Mechanical design and vibro-acoustic testing of ultrathin carbon foils for a spacecraft instrument
- Los Alamos National Laboratory
- SNL
IBEX-Hi is an electrostatic analyzer spacecraft instrument designed to measure the energy and flux distribution of energetic neutral atoms (ENAs) emanating from the interaction zone between the Earth's solar system and the Milky Way galaxy. A key element to this electro-optic instrument is an array of fourteen carbon foils that are used to ionize the ENAs. The foils are comprised of an ultrathin (50-100 {angstrom} thick) layer of carbon suspended across the surface of an electroformed Nickel wire screen, which in turn is held taught by a metal frame holder. The electro formed orthogonal screen has square wire elements, 12.7 {micro}m thick, with a pitch of 131.1 wires/cm. Each foil holder has an open aperture approximately 5 cm by 2.5 cm. Designing and implementing foil holders with such a large surface area has not been attempted for spaceflight in the past and has proven to be extremely challenging. The delicate carbon foils are subject to fatigue failure from the large acoustic and vibration loads that they will be exposed to during launch of the spacecraft. This paper describes the evolution of the foil holder design from previous space instrument applications to a flight-like IBEX-Hi prototype. Vibro-acoustic qualification tests of the IBEX-Hi prototype instrument and the resulting failure of several foils are summarized. This is followed by a discussion of iterative foil holder design modifications and laser vibrometer modal testing to support future fatigue failure analyses, along with additional acoustic testing of the IBEX-Hi prototype instrument. The results of these design and testing activities are merged and the resulting flight-like foil holder assembly is proposed.
- Research Organization:
- Los Alamos National Laboratory (LANL), Los Alamos, NM (United States)
- Sponsoring Organization:
- USDOE
- DOE Contract Number:
- AC52-06NA25396
- OSTI ID:
- 989783
- Report Number(s):
- LA-UR-09-03478; LA-UR-09-3478; TRN: US201019%%841
- Resource Relation:
- Conference: 2009 ASME International Mechanical Engineering Congress & Exposition ; December 13, 2009 ; Lake Buena Vista, FL
- Country of Publication:
- United States
- Language:
- English
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