usage in day and
 night/shadow, mass, heat transport when turned on, heat leak when turned off, temperature drops through the system, heat storage/release amount,
 sensitivity to lunar topography and orientation, and so forth.

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Design and Bonding of Inserts to Printed Plated Coupons
 PI: Antonio Moreno and Sheri Thorn
Description and Goal to be Addressed:
• Verify design consideration for bonded joint interfaces between printed
 and plated coupons and metallic inserts with internal threads.
• The design study seeks to address structural joining of 3D printed parts
 using fastener hardware for the assembly of larger components.
• Determine adhesive bonding procedure for the surface preparation of
 electroless nickel plating to metallic insert.

Key challenge(s)/Innovation:
• Joint geometries needs to consider susceptibility to debonding
• Bonding preparation includes methods that abrade or chemically attack
 the surface. Excessive material removal could result in coating failure or
 stress concentrator.
• The final fastened joint will need to consider/minimize creep during to
 polymer substrate.
• Joint susceptible to creep due to polymer substrate.
 Lattice 3D printed and plated coupons. Left lattice as plated, right lattice compression
Approach: tested to failure. Failure defined as loss of load greater than 50%.
• Draft and analyze representative joints for blind and through fastened joint
 configurations. Milestones and Schedule:
• Blind joints to consider tensile, shear, and torque loading. Through joints • Design study through hole geometry with insert: 3/18/2022
 to consider joint separation and loss of preload due to creep. • Mass optimization through hole geometry: 4/15/2021
 • Design study blind fastener geometry Tensile, Torsion, and shear : 4/29/2022
Applications / Mission: • Bonding procedure SOP 5/6/2022
• Assembly of structures that require light weighting and low outgassing to • FEA analysis of through hole optimized joint: 5/6/2022
 include balloon missions and CubeSats
• Manufacturing of GSE with complex geometries Space Technology Roadmap Mapping: Technology Readiness Level:
 • Primary Technical Area: TX 12.1, 12.2, 12.4 • Starting TRL: 2
External Partners/Collaborators: • Secondary Technical Area: TX 13.2 • Anticipated Ending TRL: 3
• Sean Wise, RePliForm Inc. • Additional Technical Area(s):

 38

Non-Destructive Evaluation of 3D-Printed
 Continuous Fiber Composites (MRAD)

 PI: William Mulhearn
 (william.d.mulhearn@nasa.gov)

 Co-I: Scott Santoro, Justin Jones

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NDE Capabilities of the Aerospace Materials Group
• Effective screening of 3D-printed composites for internal delamination defects is essential for parts in load-bearing applications. Inspection of
 continuous-fiber composites poses a challenge due to internal heterogeneity at the fiber/matric interface, obscuring defect indications. Candidate
 non-destructive evaluation (NDE) methods will be assessed, building up transferrable expertise in the process.
• Objectives:
 Develop experience with non-destructive evaluation (NDE) capabilities within Code 541 laboratories, specifically applied to 3D-printed composites
 Methods: x-ray computed tomography (CT) with composite fiber analysis software, ultrasonic testing (UT), flash infrared thermography (flash IR), and laser shearography.
 Visualize and quantify internal delamination defects and defect growth in 3D-printed composites.

 Ultrasonic Testing Laser Shearography Flash Infrared Thermography X-Ray Computed Tomography
 (immersion system shown) Surface deflections Rate of surface heat dissipation Volumetric reconstruction via
 Pulse-echo: acoustic induced by applied thermal affected by sub-surface features X-ray transmission.
 reflections from defects. or vacuum stress; irregularities with different heat conduction
 indicate sub-surface defects. behavior. 40

Approach

 • Print reference composite coupons on Markforged 3D printer. Coupons can be made without defects,
 with single-sided depressions simulating voids, or with inserts trapping air.
 • Carbon fiber in nylon matrix; short- and continuous-fibers available.

 • Assess viability of NDE methods for detecting defect indications.

