Corrosion in Space
Corrosion in Space
Corrosion in Space
A. de Rooij
Head of Materials Technology Section
Product Assurance and Safety Department
Materials and Components Technology Division
European Space Agency
European Space Technology and Research Centre
Noordwijk, The Netherlands
Keywords:
atomic oxygen, corrosion, space, low earth orbit, LEO, ATOX, flight testing, onground testing
Abstract
The corrosion in space is described by the effect of atomic oxygen on several
materials. The metal which was most affected is silver. Silver oxidises according to a
linear-parabolic law and due to the thermal stresses the oxide layer continuously
breaks up, resulting in a linear degradation.
Atomic oxygen not only attacks materials in the line of sight of the ram flux, but also
by reflected atomic oxygen.
Many materials form an adherent oxide layer, such as Cu, Al and stainless steel and
are as such protected once this oxide layer is formed. Some materials have a volatile
oxide such as Osmium and many polymers materials. They show a linear behaviour.
1 INTRODUCTION
Corrosion in the space environment can happen during several occasions. In satellites,
manned and unmanned, the environment is present which can contribute to all kinds
of corrosion. The presence of electrolytes in batteries and/or cooling loops can cause
galvanic corrosion, general corrosion and stress corrosion. These corrosion types are
fully equivalent to ones find on ground. In the life of a spacecraft most of the dangers
of corrosion happens on ground during manufacturing, assembly, testing and or
storage. The one corrosion type which is usually not found on ground is corrosion by
atomic oxygen (ATOX). ATOX is considered as one of the most serious hazards to
spacecraft materials and is present at altitudes between 200 and 700 km.
The degrading environment for spacecraft materials includes atomic oxygen,
Ultraviolet (UV) radiation, ionizing radiation, ultrahigh vacuum (UHV), charged
particles, thermal cycles, electromagnetic radiation, micrometeoroids, and man-made
debris, micrometeoroids and orbital debris. Synergistic or separate interactions in this
environment, the spacecraft materials might suffer corrosion, erosion, structure
modification and surface roughening, which can degrade the optical, thermal,
electrical and mechanical properties.
2 WHAT IS ATOMIC OXYGEN
ATOX is produced by the photo-dissociation of molecular oxygen in the upper
atmosphere by solar radiation of wavelength less than or equal to 243 nm [1]. It is the
main constituent of the residual atmosphere in Low Earth Orbit (LEO) as illustrated in
figure 1 [2]. The oxygen atoms have a density of 107 to 108 atoms/cm3 at International
Space Station (ISS) altitude (around 400 km) with a thermal energy of approx. 0.1 eV.
The orbital atomic oxygen density can be calculated with the aid of the MSIS86/CIRA Neutral Thermophere Model of Hedin[3].
Referring to figure 1 one can see the dominant atmospheric constituent concentrations
as a function of altitude. Space vehicles are orbiting with a velocity of 7.78 to 8
km/sec at those altitudes. For satellite-gas collision interactions, this orbital velocity
corresponds to impact gas energies of 0.34, 4.40 and 5.03 eV for hydrogen, nitrogen
and oxygen atoms, respectively.
Concentrating only on the O-atoms and taking into account the solar activity the
maximum and minimum atomic oxygen density as function of altitude is shown in
figure 2. The atomic oxygen flux depends on the altitude, the solar activity, the orbital
inclination and the time of year. The collision with the external surfaces of space
vehicles, orbiting at a velocity of 8 km/s, results in a ram flux of 1014 -1015 Oatoms/(cm2.s).
3 ATOMIC OXYGEN EFFECTS
A number of processes can take place when oxygen atoms strike a spacecraft surface
at orbital velocities. These include chemical reaction with surface atoms or adsorbed
molecules, elastic scattering, scattering with partial or full thermal accommodation,
recombination, or excitation of ram species.
The chemical reaction of ATOX with a surface may cause the formation of volatile
oxides from polymers, carbon, and osmium; or oxides which do not adhere very well
to the surface and tend to spall, as in case of silver. Volatile and spalling oxides
contribute to the erosion of the surface. In several cases the oxide remains adhered to
the surface and is not porous. In these cases the surface oxide is protective and the
underlying material will not erode away. This is the case for most metals such as
aluminium, copper, steel and also for silicon. The oxidation product for most
polymers is a gas and erosion results.
