2006-01-2285 Micrometeoroid and Orbital Debris Enhancements of Shuttle Extravehicular Mobility Unit Thermal Micrometeoroid Garment Robert Jones, David Graziosi, Jinny Ferl, Keith Splawn, David Zetune and David Cadogan ILC Dover LP Eric L. Christiansen NASA Johnson Space Center Copyright © 2006 SAE International ABSTRACT As NASA is preparing to extend man’s reach into space, it is expected that astronauts will be required to spend more and more time exposed to the hazards of performing Extra-Vehicular Activity (EVA). One of these hazards includes the risk of the space suit bladder being penetrated by hypervelocity micrometeoroid and orbital debris (MMOD) particles. Therefore, it has become increasingly important to investigate new ways to improve the protectiveness of the current Extravehicular Mobility Unit (EMU) against MMOD penetration. ILC Dover conducted a NASA funded study into identifying methods of improving the current EMU protection. The first part of this evaluation focused on identifying how to increase the EMU shielding, selecting materials to accomplish this, and testing these materials to determine the best lay-up combinations to integrate into the current thermal micrometeoroid garment (TMG) design. Part of this study included using extensive hypervelocity testing to identify potential candidate materials. The last part of this study expanded on the previous results by conducting a more thorough investigation into the performance of the top three candidate lay-ups for micrometeor protection. The ability to manufacture the candidates into the current TMG and their effects on the torque of a mobility joint were the main focus points. This paper summarizes the findings of this study. INTRODUCTION In an attempt to better understand and mitigate the risk of micrometeoroid and orbital debris penetrating the bladder of the EMU (see Figure 1), NASA implements a probability model to estimate the protection provided by the outer layers of the suit to the bladder. The estimate Fig 1: Extravehicular Mobility Unit (EMU) of protection is reflected in a Probability of No Penetration (PNP) value. The current level of acceptable PNP through the EMU bladder is .91 which was defined by the prediction model, “ORDEM 96”. Recently, a new MMOD Environmental Model, “ORDEM 2000”, was developed to refine the PNP value and replace the previous ORDEM 96 model. However before the new model was finished, NASA expressed concern that new data and a refinement to the prediction model may indicate that the current level of protection to the EMU bladder maybe insufficient. To prepare for the results of the new model, NASA initiated a study through ILC Dover into how to increase the current level of protection provided by the EMU outer layers. Thus far, this study has been divided into three phases. The first phase began by reviewing literature and new technology on how to improve the current EMU to withstand impact. Two methods were studied: 1.) the use of a self-sealing bladder and 2.) adding more shielding to the EMU TMG. The self-sealing bladder approach was reviewed in 2003 by ILC. In that study, methods of containing self-sealing material were reviewed to evaluate implementation into the current restraint/bladder fabrication. A self-sealing bladder with gores was fabricated and integrated into a lower arm assembly. The result of that evaluation proved that a sealing bladder is possible but it is difficult to manufacture and adds weight. (1) The first part of the study into improving the shielding effectiveness of the TMG began by examining current MMOD shielding found on satellites, the ISS, and the current TMG lay-up to observe how they were fabricated. It was noted that the majority of the MMOD protection system designs are based on the Whipple Bumper effect. In a Whipple Bumper, hypervelocity particles are broken apart by an outer “smasher” layer, the particles are dispersed through a “spacer” layer, and are finally absorbed by an “absorber” layer. This type of shielding is already built into the current TMG. into a number of different combinations to be compared using hyper velocity impact (HVI) testing at the NASA facility in White Sands New Mexico. The purpose of this testing was to find the ballistic limit of each material to identify which material provided the best protection. From this testing, it was found that Silicone Coated Nextel, Silicone Coated Kevlar, and Neoprene Coated Nylon all have similar ballistic limits. Therefore, the Neoprene Coated Nylon was selected as the absorber material because it is already used on the current TMG. The ballistic testing concluded that the Prima Loft performed as good as the Open Cell Foam did but because of undesirable thermal limitations with Prima Loft, the OCF was selected as the best