 • Measure defect growth resulting from mechanical stress/fatigue.

CAD Model of an Ultrasonic Testing Reference Standard Markforged Mark Two 3D Printer Printed Reference Standard

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Thermal Coatings Technology
 Mark.M.Hasegawa@nasa.gov
 Coatings Group Leader

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Thermal Coatings Technology

• Low surface energy sprayable and vacuum deposited systems for dust mitigation
 • Self assembling monolayer systems on nanotextured inorganic surfaces
 • Surface densification techniques and thin film deposition of silicate coatings for dust mitigation
 • To be included on Patch Plate lander experiment

• Thin film protective systems for improved environmental stability of sprayed
 dissipative silicate coatings

• Gold black UV absorptive vacuum deposited coating

• Improved terrestrial stability of second surface mirrored surfaces for MLI outer cover

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Microgap Coolers for 3D Printed Circuits (Frank Robinson)

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ELECTRICALLY DRIVEN THERMAL MANAGEMENT (EHD Technology)

Electrically Driven Thin Film Boiling Significant Results:
 • Demonstrated feasibility
 • Enhanced heat transfer at least 2X
 • Normalized thin film boiling phenomena up to 1.8 g NEW SHEPARD

 2.1 New Shepard System

Development Plan to TRL – 6 Blue Origin was created to develop spacecraft and launch systems with the goal
 of contributing to an enduring human presence in space. Blue Origin is currently

 • New Sheppard Flight P12: variable gravity & 2 minutes micro-gravity
 flying the New Shepard system, a suborbital vehicle that will ultimately carry up
 to six astronauts and/or payload stacks to an altitude of at least 328,000 feet (100
 km).

 • Electrically Driven Thin Film Boiling in Absence of Gravity:
 • ISS based experiment to characterize phenomena Crew Capsule (CC)
 Forward Fins (x4)

 • Microgravity Science Glovebox – sponsor:
 STP-H5 EHD ConductionNASA
 Pump LifeHQ
 Loop & Flight Demonstration
 Test BPS
 Drag Brakes (x8)

Impact: Flight Validated Technology for GSFC
 Mission Infusion
 ISEM Package: Thomas Flatley PI
 EHD Experiment: Jeffrey Didion PI

 Propulsion Module (PM)

 Landing Gear (x4)

 Aft Fins (x4)

 BE-3 Engine

 GODDARD SPACE FLIGHT CENTER
 6 Figure 2-1 45
 Integrated New Shepard Vehicle (Crew Capsule and Propulsion Module)

EHD THIN FILM LIQUID BOILING VARIABLE GRAVITY FLIGHT
 NEW SHEPPARD FLIGHT P12 EHD-LFB
 Electrically Driven Thin Film Boiling Experiment Payload: Micro-G to 5G

 ISS MICROGRAVITY SCIENCE GLOVEBOX EXPERIMENT: MICRO-G VALIDATION

Microgravity Science Glovebox ISS EHD Experiment
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NASA SPACE TECHNOLOGY GRADUATE RESEARCH OPPORTUNITY
 Grant 80NSSC20K1220