The factors that may influence the erosion yield of materials in space are impact
angle, material temperature, oxide spalling, ATOX flux, ATOX fluence, synergistic
solar radiation, and ATOX impact energy. Following the sequence of Banks and
Rutledge [4]:
3.1.1 ATOX fluence
The erosion yield of Kapton due to space exposure reveals no pronounced dependence
upon ATOX flux or fluence based on information from Space Transportation System
(STS) flight 3, 4, 5, and 8. The corrosion of silver slows down with increasing ATOX
fluence due to the protective oxide layer when still on the surface. No dependence on
ATOX flux is seen based on STS-8, 41 and Long Duration Exposure Facility (LDEF)
information.
3.1.2 ATOX impact energy
The dependence of erosion yield upon impact energy has been measured both in the
ground-based laboratory and in space simulation. In the simulations, an erosion yield
dependence of Kapton to energy E can be expressed as Yield=E0.68 [5]
The energy of atomic oxygen arrival may have a significant influence on the erosion
yield of materials relative to Kapton H. At thermal energies in RF plasma ashers,
materials with high chlorine or fluorine atomic contents have anomalously high
Fk = ( n1 n 2 )
(1)
where
The atoms entering the pore loose their velocity due to scattering in the pores during
the first wall collisions. Their speed is than reduced to
The expression for n1 is then
n1 =
where
N
v
Nv
Nv
8 RT
M
(2)
(3)
R = gas constant
T = temperature
M = molecular mass
The probability factor depends on the geometry of the pore and is given by the
Clausing factor
3 Lr H
= 1 +
16 A
(4)
3 Hy
Fk = 1 +
16 A
{ n2 }
(6)
D (1 )
n2
y
(7)
Q
where D =diffusion coefficient = D0 exp
RT
The oxygen atoms reaching the metal surface will finally react with the base metal
and form the oxide. This type of reactions is usually linear and with an oxide flux of:
Fo = Kn 2
(8)
For a steady state situation the oxygen flux through the pores Fk and from the
diffusional transport Fd must be equal to the oxide flux Fo produced by the oxidation:
Fk + Fd = Fo
(9)
The unit for the oxide flux Fo is related to the oxide growth rate by
dy
= C r Fo
dt ox
(10)
Where
C
= conversion factor from atoms/cm3 to cm3 metal-oxide
= 1.70520 10-23 for silver
r = real volume ration oxide/metal due to porosity
r =
th
(1 )
(11)
KP
thCK.t
K KP D
K KP D
= y 2 c + y 1 + c 2 V c 2
W
2W
W
(1 )
W
W
Where
(13)
3 H
16 A
D = D (1 )
Pc =
W = + Pc D
V=
Wy
D
log 1 +
W
D
This general solution reduces to the well known linear-parabolic equation when
gasflow is absent:
y 2 2 y 2 thC .t
+
=
D K
(14)
y 2 Pc +
2
2thC .t
y=
K
1
(15)
It may be noted that also the gasflow equation 15 is linear-parabolic. The temperature
dependence of eq. 15 is weak and only present in the linear part, meaning when y is
very small. With thicker oxide layers the gasflow through the pores behaves parabolic
because of the collisions of the atoms with the wall of the pore. The diffusion
equation 14 has the temperature dependence both in the linear and in the parabolic
part. It demonstrates that at low temperatures the gasflow through the pores is the
dominating process, while at high temperature the diffusion is rate controlling.
At a typical ISS orbit the silver loss due to oxidation is calculated as 11.5 m per year
with an oxide thickness of 23 m when no spallation is assumed. When complete
flaking is assumed the maximum loss is 300 m per year.
The solar cell interconnectors are typically silver foil with a thickness of 20 m. A
stress relief loop is formed in the foil to accommodate for the displacements between
the solar cells. This out-of plane-loop is mechanically formed. The atomic oxygen
effect is usually most pronounced on out-of-plane stress relief loops. In this area the
manufacturing stresses and the stresses as a result of the temperature excursions are
large. Past experience showed that in these areas the oxide layer tends to flake off and
a fresh surface is exposed to the atomic oxygen environment. On flat surfaces this
effect is less pronounced while there mainly the difference in volume between the
oxide and the parent metal is responsible for cracking of the oxide layer. The largest
effect is seen on the ram surface. However, also on surface not directly exposed to the
ram fluence, atomic oxygen oxidation is seen as evidenced by the fact that the rear
side of the silver samples were always oxidized although to a lesser extend. In general
this effect is about 25-50% of the front side of the exposed samples.