spacer candidate. The next part of this phase involved defining how much and where these materials needed to be integrated into the TMG. Three combinations of lay-ups were proposed as samples to be tested, which are identified as thin, medium, and thick. Layers Outer Layer Material Orthofabric MLI (5 - 7 layers) Neoprene Coated Nylon Radiation Liner Layer Baseline MMOD Lay-up Fig 2: Functions of current TMG layers – MMOD specific Layers Outer Layer Material Orthofabric MLI (7 layers) Radiation The Whipple Bumper design was broken apart to identify areas where the TMG could be modified to enhance the effect. The amount of lofting, the number of particle destroying layers, the tenacity of the fabric layers, the stopping effectiveness of the outer layer, the thickness, and the mass of the layers were all identified as potential items for improvement. These properties were then rated according to how much they would improve the current TMG against penetration. A trades study was performed on different types and lay-ups of materials to identify which could yield the largest gains in protection while also maintaining the mobility of the TMG for flexing parts. This study aided in the down selection of materials to be evaluated as possible candidates to enhance the TMG. It was decided early on that the Orthofabric currently used on the TMG was a good choice as an outer “smasher” layer due to its ideal combination of properties. These properties include protection against atomic oxygen and abrasions, strength, resistance against wear and tear, electrostatic charge dispersion, and protection against chemical influences such as spacecraft fuel remainders. Prima Loft, a spun-laced polyester, and Open Cell Foam (OCF), a urethane, were suggested as possible “spacer” layers. Finally, silicone coated Kevlar, silicone coated Nextel, Spectra 1000, silicone coated Vectran, and Neoprene Coated Nylon were reviewed as possible “absorber” layers. Phase II involved the testing of these selected materials. The absorber and spacer candidates were constructed Absorber Layer Neoprene Coated Nylon Liner Layer Neoprene Coated Nylon Thin MMOD Lay-up Layers Outer Layer Material Orthofabric MLI (7 layers) Open Cell Foam (OCF) Neoprene Coated Nylon Neoprene Coated Nylon Radiation Spacer Layer Absorber Layer Liner Layer Medium MMOD Lay-up Layers Outer Layer Material Orthofabric MLI (7 layers) Open Cell Foam (OCF) Neoprene Coated Nylon Open Cell Foam (OCF) Neoprene Coated Nylon Radiation Spacer Layer Absorber Layer Spacer Layer Liner Layer Thick MMOD Lay-up Fig 3: Proposed Lay-ups of Selected Materials (Note: At the time these lay-ups were proposed, it was undecided where the best location was for the OCF. Testing found that the location of the OCF was best between the two-absorber layers. This also provided protection from the OCF abrading the MLI). Using this data, the new MMOD Environmental Model, and these proposed lay-ups, a sensitivity study was performed on various regions of the EMU. This study enabled a determination of which areas of the EMU are most vulnerable to penetration and therefore which areas are in greatest need of improvement. A finite element model of the EMU was used to perform this analysis. The waist, thigh, leg, boot, shoulder, and PLSS were all identified as areas with the greatest MMOD risk. The prediction model was updated to reflect the prototype lay-ups covering critical parts of the EMU. The thick lay-up was not considered in this part of the study due to the determination that it was too thick and bulky for mobility and manufacturability. See the following figures for the results of this model. As can be seen from the above figures, the new MMOD model predicted a doubling of the amount of protection to the EMU with most of the vulnerable parts being covered with the thin combination. Also, it predicted a tripling of the protection with most of the vulnerable parts being covered with the medium lay-up. These findings led to further testing for verification of the model’s results which Phase III of this evaluation addressed. CURRENT MMOD EVALUATION The goals of Phase III of this study were to validate the predictions made by the MMOD Environmental Model, manufacture a mock-up leg TMG to evaluate manufacturability and impact to torque and to provide recommendations on what changes to make to the current EMU. All of these goals were accomplished. HYPERVELOCITY TESTING Fig 4: Extravehicular Mobility Unit Baseline Lay-up PNP: 0.938 Risk: 6.2% Odds: 1 in 16 Gray = Baseline, Aqua = Thin, Blue = Medium Fig 5: Extravehicular Mobility Unit Option 1 Thin Lay-up PNP: 0.971 Risk: 2.9% Odds: 1 in 34 Gray = Baseline, Aqua = Thin, Blue = Medium Fig 6: Extravehicular Mobility Unit Option 2 Medium Lay-up PNP: 0.978 Risk: 2.2% Odds: 1 in 45 