ALBERT

Description: The starboard SARJ mechanism on the ISS suffered a premature lubrication failure, resulting in widespread loss of the nitride case layer on its 10.3 meter circumference, 15-5PH steel race ring [1, 2]. To restore functionality, vacuum-stable grease was applied on-orbit, first to the port SARJ mechanism to save it from the damage suffered by the starboard mechanism. After 3 years of greased operation, telemetry indicated that the port mechanism required relubrication, so part of that process included sampling each of the three race ring surfaces to evaluate any wear debris recovered and the state of the originally applied grease. Extensive microscopic examination was conducted, which directed subsequent microanalysis of particulate. Since the SARJ mechanism operates in the vacuum of space, a sampling method and tool had to be developed for use by astronauts while working in the extravehicular mobility unit (EMU). The sampling tool developed was a cotton terry-cloth mitt for the EMU glove, with samples taken by swiping each of the three port SARJ race-ring surfaces. The sample mitts for each surface were folded inward after sampling to preserve sample integrity, for return and ground analysis. The sample mitt for what is termed the outer canted surface of the SARJ race-ring is shown in Figure 1. Figure 1 also demonstrates how increasing levels of magnification were used to survey the contamination removed in sampling, specifically looking for signs of wear debris or other features which could be further evaluated using Scanning Electron Microscopy (SEM) methods. The most surprising overall result at this point in the analysis was the relatively small amounts of grease recovered during sampling. It is clear that the mechanism was not operating with surplus lubricant. Obviously, evidence of molybdenum disulfide (MoS2), a major component in the grease applied, was prevalent in the analysis conducted. But a small amount of mechanism wear debris was observed. Figure 2 shows an example of a region of concentrated wear debris. Although some MoS2 is observed, most of the contaminant in this location is nitrided 15-5PH steel, as verified by the associated chemical analysis. High oxygen content was also observed which, when associated with the apparent friable nature of the steel material, suggests that this contaminant could be quite old, perhaps even associated with the mechanism s original manufacture and acceptance testing. Additional microscopic

Description: The Main Propulsion System (MPS) uses three Flow Control Valves (FCV) to modulate the flow of pressurant hydrogen gas from the Space Shuttle Main Engines (SSME) to the hydrogen External Tank (ET). This maintains pressure in the ullage volume as the liquid level drops, preserving ET structural integrity and assuring the engines receive a sufficient amount of head pressure. On Space Transportation System (STS)-126 (2009), with only a handful of International Space Station (ISS) assembly flights from the end of the Shuttle program, a portion of a single FCV?s poppet head broke off at about a minute and a half after liftoff. The risk of the poppet head failure is that the increased flow area through the FCV could result in excessive gaseous hydrogen flow back to the external tank, which could result in overboard venting of hydrogen ullage pressure. If the hydrogen venting were to occur in first stage (i.e., lower atmosphere), a flammability hazard exists that could lead to catastrophic loss of crew and vehicle. Other failure risks included particle impact damage to MPS downstream hardware. Although the FCV design had been plagued by contamination-related sluggish valve response problems prior to a redesign at STS-80 (1996), contamination was ruled out as the cause of the STS-126 failure. Employing a combination of enhanced hardware inspection and a better understanding of the consequences of a poppet failure, safe flight rationale for subsequent flights (STS-119 and later) was achieved. This paper deals with the technical lessons learned during the investigation and mitigation of this problem at a time when assembly flights were each in the critical path to Space Station success.

Description: A Space Shuttle Reaction Control System (RCS) thruster failed during a firing test at the NASA White Sands Test Facility (WSTF), Las Cruces, New Mexico. The firing test was being conducted to investigate a previous electrical malfunction. A number of cracks were found associated with the fuel closure plate/injector assembly (Fig 1). The firing test failure generated a flight constraint to the launch of STS-133. A team comprised of several NASA centers and other research institutes was assembled to investigate and determine the root cause of the failure. The JSC Materials Evaluation Laboratory was asked to compare and characterize the outboard circumferential electron beam (EB) weld between the fuel closure plate (Titanium 6Al-4V) and the injector (Niobium C-103 alloy) of four different RCS thrusters, including the failed RCS thruster. Several metallographic challenges in grinding/polishing, and particularly in etching were encountered because of the differences in hardness, ductility, and chemical resistance between the two alloys and the bimetallic weld. Segments from each thruster were sectioned from the outboard weld. The segments were hot-compression mounted using a conductive, carbon-filled epoxy. A grinding/polishing procedure for titanium alloys was used [1]. This procedure worked well on the titanium; but a thin, disturbed layer was visible on the niobium surface by means of polarized light. Once polished, each sample was micrographed using bright field, differential interference contrast optical microscopy, and scanning electron microscopy (SEM) using a backscatter electron (BSE) detector. No typical weld anomalies were observed in any of the cross sections. However, areas of large atomic contrast were clearly visible in the weld nugget, particularly along fusion line interfaces between the titanium and the niobium. This prompted the need to better understand the chemistry and microstructure of the weld (Fig 2). Energy Dispersive X-Ray Spectroscopy (EDS) was used to confirm the chemical composition of the variations in contrast in these areas. Niobium alloys generally require exposure to more aggressive chemical reagents than titanium alloys for etching because of niobium s chemical resistance; therefore, the titanium portion of the sample was etched first. A five second immersion in Kroll s reagent revealed a general microstructure on the titanium portion of the sample; however, the titanium heat affected zone closest to the weld, was over-etched due to higher concentrations of refined grains and an increase in eta-phase. The Kroll s etchant also revealed some microstructure in the weld nugget itself; the niobium portion of the sample remained unetched.