On way to protect the silver of being oxidized by atomic oxygen is by plating with
gold. Gold is supposed to not be affected by atomic oxygen and when very thin it also
does not influence the working of the stress relief loops. As with all protective
coatings they should remain intact. Deformations required for manufacturing or
during services can jeopardize the integrity of coatings and make them unreliable.
The gold plated interconnectors were finally rejected for out-of-plane stress relief
loops because it was impossible to apply a gold coating with such properties that it
remained intact after forming the stress relief loop. It was seen several times that these
gold layers were either cracking (especially in the out-of-plane loop) or contained
small pinhole type defects.
Through these defects the underlying silver was oxidised. Large holes under the gold
plating were created and silver-oxide was found at the surface.
In the low Earth orbital environment, one should not use materials which suffer from
atomic oxygen corrosion on external surfaces nor on surfaces which can be reached
by atomic oxygen neither should one protect materials such as silver by materials with
low erosion or corrosion yields.
Other metals investigated are Cu, Au, Al, stainless steel, Ta, Al alloys and Mo. These
materials were exposed with and without coatings, such as silicones. Cu was exposed
during the LDEF mission and showed a severe darkening (dark red) of the surface,
changing the optical properties significantly. The cuprous oxide was adherent to the
surface. Other groups investigated Os, Pt, Ni, Fe-alloys and carbon.
3.3 Atomic Oxygen on non-metals
Glasses and ceramics which are based on oxides are expected not to oxidise further.
No degradation is reported.
3.4 Atomic Oxygen on organic materials
It is well documented through orbital and ground measurements that most
hydrocarbon polymers and active metals are highly reactive towards the orbital
atomic oxygen. Materials containing silicones, fluorides, oxides and noble metals are
believed to be moderately inert for short exposures to atomic oxygen; however,
samples recovered from LDEF indicate that many materials are severely degraded on
long-term exposure to atomic oxygen
The tests conducted by Miller et.al. in [9] indicate that environments which produce
synergistic effects with regard to the magnitude of erosion by atomic oxygen exposure
are not the same for each polymer. Each polymer appears to be sensitive to a different
component of the environment. Predicting the atomic oxygen durability of a material
in the space environment can be a very complex task complicated by the fact that each
material may be sensitive to a different synergistic component in the environment.
3.5 Atomic Oxygen on lubricants
Atomic oxygen can gives serious problem in wear-life of MoS2 lubricant. For MoS2
films sputter-deposited at 5070 C, friction measurements showed a high initial
friction coefficient (up to 0.25) for MoS2 surfaces exposed to atomic oxygen, which
dropped to the normal low values after several cycles of operation in air and ultrahigh
vacuum.[10]. Mo-oxide, once formed, act as a protective layer against further atomic
oxygen attack. Delamination of cracking of the oxide layer caused by operation of the
parts can reduce the wear-life of the film.
3.6 Trapping of Atomic Oxygen between Defected Protective Surfaces
Although atomic oxygen attack on internal or interior surfaces may not have direct
exposure to the LEO atomic oxygen flux, scattered impingement can have can have
serious degradation effects where sensitive interior surfaces are present.
Atomic oxygen not only attacks surfaces which are exposed directly to the flux, also
surfaces not directly exposed, but in one way or another accessible to the atoms can
be oxidised. An example is the thermal blanket covering the Ultra High Cosmic Ray
(UHCR) experiment exposed on Eureca. This blanket consists of a four layers with
Teflon as outer layer and a silver and Inconel as internal layers with black paint at the
back side. The internal silver was oxidised by ATOX through a hole created by a
micro-meteorite.
The lack of atomic oxygen protection provided by the aluminized Kapton blanket
cover for the ISS photovoltaic arrays box cushion is thought to be due to due to the
trapping of atomic oxygen between the two aluminized surfaces on the 0.0254 mm
thick Kapton blanket. Defects in the space exposed aluminized surface allow atomic
oxygen to erode undercut cavities.