Gray = Baseline, Aqua = Thin, Blue = Medium The first goal of this phase was met by manufacturing and testing another round of samples using the Hypervelocity Impact (HVI) testing to determine more precise ballistic limit equations to input into the bumper model. This testing was coordinated by the JSC Hypervelocity Impact Technology Facility (HITF) and was conducted during May and June of 2005. ILC Dover manufactured ninety (90) test articles used for investigating their ballistic limits. The HITF supported the testing by conducting the tests, analyzing the results, and writing a report that summarized the results. HITF’s test objectives were to perform hypervelocity impact tests with different sizes and types of projectiles, assess the damage done, determine the critical projectile diameter, and determine the ballistic limit(s) of the layups by simulating MMOD damage to the EMU TMG. Also, they were asked to determine if the addition of 2 more layers of aluminized Mylar insulation (MLI) would significantly alter the ballistic limit of the TMG and to determine the optimum location for the OCF in the layup. During testing, they rated the results of each sample and gave it a “pass/fail” by inspecting the damage inflicted to the Urethane Coated Nylon Bladder. They defined failure as “an impact that penetrates the Urethane Coated Bladder layer of the sample lay-up and causes the Leak-Tec to bubble out when the bladder is pressurized to 2-psi or it is clear that the bladder has been penetrated and there is impact residue on the Plexiglas witness plate in such case no pressure test is warranted.” 90 test articles were fabricated which were comprised of fifteen EMU TMG Thin Lay-ups, thirty-nine EMU TMG Thin-2 Lay-ups, and thirty-six EMU TMG Medium Layups. The Thin-2 Lay-ups were a result of some questions that arose during testing concerning the amount of standoff between materials that the current EMU contains. They were fabricated in order to represent the current TMG configuration more accurately. Each combination was constructed into a 6” x 7” panel with a Plexiglas back to view bladder damage. Figure 9: Front of EMU TMG Medium Lay-up Test #48 Urethane Coated Nylon (Bladder) – Front Fig 7: Test Article Assembly Below are some photographs taken after a shot was fired. The pictures included below represent the medium lay-up. As can be seen, this lay-up was able to adequately protect the Urethane bladder and thus was given a “pass” rating. This testing resulted in a large matrix that outlines the ballistic limits for all of the lay-ups and is included in the Appendix “A.1 – Phase II Hypervelocity Impact Testing Results” at the end of this report. From this testing, it was also determined that the addition of 2 extra layers of aluminized Mylar insulation did not improve the protection significantly. In the case of both the five layer samples and the seven layer samples, the bladder was perforated each time. It was also determined that the two neoprene coated nylon layers separated by the open cell foam allowed the debris cloud to better disperse. Therefore, the optimal medium lay-up was proven to be Orthofabric, MLI, Neoprene Coated Nylon Absorber, Open Cell Foam, Neoprene Coated Nylon, Dacron Polyester Restraint, and Urethane Coated Nylon Bladder. After testing was completed, the results were input into the bumper model to refine the risk estimates. This analysis was run in parallel with the next step of this phase. MANUFACTURING Fig 8: Front of Post-Test EMU TMG Medium Lay-up Test #48 The second goal of this phase was to manufacture a mock-up leg TMG to assess the best method for integrating these new materials into the current TMG. A leg TMG was chosen because it is a flexing part and an increase in TMG thickness would increase the torque, a critical design consideration. At this point in the study, the bumper model and results from the ballistic testing indicated that the level of protection of the EMU could increase three times if the majority of the most vulnerable parts were covered with the medium lay-up. The majority of the vulnerable parts are flexing parts and therefore are susceptible to a change in torque. As a result, it was decided that the medium lay-up would be used for the mock-up TMG. Due to its robustness over the thin lay-up, it was surmised that the medium lay-up would yield the largest gains for the scope of the project. The manufacturing study began by fabricating sample gores to assess how the layers would interact with each other and what technique would minimize the amount of torque the additional layers would add. Since the TMG lay-up would remain relatively the same with the exception of an additional layer of Neoprene Coated Nylon, the issue to resolve was how to integrate the Open Cell Foam. Thirteen