Introduction

In the demanding field of spacecraft design and construction, every component must meet exacting standards to ensure reliability and longevity in the harsh environment of space. One critical aspect of materials selection for space applications is the control of outgassing – the release of trapped gases from materials when exposed to the vacuum of space. Rogers Corporation, a leader in engineered materials solutions, has developed a range of laminates specifically designed to meet the stringent outgassing requirements for spacecraft applications. This article explores the low outgassing characteristics of Rogers laminates and their importance in space technology.

Understanding Outgassing in Space Applications

What is Outgassing?

Outgassing is the release of gas that was dissolved, trapped, frozen, or absorbed in some material. In the context of spacecraft, outgassing occurs when materials are exposed to the vacuum of space, causing them to release trapped gases, moisture, and other volatile compounds.

Why is Low Outgassing Important?

1. Equipment Functionality: Released gases can condense on sensitive surfaces like optical lenses, solar cells, and thermal control surfaces, degrading their performance.
2. Contamination: Outgassed materials can contaminate other spacecraft components or scientific instruments, potentially compromising mission objectives.
3. Structural Integrity: Excessive outgassing can lead to material degradation and dimensional changes, affecting the structural integrity of spacecraft components.
4. Thermal Control: Outgassing can alter the thermal properties of materials, impacting the spacecraft’s thermal management systems.

Rogers Laminates: Engineered for Low Outgassing

Rogers Corporation has developed a range of high-performance laminates specifically designed to meet the stringent outgassing requirements for spacecraft applications. These laminates are engineered to minimize the release of volatile materials in vacuum environments.

Key Features of Rogers Low Outgassing Laminates

1. Material Composition: Rogers uses carefully selected raw materials and proprietary formulations to ensure minimal volatile content.
2. Manufacturing Process: The laminates undergo specialized manufacturing processes designed to reduce trapped gases and moisture.
3. Quality Control: Rigorous testing and quality control measures are implemented to ensure consistency in low outgassing performance.
4. Versatility: Rogers offers a range of laminates with low outgassing properties, suitable for various spacecraft applications.

Specific Rogers Laminates for Space Applications

RT/duroid® 6002

RT/duroid 6002 is a high-frequency laminate that offers excellent electrical and mechanical properties combined with low outgassing characteristics.

• Composition: PTFE composite with reinforcing glass microfibers
• Dielectric Constant: 2.94 ± 0.04 (10 GHz)
• Outgassing Performance: Meets NASA outgassing specifications
• Applications: Antenna systems, phased array antennas, beam-forming networks

AD1000™

AD1000 is a thermoset, ceramic-filled laminate designed for high reliability in space applications.

• Composition: Ceramic-filled, non-PTFE thermoset resin system
• Dielectric Constant: 10.0 ± 0.3 (10 GHz)
• Outgassing Performance: Exceptionally low outgassing
• Applications: GPS and communication satellite antennas, high-frequency circuit elements

RO3000® Series

The RO3000 series laminates offer a range of dielectric constants with excellent electrical and mechanical stability.

• Composition: Ceramic-filled PTFE composite
• Dielectric Constant: Various options (3.0, 3.38, 3.55, 6.15, 10.2)
• Outgassing Performance: Meets NASA outgassing specifications
• Applications: Satellite communication systems, radar systems, high-frequency circuit elements

Read more about:

• Rogers 4350B
• Rogers 5880
• Rogers 4003c
• Rogers 3003

Outgassing Testing and Certification

To ensure compliance with spacecraft requirements, Rogers laminates undergo rigorous outgassing testing according to established standards.

ASTM E595 Test Method

The ASTM E595 test is the industry standard for evaluating outgassing properties of materials for spacecraft use. The test involves:

1. Sample Preparation: Precise cutting and cleaning of laminate samples.
2. Conditioning: Samples are conditioned at 50% relative humidity and 23°C for 24 hours.
3. Vacuum Exposure: Samples are exposed to high vacuum (≤5 x 10^-5 Torr) at 125°C for 24 hours.
4. Measurement: Total Mass Loss (TML) and Collected Volatile Condensable Materials (CVCM) are measured.

NASA Outgassing Specifications

NASA has established the following criteria for low outgassing materials:

• Total Mass Loss (TML) ≤ 1.0%
• Collected Volatile Condensable Materials (CVCM) ≤ 0.1%

Rogers laminates approved for spacecraft applications meet or exceed these stringent requirements.

Benefits of Rogers Low Outgassing Laminates in Spacecraft Design

1. Reliability in Extreme Environments

Rogers laminates maintain their electrical and mechanical properties in the harsh space environment, ensuring long-term reliability of spacecraft systems.

2. Minimal Contamination Risk

The low outgassing characteristics significantly reduce the risk of contamination to sensitive spacecraft components and instruments.

3. Dimensional Stability

With minimal outgassing, Rogers laminates maintain excellent dimensional stability, crucial for precise antenna and circuit designs.

4. Versatility in Applications

The range of available laminates allows designers to select the optimal material for specific spacecraft applications, from high-frequency antennas to power distribution systems.

5. Compliance with Space Agency Standards

Rogers laminates meet the stringent outgassing requirements set by NASA and other space agencies, simplifying the material approval process for spacecraft designers.

Case Studies: Rogers Laminates in Space

Satellite Communication Systems

Rogers RT/duroid 6002 has been successfully used in the construction of high-gain antennas for communication satellites, providing excellent performance and reliability over extended missions.

Mars Rover Components

Certain Rogers laminates have been utilized in the construction of circuit boards for Mars rover missions, where the extreme temperature variations and harsh environment demand materials with exceptional stability and low outgassing.

International Space Station (ISS) Applications

Rogers materials have found applications in various systems aboard the ISS, where long-term reliability and minimal contamination are paramount.

Future Developments in Low Outgassing Laminates

Rogers Corporation continues to invest in research and development to further improve the outgassing characteristics and overall performance of their laminates for space applications. Some areas of focus include:

1. Advanced Material Formulations: Developing new resin systems and fillers to achieve even lower outgassing levels while maintaining or improving electrical properties.
2. Enhanced Manufacturing Processes: Refining production techniques to further reduce trapped gases and volatile compounds in the laminates.
3. Expanded Testing Capabilities: Investing in state-of-the-art testing equipment and methodologies to provide more comprehensive outgassing data and analysis.
4. Customization for Specific Space Applications: Working closely with spacecraft designers to develop tailored laminate solutions for unique mission requirements.

Conclusion

The low outgassing characteristics of Rogers laminates make them an essential component in the design and construction of reliable spacecraft systems. By meeting stringent outgassing requirements while offering excellent electrical and mechanical properties, these materials enable engineers to create high-performance, long-lasting spacecraft components. As space exploration continues to advance, the importance of low outgassing materials like Rogers laminates will only grow, supporting the development of more sophisticated and capable spacecraft for future missions.