Prediction of the attenuation of the oxidizing effects of the atomic oxygen flux can be
reasonably achieved through the use of Monte Carlo computational modelling. A twodimensional Monte Carlo model has been developed which has been used for such
predictions. [11]
4 TESTING
The atomic oxygen erosion measurement techniques should follow the protocols
designated in the ASTM procedure E 2089-00 for Standard Practices for Ground
Laboratory Atomic Oxygen Interaction Evaluation of Materials for Space
Applications[12].
4.1 Flight testing
Surfaces of materials used in the Space Shuttle Orbiter payload bay and exposed
during STS-1 through STS-3 were examined after flight.[13]
Films made of carbon, silver, and osmium, were exposed during the Shuttle STS-4
mission examined for the anticipated reaction with atomic oxygen[14]
Bare silver samples and partly coated silver samples were exposed to low earth orbit
conditions during Shuttle flights STS-8 and STS-17.[15] The influence of atomic
oxygen on the amount of erosion-corrosion of metal surfaces, especially silver, was
examined. Protection schemes for silver were also investigated.
The STS Mission 46 carried in orbit a large number of experiments collectively
grouped under the designation of Evaluation of Oxygen Interaction with Materials
(EOIM-III)-third phase
Some results have been given by the Solar Max (1984) returned materials, but not as a
planned experiment.
LDEF was a large cylindrical space experiment rack that exposed various material
samples to outer space for about 5.7 years. It was retrieved from space in 1990.
The retrieval of Eureca gave the opportunity to study the effects of atomic oxygen on
exposed spacecraft surfaces in Low Earth Orbit. Large areas of identical surface
materials, were exposed during the 1992-1993 period,
The first solar array of Hubble Space Telescope was returned after 3 years of
operation. All materials presents were examined including Ag, Inconel, stainless steel,
copper and kapton.
Samples of Kapton H were transported to the International Space Station attached to
the exterior of the ISS during the STS 105 Shuttle mission. The materials were
retrieved during the STS-114 Shuttle mission.
There have been five Materials International Space Station Experiment (MISSE)
passive experiment carriers (MISSE 1-5) to date that have been launched, exposed in
space on the exterior of International Space Station (ISS) and than returned to Earth
for analysis.
The Material Exposure and Degradation ExperimenT (MEDET) will actively monitor
material degradation dynamics in low Earth orbit and acquire information about the
International Space Station environment in terms of contamination, atomic oxygen,
ultraviolet and X-ray radiation, micrometeoroids and debris.
4.2 Ground based Atomic Oxygen testing
The existing AO beam sources can be classified according to the physical process
involved in dissociation of molecular oxygen: laser-induced breakdown, microwave
resistor which is incorporated into the sample holder. Furthermore the sample holder
can be rotated up to a beam axis angle of attack of 70.
5 CONCLUSION
The effect of atomic oxygen on surfaces in laboratory experiments might be different
from the effect encountered during low earth orbit exposure. During orbit the exposed
samples undergo a thermal cycling sequence of +100/-100C. This might have a
detrimental effect on some oxides. The simultaneous action of atomic oxygen attack
and thermal cycling might be compared with such effects as static stress and corrosion
(stress corrosion) and fatigue and corrosion (corrosion fatigue), where the result of the
combined action is more than the sum of the separate effects. The pure metals are
virtually unaffected by thermal cycling itself, also the effect of atomic oxygen on
metals such as Au, Pd and Al is in the line of expectation compared to the sputtering
yields under 20 KeV O2+ bombardment. Following these yields, the value for silver
(and osmium) has to be in the same order of magnitude. However, a dramatic effect
on silver and osmium is observed in LEO, which is due to the combined action of
atomic oxygen attack and thermal excursions. Therefore, on ground testing of
materials of materials for LEO behaviour should always incorporate both atomic
oxygen attack as well as thermal cycling. To predict materials performance in low
earth orbit, one must accurately simulate the conditions of the low earth orbit
environment or at least understand how the performance of materials under simulated
conditions relates to that in space.
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REFERENCES
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Figure 6: A microsection through a defect in the gold plating. It shows that silver
is also attacked under the gold plating.