concepts were fabricated, each one detailing a different method of attaching the OCF. Methods were derived from other soft good products that ILC has manufactured and used at other locations on the space suit. After these concepts were fabricated, a trades study was conducted to down select to the best manufacturing method. The chosen concept would be made into a fullsized mock-up. A trades matrix was generated to rate all thirteen concepts according to ten categories that were created to compare the concepts’ attributes in all areas. For each category, a specific concept was given a grade on a scale of 1 to 10 on how well it satisfied the category. The higher the grade a concept got for a category, the better it was compared to the other concepts. Grades were assigned keeping in mind the objectives of this evaluation and the concept’s impact on the current EMU design and fabrication. This grade was then multiplied by a weighting factor in order to enable certain categories to have more weight in the final rating of the concept. For instance, a concept’s effect on torque was weighted more heavily than its required manufacturing time. This weighting aided in making each category impact the final score according to its importance. The weighted grade for each respective category was added up for each concept to form the total rating, which determined each concept’s ranking with respect to one another. The higher the total rating, the better the concept accomplished the goal while decreasing the cost of adding extra layers. ILC Dover compiled a trades matrix for this study using engineering judgement and experience to rank each concept. This trades matrix is included in Appendix “A.2 – MMOD Trades Matrix for TMG Thickening of Knee Joint.” With torque being one of the most heavily weighted categories in the study, it was decided that all of the concepts that rated high in the torque category could be eliminated. chosen concept and also allow comparison testing of each concept to help to better understand the unknowns involved. For fabricating layers in the current TMG such as the Orthofabric layer and the MLI layers, work instructions were followed as closely as possible maintaining all of the required tolerances and precision. For each new OCF concept, detailed notes were kept on the fabrication of the new layers to document the process and then work instructions for those layers were generated. This was done for each concept so that after manufacturing was completed each process could be reviewed to assess its difficulty compared to the others. Also, pictures were taken detailing the techniques used in the process to capture what each concept looked like. The completed concepts were weighed to compare them to a traditional TMG as a first step in analyzing how much the additional layers would impact the weight of the EMU. Fig 10: Completed TMG Mock-ups TMG Weight (lb) Baseline* 1.18 3 1.71 8 1.72 13 1.73 *Average of 5 Class I TMG's Table 1: Weight Comparison The evaluation showed that multiple concepts appeared to be good and ranked high and almost equal in the matrix. One reason why it was difficult to narrow it down to one concept was that, as with any trades study performed on a prototype, some categories must be ranked on an educated guess rather than knowledge because this type of manufacturing had never been done before. Therefore, it was decided that it was within the scope and timetable of this evaluation to fabricate and test three full-sized leg TMG mock-ups to aid in the selection of one best method. Three mock-ups would allow the complete fabrication of a TMG using each The average percent weight increase of the prototypes over the baseline was 45.8%. By completing these three concepts, it was found that each concept had its own unique challenges to building it into a TMG and the manufacturing categories listed in the trades matrix could further be defined. It was decided from a manufacturing standpoint that Concept 13 seemed the best concept to recommend for this evaluation. The third goal of this phase was to provide a torque evaluation of the selected construction method verses a baseline Class I leg TMG. Because three TMG mockups were constructed each representing a different manufacturing concept, the torque evaluation was also used to determine if one manufacturing method was better for torque over the others. The thought was that this would also aid in selecting one best concept. The torque evaluation began immediately after the completion of the three TMG mock-ups. The testing was performed in the ILC Test Lab. To serve as a baseline measurement, a Class I leg TMG was used. It was decided to use a Class I item because of its relatively low amount of wear. It was a concern that a “broken in” TMG would yield