Nanotechnology for Aerospace

Nanomaterials will play a disruptive role in next-generation thermal management for high power electronics in aerospace platforms. These high power and high frequency devices have been experiencing a paradigm shift toward designs that favor extreme integration and compaction. The reduction in form factor amplifies the intensity of the thermal loads and imposes extreme requirements on the thermal management architecture for reliable operation. In this perspective, we introduce the opportunities and challenges enabled by rationally integrating nanomaterials along the entire thermal resistance chain, beginning at the high heat flux source up to the system-level heat rejection. Using gallium nitride radio frequency devices as a case study, we employ a combination of viewpoints comprised of original research, academic literature, and industry adoption of emerging nanotechnologies being used to construct advanced thermal management architectures. We consider the benefits and challenges for nanomaterials along the entire thermal pathway from synthetic diamond and on-chip microfluidics at the heat source to vertically-aligned copper nanowires and nanoporous media along the heat rejection pathway. We then propose a vision for a materials-by-design approach to the rational engineering of complex nanostructures to achieve tunable property combinations on demand. These strategies offer a snapshot of the opportunities enabled by the rational design of nanomaterials to mitigate thermal constraints and approach the limits of performance in complex aerospace electronics.

Recent availability of carbon nanotubes (CNTs) in quantities and formats amenable to producing macroscale components invites consideration of these materials in space applications where their attractive properties can enable the realization of bold concepts for affordable space exploration. The challenge is to identify relevant systems and quantify the benefits at the systems level. Before significant investment or adoption of CNTs for large aerospace systems can be justified, there must be a plausible path to attain the perceived systems level benefits. This challenging step requires a close collaboration among experts on CNTs and aerospace system communities. This paper provides an overview of a few relevant potential CNTs applications for space systems and the gap that must be overcome for deployment of CNTs. It also provides a simple engineering-level systems analysis approach to quantify the benefits of using CNTs over state of the art material solutions.

We describe the super compressible and highly recoverable response of bucky sponges as they are struck by a heavy flat-punch striker. The bucky sponges studied here are structurally stable, self-assembled mixtures of multiwalled carbon nanotubes (MWCNTs) and carbon fibers (CFs). We engineered the microstructure of the sponges by controlling their porosity using different CF contents. Their mechanical properties and energy dissipation characteristics during impact loading are presented as a function of their composition. The inclusion of CFs improves the impact force damping by up to 50% and the specific damping capacity by up to 7% compared to bucky sponges without CFs. The sponges also exhibit significantly better stress mitigation characteristics compared to vertically aligned CNT foams of similar densities. We show that delamination occurs at the MWCNT–CF interfaces during unloading, and it arises from the heterogeneous fibrous microstructure of the bucky sponges.

In this paper, we investigate the recovery of some semiconductor-based components, such as N/P-type field-effect transistors (FETs) and a complementary metal–oxide–semiconductor (CMOS) inverter, after being exposed to a high total dose of gamma ray radiation. The employed method consists mainly of a rapid, low power and in situ annealing mitigation technique by silicon-on-insulator micro-hotplates. Due to the ionizing effect of the gamma irradiation, the threshold voltages showed an average shift of −580 mV for N-channel transistors, and −360 mV for P-MOSFETs. A 4 min double-cycle annealing of components with a heater temperature up to 465 °C, corresponding to a maximum power of 38 mW, ensured partial recovery but was not sufficient for full recovery. The degradation was completely recovered after the use of a built-in high temperature annealing process, up to 975 °C for 8 min corresponding to a maximum power of 112 mW, which restored the normal operating characteristics for all devices after their irradiation.

Robust carbon nanotube (CNT)-based cold cathodes were fabricated on titanium (Ti) substrates. Methods to grow vertically aligned CNTs  directly on Ti substrates were developed. These cathodes can be treated post-growth at elevated temperatures under inert atmosphere which causes the surface-grown CNTs to become anchored to the substrate surface. These samples offer improvements in field emission properties over previously studied silicon (Si) substrate-based cathodes with no anchoring, displaying low threshold voltages, high field enhancement factors, and long operating lifetimes. Current densities of 25 mA cm⁻² were held for over 24 h with anchored samples at low electric fields (observed thresholds as low as 0.5 V μm⁻¹) and more current stability. Higher current densities of up to 150 mA cm⁻² could be reached with anchored samples, limited only by the experimental setup. In efforts to generate even more stable and reproducible field emission, a transfer process of CNTs from polished Si to Ti with copper (Cu) was developed (flipCNTs). These cathodes display extreme improvements over previous results, with observed thresholds as low as 0.2 V μm⁻¹ and γ-factors as high as 30 000. To demonstrate the utility of these robust cathodes, a flipCNT-based cathode was assembled into a fully functioning vacuum triode.

Radiation shielding in space missions is critical in order to protect astronauts, spacecraft and payloads from radiation damage. Low atomic-number materials are efficient in shielding particle-radiation, but they have relatively weak material properties compared to alloys that are widely used in space applications as structural materials. However, the issues related to weight and the secondary radiation generation make alloys not suitable for space radiation shielding. Polymers, on the other hand, can be filled with different filler materials for reinforcement of material properties, while at the same time provide sufficient radiation shielding function with lower weight and less secondary radiation generation. In this study, poly(methyl-methacrylate)/multi-walled carbon nanotube (PMMA/MWCNT) nanocomposite was fabricated. The role of MWCNTs embedded in PMMA matrix, in terms of radiation shielding effectiveness, was experimentally evaluated by comparing the proton transmission properties and secondary neutron generation of the PMMA/MWCNT nanocomposite with pure PMMA and aluminum. The results showed that the addition of MWCNTs in PMMA matrix can further reduce the secondary neutron generation of the pure polymer, while no obvious change was found in the proton transmission property. On the other hand, both the pure PMMA and the nanocomposite were 18%–19% lighter in weight than aluminum for stopping the protons with the same energy and generated up to 5% fewer secondary neutrons. Furthermore, the use of MWCNTs showed enhanced thermal stability over the pure polymer, and thus the overall reinforcement effects make MWCNT an effective filler material for applications in the space industry.