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2019 NASA Early Career Faculty (ECF19)
TITLE High Turndown Ratio Heat Switch using Temperature-Dependent Magnetic Forces
PI Geoffrey Wehmeyer UNIVERSITY William Marsh Rice University
RESEARCH OBJECTIVES AND RELEVANCE
 Passive magnetic heat switch SIGNIFICANT ACCOMPLISHMENTS
TO NASA
 • Measured PMHS switch ratio = 38 ( on =
 • Objective. Demonstrate a passive magnetic Low T: OFF state W mW
 heat switch (PMHS) for spacecraft thermal 0.27 , off ≅ 7 ) under high vacuum with
 K 
 control using temperature ( )-dependent switch ~18o C , thickness 1.2 cm, and a total
 magnetic forces to make and break thermal switch area >16 cm2 .
 contact between surfaces. • Used thermal and magnetic finite-element method
 • Relevance. Compact magnetic heat (FEM) simulations to design PMHS using Gd and
 switches with high thermal conductance Neodymium (Nd) magnets.
 turndown ratios (>400:1) across a narrow • Fabricated 1st gen. PMHS using sliding contact
 switching range (-15 to +15 oC) have the with copper guides to facilitate ON-state heat flow.
 potential to replace SOA paraffin heat • Demonstrated 1st gen. PMHS switching in ambient
 switches in next-generation spacecraft environment with switch ~18o C and switch
 thermal management systems. deadband of ~8o C.
 • Constructed and validated cut-bar apparatus to
TECHNICAL APPROACH OFF, < 14o measure and in vacuum environment.
 • Utilize Gadolinium (Gd), a ferromagnet with • Used thermal interface materials to reduce contact
 highly -dependent magnetization near the High T: ON state resistances and improve on .
 Curie temperature of 20o C. • Designed and constructed 2nd gen. PMHS with
 • Generate PMHS designs and use thermal overhanging copper guides, with goal of enhancing
 modeling to illustrate potential for high on while maintaining off.
 W
 turndown ratio ( = Gon /Goff). • Demonstrated improved on = 0.43 using
 K
 • Demonstrate proof-of-concept PMHS device springs to facilitate ON state conduction while
 with large switching area (16 cm 2), small maintaining passive magnetic OFF actuation.
 thickness ( 2 W/K , off < • Began preliminary thermal cycling and durability
 5 mW/K , and switch temperatures measurements of 1st gen. PMHS in ambient.
 between -15 to +15 oC PLANNED ACTIVITIES
 • Demonstrate target milestones (including on >
TEAM MEMBERS AND AFFILIATIONS 2 W/K) and advance PMHS from TRL 1 to TRL 3.
 PI: Dr. Geoff Wehmeyer, Rice • Perform steady-state and transient thermal
 Postdoctoral scholar: Dr. Qing Zhu, Rice
 ON, > 22o 
 characterization of 1st and 2nd gen. PMHS.
 Graduate students: Ajay Garg, Trevor • Comprehensive cycling, durability, hysteresis, and
 Shimokusu, Rice Concept: T-dependent magnetic forces vibrations measurements
 Undergraduates: Juan Pablo Martinez passively actuate mechanical motion to • Work with NASA experts for updated structural
 Cordeiro, Kaitlyn Zdrojewski, Hociel Landa, achieve high turndown ratios near 0o C. design, magnetic design and integration of PMHS
 Alisa Webb, Rice; Andrea Fabila, UT Tyler within thermal subsystems 48

Switchable Wettability for Condensation Heat Transfer
Jonathan M. Ludwicki/Cornell, Paul H. Steen/Cornell, and Franklin L. Robinson/GSFC

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DaVinci – Extreme Temperature Technologies (Venus environment)
• NASA’s DAVINCI mission will study the origin, evolution, and present state of Venus in
 unprecedented detail from near the top of the clouds to the planet’s surface. The mission’s goal is
 to help answer longstanding questions about our neighboring planet, especially whether Venus
 was ever wet and habitable like Earth.
• Named after visionary Renaissance artist and scientist Leonardo da Vinci, the DAVINCI mission
 Deep Atmosphere Venus Investigation of Noble gases, Chemistry, and Imaging is scheduled to
 launch in the late 2020s.

• Carrying an atmospheric descent probe, the DAVINCI spacecraft will serve as a
 telecommunications hub by relaying information from the probe to Earth. It will also use its two
 onboard instruments to study Venusian clouds and map its highland areas as it flies by the planet.

• During two gravity assist flybys, DAVINCI will study the cloud tops in ultraviolet light. Both flybys
 will also examine heat emanating from the Venus surface on the planet's night side.We will look
 for geological clues of this planet's mysterious past to paint a global picture of surface composition
 and the evolution of the planet's ancient highlands.

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