lower torque measurements than a new one. Test plugs were machined for the test stand and a Test Plan was generated to outline the scope of the test. In the test, each TMG including the baseline was laced onto a leg restraint and bladder that had been down-graded and given to Engineering for the testing. The leg was inflated to 4.3 psig to simulate pressures used in the EMU during EVA. It was found in the Specification/Assembly Drawing (S/AD) requirements for the lower torso assembly (LTA) of the current EMU, that the knee joint should not exceed 155 in-lbs. of torque when flexed to 75 degrees. The outputs from a rotational encoder and a force transducer were fed into a DAQ system and the real-time results such as angular velocity and rotation could be viewed during testing. This also aided in maintaining consistency from trial to trial for the test to be fair. could flex the leg while monitoring the data on the output screen. Second, each TMG was flexed from an initial starting position to the maximum deflection that the restraint and bladder would allow, and then back to the initial position. The maximum angle was determined to be 75 degrees, which is the point where the cylinder began to break down and the gore pattern was no longer effective. This range was completed five times for each TMG. Data from both ranges of motion was collected so that the torque values of each trial could be averaged and compared. Shown here are the results of the torque testing from averaging the data for each TMG: Compare Results of 55 Degrees Torque Testing 200 150 100 Torque (in-lb) TORQUE EVALUATION Concept 3 Avg. Concept 8 Avg. Concept 13 Avg. Class I Avg. 50 0 0 10 20 30 40 50 60 70 80 90 -50 -100 Rotation (deg) Fig 12: Graph Comparing Results of 55 Degree Torque Testing *Note: Red line indicates 75 in-lbs of torque but is shown in this graph merely to aid in visual comparison of the data Compare Results of Max Degrees Torque Testing 200 150 Fig 11: Test Stand / Installed TMG Each TMG was subjected to two ranges of motion for the purpose of comparing them at two different points. First, each TMG was flexed from an initial starting position, marked by 0 degrees and which was determined by pressurizing the restraint and bladder and allowing them to inflate without guidance to their natural resting position, to a maximum rotation of 55 degrees and then back to the initial position. This range was completed seven times for each TMG so data could be averaged to eliminate any operator-induced results such as a sudden increase in angular velocity, which would cause an unnatural spike in the recorded torque. Also as each trial was run, an attempt was made to hold the angular velocity constant at 2°/sec to maintain consistency. This value was established after performing several test trials to determine the optimal rate at which the test operator Torque (in-lb) 100 Concept 3 Avg. Concept 8 Avg. Concept 13 Avg. Class I Avg. 50 0 0 10 20 30 40 50 60 70 80 90 -50 -100 Rotation (deg) Fig 13: Graph Comparing Results of Maximum Degree Torque Testing *Note: Red line indicates 75 in-lbs of torque but is shown in this graph merely to aid in visual comparison of the data Several results came from performing this testing. First, it is clearly shown in the graphs that the torque required to flex the studied TMG’s resulted in a hysteresis pattern. This could be felt in the TMG as it was flexed to its farthest rotation and back as it had a “spring-back” feel to it. The hysteresis was a result of the “memory” of the material and its tendency to return to its natural, unflexed state similar to how a spring behaves. However, due to the construction of the TMG which has multiple layers rubbing against each other and creating friction, the leg assembly tended to come to rest before returning to its starting position therefore requiring a negative torque to push it back into place. This is why the hysteresis curves begin and end at different values on the graph. This effect was expected as it has been observed during torque studies performed on other EMU parts. Second, during testing it was noted that the way the test operator applied force to the handle of the test stand varied the torque output in a way not related to the construction of the TMG. While this does not apply directly to the outcomes of interest for this study, it is important to note here to show that during testing a more consistent method of testing was applied to the trials and therefore created the need for several trials to be rerun. This insured that all testing was completed accurately and that the data reflects a fair comparison. Initially, the operator was holding the handle of test stand in a grip, which applied some downward force thus effectively reducing the amount of torque in the