Description: The goal of NASA's Edison Demonstration of Smallsat Networks (EDSN) mission is to demonstrate interactive satellite swarms capable of collecting, exchanging and transmitting multi-point scientific measurements. Satellite swarms enable a wide array of scientific, commercial and academic research not achievable with a single satellite. The EDSN satellites are scheduled to be launched into space as secondary payloads on the first flight of the Super Strypi launch vehicle no earlier than Oct. 29, 2015.

Description: The CubeSat Proximity Operations Demonstration (CPOD) project will demonstrate rendezvous, proximity operations and docking (RPOD) using two 3-unit (3U) CubeSats. Each CubeSat is a satellite with the dimensions 4 inches x 4 inches x 13 inches (10 centimeters x 10 centimeters x 33 centimeters) and weighing approximately 11 pounds (5 kilograms). This flight demonstration will validate and characterize many new miniature low-power proximity operations technologies applicable to future missions. This mission will advance the state of the art in nanosatellite attitude determination,navigation and control systems, in addition to demonstrating relative navigation capabilities.The two CPOD satellites are scheduled to be launched together to low-Earth orbit no earlier than Dec. 1, 2015.

Description: The outstanding problem for useful applications of electrodynamic tethers is obtaining sufficient electron current from the ionospheric plasma. Bare tether collectors, in which the conducting tether itself, left uninsulated over kilometers of its length, acts as the collecting anode, promise to attain currents of 10 A or more from reasonably sized systems. Current collection by a bare tether is also relatively insensitive to drops in electron density, which are regularly encountered on each revolution of an orbit. This makes nighttime operation feasible. We show how the bare tether's high efficiency of current collection and ability to adjust to density variations follow from the orbital motion limited collection law of thin cylinders. We consider both upwardly deployed (power generation mode) and downwardly deployed (reboost mode) tethers, and present results that indicate how bare tether systems would perform as their magnetic and plasma environment varies in low earth orbit.

Description: The continued advancement of small satellite-based science missions requires the solution to a number of important technical challenges. Of particular note is that small satellite missions are characterized by tight constraints on cost, mass, power, and volume that make them unable to fly the high-quality Inertial Measurement Units (IMUs) required for orbital missions demanding precise orientation and positioning. Instead, small satellite missions typically fly low-cost Micro-Electro-Mechanical System (MEMS) IMUs. Unfortunately, the performance characteristics of these MEMS IMUs make them ineffectual in many spaceflight applications when employed in a single IMU system configuration.

Description: Relatively short electrodynamic tethers can use solar power to 'push' against a planetary magnetic field to achieve propulsion without the expenditure of propellant. The groundwork has been laid for this type of propulsion. Important recent milestones include retrieval of a tether in space (TSS-1, 1992), successful deployment of a 20-km-long tether in space (SEDS-1, 1993), and operation of an electrodynamic tether with tether current driven in both directions (PMG, 1993). The planned Propulsive Small Expendable Deployer System (ProSEDS) experiment will use the flight-proven Small Expendable Deployer System (SEDS) to deploy a 5 km bare copper tether from a Delta II upper stage to achieve approximately 0.4 N drag thrust, thus deorbiting the stage. The experiment will use a predominantly 'bare' tether for current collection in lieu of the endmass collector and insulated tether approach used on previous missions. The flight experiment is a precursor to utilization of the technology on the International Space Station for reboost and the electrodynamic tether upper stage demonstration mission which will be capable of orbit raising, lowering and inclination changes, all using electrodynamic thrust. In addition, the use of this type of propulsion may be attractive for future missions at Jupiter.

Description: Relatively short electrodynamic tethers can extract orbital energy to 'push' against a planetary magnetic field to achieve propulsion without the expenditure of propellant. The Propulsive Small Expendable Deployer System experiment will use the flight-proven Small Expendable Deployer System (SEDS) to deploy a 5 km bare copper tether from a Delta II upper stage to achieve approximately 0.4 N drag thrust, thus lowering the altitude of the stage. The experiment will use a predominantly 'bare' tether for current collection in lieu of the endmass collector and insulated tether approach used on previous missions. The flight experiment is a precursor to a more ambitious electrodynamic tether upper stage demonstration mission which will be capable of orbit raising, lowering and inclination changes - all using electrodynamic thrust. The expected performance of the tether propulsion system during the experiment is described.

Description: Synchronized Position Hold, Engage, Reorient, Experimental Satellites (SPHERES) are bowling-ball sized satellites that provide a test bed for development and research into multi-body formation flying, multi-spacecraft control algorithms, and free-flying physical and material science investigations. Up to three self-contained free-flying satellites can fly within the cabin of the International Space Station (ISS), performing flight formations, testing of control algorithms or as a platform for investigations requiring this unique free-flying test environment. Each satellite is a self-contained unit with power, propulsion, computers, navigation equipment, and provides physical and electrical connections (via standardized expansion ports) for Principal Investigator (PI) provided hardware and sensors.