Fabrication of Advanced Materials for Space

Peter King, Daniel Liang , CSIRO Manufacturing (Clayton)

CSIRO MANUFACTURING

OzSpace 19 Workshop, Monday, July 22nd 2019, The University of Melbourne, School of Physics (David Caro Building) Outline

Thermal Management Shielding, Cooling & Zero CTE

Space Shielding Radiation, Electromagnetic Interference and Effects (EMI & EME)

Self-Deployable Structure: Rollable Solar Arrays Shape-memory materials actuation: manufacturing materials, modelling and control Thermal Management

Zero Thermal Expansion • Zero CTE, high stiffness • Compact and lightweight

The universe of available structurally robust materials The pinned and bonded planar experimental specimen of low STE lattices (ceramics are not included), plotted in the space of composed of titanium 6Al–4V and aluminium 7075-T6. stiffness and thermal expansion Source: Steevesa C. A., et al, 2007) Thermal Management Cold Spray Additive Manufacturing

• Solid state deposition – no melting, therefore no solidification defects

• No need for vacuum chamber or protective atmosphere

• Deposition rates of kilograms per hour

4 | CSIRO Lab22 Thermal Management Cold Spray at CSIRO

Impact Innovations System with dual robots at CSIRO Plasma Giken Cold Spray System at CSIRO

• CSIRO Cold Spray Lab has two dedicated spray rooms

• Commercially-available high pressure cold spray machines

5 | CSIRO Lab22 Space Radiation Shielding

• Radiation Sources: Van Allen inner belt, Galactic Cosmic Rays (GCRs), and Solar Particle Events (SPEs). • Particles: protons, alpha particles (helium nuclei), beta particles (electrons), and heavy ions, as well as secondary radiation. Space Radiation Shielding High-Energy Proton Testing Set-up • The test focused on the primary, high energy radiation. • Configuration: the CSIRO sample is position between a proton source and a detector. • Proton beam source: 200MeV at a NASA sanctioned research facility. • Detector: tissue equivalent proportional counter (TEPC) measured the radiation quantities of adsorbed dose and dose equivalent to human tissue Space Radiation Shielding TRL 6 Demonstrations: flying and testing a prototype on ISS shielding electronic devices against radiation in IRB, GCR and ORB • Determine dimension and geometry of the prototype for protecting a selected electronics.

Radiation sources on ISS: • IRB: trapped proton Inner Radiation Belt. • ORB: mainly electron in Outer Radiation Belt. • GCR: energetic proton, ions, etc., of Galactic Cosmic Rays SD = specific dose.

Credit: Dachev T., 2015. Self-Deployable Structures

Rollable, High-Power Solar Arrays

• Minimise the stowed volume, and maximise the solar surface area for high-power generation for a given weight. • Higher transmitter, greater broadband, high-resolution video , more payload, Deep space missions can benefit by using the Roll Out mining operations, etc. Solar Array (ROSA) technology. Source: Space Systems Loral (SSL)

Roll Out Solar Array (ROSA) technology undergoes testing. Source: Deployable Space Systems, Inc. (DSS) Self-Deployable Structures Rollable, high-power solar arrays for CubeSat

CSIRO is to combine two foil technologies, i.e. printable solar panel and SMA foil materials, to develop the rollable solar arrays CubeSat, increasing power generation by more then 20 times Self-Deployable Structures CSIRO SMA Foils Fabrication • Ti alloy foils that are free of defects and oxygen contamination by novel nozzle design and controls of melting , melt flows and rapid solidification. • High temperature melting facility (up to 2000oC) for producing contamination-free metal alloy materials. The SMA foil of larger width fabricated at CSIRO

Videos showing one-way (right) and two-way actuation of the SMA NASA Jet Propulsion Lab. – CSIRO JPL IRAD, AIM Future Science Platform. The need for new material solutions for rover development aimed at the Europa lander.

Challenges ▪Extremes of temperature. ▪Long life cutting tools. ▪Sensing of the environment. ▪Environmental change from ice to liquid to rock.

http://photojournal.jpl.nasa.gov/catalog/PIA00502 NASA Jet Propulsion Lab. – CSIRO CSIRO - Daniel East NASA-JPL - Doug Hoffman Extremes of temperature: Bulk metallic glasses:

Bulk metallic glass gears for dry running at cryogenic temperature JPL NASA: Hoffman

Long life cutting tools: metal matrix composites.Diamond metal matrix composites: cutting tools Thank You

Contact: Daniel Liang Metal Industry Program CSIRO Manufacturing Normanby Road, Clayton Victoria 3168 Australia E: Daniel.liang@csiro.au P: +61 3 9545 2981

CSIRO MANUFACTURING