direction of the bent knee. After realizing this, a new method of applying force with one finger only in the direction of rotation was applied. This allowed for much more uniform results. evaluation because the method of fabrication does not change the torque significantly enough for it to determine which method to use. However, the tests also showed that altering the current TMG lay-up to reflect the proposed medium MMOD layup would increase the torque at least 13 in-lbs. at a rotation of 55 degrees. CONCLUSION This study was initiated due to concerns that the current EMU may not provide an acceptable level of MMOD protection. Therefore, the overall goal of this study was to evaluate how to increase the protection provided to the bladder in the EMU. In the first two phases of this evaluation, materials were selected and tested to determine the order of the various layers that would provide the optimal MMOD protection. Orthofabric, Open Cell Foam (OCF) and Neoprene Coated Nylon were the materials selected from this testing. After these materials were identified, they were combined into lay-ups of varying thickness. The purpose of the third phase was to evaluate the manufacturability and performance of the medium thickness lay-up selected in the previous phases. Thirteen methods of fabricating a full-scale mock-up were evaluated, and three were selected. After further evaluation, the final method chosen was the one where assembling the mock-up closely resembled the assembly of production line TMGs. A weight comparison was performed. The mock-up TMG weighed 46% more than a baseline TMG. Figure 14: Proper Technique Used for Consistent Torque Testing Finally, the most interesting conclusion from this testing pertains to the goal of this study: to find out how the additional protection to the TMG affected the torque and which fabrication method reduced the torque increase the most. This testing indicated that there were no significant differences in torque among these three manufacturing methods. For the 55-degree range comparison, all three prototypes reached an almost identical maximum torque of 87 ft-lbs compared to the 74 ft-lbs reached by the baseline. This was a 17.6% increase. For the 75-degree comparison, they again tested very similarly with only Concept 8 reaching a slightly less maximum torque value. The average percent increase of the prototypes from the baseline for this degree range was a 35.4% increase. Therefore, it can be concluded that the method of fabrication for this new lay-up should be based solely on the manufacturing When torque evaluations were performed on the mockups based on the three methods mentioned above, data indicated that there were no significant differences in torque among the three manufacturing methods. However, the mock-ups required an average of 35% more torque than the baseline TMG. Since the new layup exceeds the current maximum allowable torque for the knee joint, a reassessment of the current requirement would be needed before this lay-up could be incorporated into the suit. During this evaluation, there was a concurrent effort to improve the risk predictions made by the MMOD probability model. The outcome of that effort was that th after re-sizing the EMU model for a 95 percentile male, the PNP (probability of no penetration) increased to 0.938, which is higher than the previous value and therefore meets the current requirement. Thus, no changes to the current EMU are required by NASA. Furthermore, the model shows that by modifying some of the non-mobility areas of the TMG the PNP can be increased two- to three-fold. While this degree of protection may not be required currently, future EVA activity may call for a suit that offers such protection. REFERENCES 1. D. Cadogan, C. Shear, A. Dixit, J. Ware, J. Ferl, E. Cooper, P. Kopf, “Intelligent Flexible Materials For Deployable Space Structures (INFLEX).” 36th ICES Conference, SAE, 2006 CONTACT Bobby Jones ILC Dover 302-335-3911 x512 [email protected] DEFINITIONS, ACRONYMS, ABBREVIATIONS EMU - Extravehicular Mobility Unit EVA – Extra Vehicular Activity HITF - Hypervelocity Impact Technology Facility HVI - Hyper Velocity Impact MLI – Multi-Layer Insulation MMOD - Micrometeoroid and Orbital Debris OCF - Open Cell Foam PNP - Probability of No Penetration TMG - Thermal Micrometeoroid Garment APPENDIX A.1 PHASE II HYPERVELOCITY IMPACT TESTING RESULTS A.2 MMOD TRADES MATRIX FOR TMG THICKENING OF KNEE JOINT (*Note: This trades matrix was generated during the study in an effort to down select to a few candidates for integrating the foam into the TMG. Weighted categories were chosen to reflect differences due to manufacturing techniques and do not include all issues evaluated in this study.)
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