Atomic Number (Z)-Grade Radiation Shields from Fiber Metal Laminates

A high density metal, such as tantalum or tungsten is coated onto thin aluminum sheet in precise ratios and thicknesses. The combined sheet is then easily formed into standardized enclosures compatible with CubeSat design and performance specifications.

The thin, lightweight radiation shielding is comprised of a low Z/high Z/low Z layered structure wherein the low Z layer is composed of titanium and the high Z layer is composed of either tantalum or antimony. Modelling of radiation shielding performance from a Cobalt 57 source shows a 10 times reduction in gamma radiation when using tantalum and a 25 times reduction when using antimony as compared with a single layer of lead. In addition, the Z-shielding is 25% lighter than a single lead layer with the same thickness (0.35-0.36 mm). The direct textile spraying innovation outlined by this invention enables the ability to shape this shielding into garments via the sewing of metal coated fibers. The refractory metal shielding can be added onto a variety of commodity-based fabrics including glass fabrics.

High atomic number materials, such as tantalum, do not bond well to oxygen- and hydroxyl-rich surfaces, such as glass fibers. These metals often form surface oxides when layered on glass fabric, resulting in flaking of the high atomic number material off the fabric during cutting, folding, and/or handling. To improve coating durability, this invention applies a lower atomic number metal as a tie down layer first before applying the high atomic number metal layer. The tie down layer reduces oxide formation between the substrate and the high atomic number material, promoting adhesion. Titanium has shown strong adhesion with different metals and is effective at reducing oxide formation when diffusion bonded to itself or other materials. It has been shown to be effective at improving durability when thermally sprayed onto a glass fiber fabric as a tie down layer for a subsequent tantalum layer (also applied via RF plasma spray). The titanium layer is only approximately 1 mil thick but results in strong adhesion of the tantalum layer by inter-metallic or diffusion bonding. A thermal spray process may be used, as well. This innovation enables the delivery of high atomic metal coating on glass fiber fabrics and other polymeric substrates that are lower cost, lighter weight, and durable to form a flexible cloth material with Z-graded radiation shielding. Coated samples have been produced and the technology is currently at a technology readiness level (TRL) of 4 (prototype).

One inner insulative layer, and one outer robust ablative layer comprise the AMTPS technology. When applying the heat shield to the surface of a spacecraft, the insulative layer is printed first and primarily functions to reduce the amount of heat soak into the vehicle. The formulation of the insulative layer has a slightly lower density (as compared to the robust layer) and is adjusted using a differing constituent ratio of phenolic and/or glass microballoon material. Both formulations combine a phenolic resin with various fillers to control pre- and post-cure properties that can be adjusted by varying the carbon and/or glass fiber content along with rheology modifiers to enhance the fluid flow for deposition systems. The robust layer is applied next and functions as the ablative layer that ablates away or vaporizes when subjected to extremely high temperatures such as those achieved during atmospheric entry. The formulation of the robust layer produces a gas layer as it vaporizes in the extreme heat that acts as a boundary layer. This boundary prevents heat from further penetrating the remaining robust material by pushing away the even hotter shock layer. The shock layer is a region of super-heated compressed gas, positioned in front of the Earth-facing bottom of the spacecraft during atmospheric entry, that results from the supersonic shockwave generated. Commercial space applications for this AMTPS technology include use on any spacecraft that transits a planetary or lunar atmosphere such as Mars or Saturn’s moon Titan. Additionally, the invention may be useful for launch system rockets to provide heat shielding from atmospheric reentry or to protect ground equipment on the launch pad from rocket exhaust plumes. As the number of government and commercial space missions to primary Earth orbits, the Moon, and the Solar System increase, there will be a growing need for cost-effective, on-demand, and timely fabrication of heat shields for space-related activities. AMTPS Formulations – Insulative and Robust Variation is at a technology readiness level (TRL) 5 (component and/or breadboard validation in laboratory environment) and is now available for patent licensing. Please note that NASA does not manufacture products itself for commercial sale.

Current nuclear propulsion technologies do not utilize the additional energy expelled as gamma ray radiation during nuclear fission. This results in the loss of 6.5% of the total fission energy, which could be used to improve propulsion capabilities. The NTAC Augmented Nuclear Electric Propulsion and/or Nuclear Thermal Propulsion design is more efficient than existing technology and captures an additional 6.5% (13.3 MeV) of radiation energy that is currently lost to radiation shielding. In this design the NTAC cell structure surrounds the TRISO (TRi-structural ISOtropic particle fuel) bead-filled rocket chamber, covering all sides and the top of the chamber, therefore capturing additional energy. This structure allows one-way energy flow to then be expelled through the bottom cavity as exhaust gas This technology is lower weight and less elaborate than current radiation shielded-propulsion systems. Equipping nuclear spacecraft systems with the NTAC Augmented Nuclear Electric Propulsion and/or Nuclear Thermal Propulsion design could reduce travel time to Mars by 50%. It has lower radar signatures compared to solar panels and could be used for systems that need to fly undetected, such as Earth observing satellites. Additionally, it has a lower noise output, which could have applications in reducing noise from submarine and aircraft carrier power systems.